Polypropylene Extrusion Process Engineer

Job Description

Polypropylene Extrusion Process Engineer
Location:

Surprise, AZ (100% On-Site)
Position Type:

Full-Time, Permanent
About the Role
We are seeking a hands-on, data-driven

Process Engineer

to take technical ownership of our polypropylene (PP) extrusion operations in Surprise, Arizona. In this role, you will be the primary technical authority on the plant floor, driving the efficiency, consistency, and scale-up of hollow-form corrugated PP sheet and carton manufacturing.
If you thrive in dynamic manufacturing environments, excel at solving complex rheological and mechanical extrusion challenges, and want to directly influence scrap reduction and line throughput, this role offers an immediate impact.
Key Responsibilities
Line Optimization & Process Control
Parameter Governance:

Establish, refine, and document critical operating windows for flat-die sheet extrusion lines—calibrating melt temperatures, barrel zones, screw profiles, line speeds, vacuum calibration, and downstream cooling/annealing cycles.
Shop-Floor Troubleshooting:

Partner with operators and maintenance technicians to diagnose and eliminate acute extrusion anomalies (e.g., melt fracture, surging, plate-out, die lines, thickness variation).
Throughput & Uptime:

Track line metrics (OEE, yield, cycle times) to systematically eliminate micro-stops, boost output rates, and slash changeover and startup scrap.
Continuous Improvement:

Spearhead Kaizen events and root-cause problem-solving initiatives using Lean and Six Sigma frameworks (DMAIC, 5 Whys, Fishbone).
Quality Assurance & Material Engineering
Structural Compliance:

Ensure sheets meet strict structural tolerances, focusing on flute symmetry, grammage/basis weight, drop-dart impact, flexural stiffness, and edge seal integrity.
Formulation Testing:

Test and qualify virgin resins, masterbatches, UV/slip/antistatic additives, regrind, and post-consumer recycled (PCR) blends to balance cost, processability, and structural performance.
NPI & Trial Runs:

Design and execute commercial validation runs (DOE) for new tooling, dies, and custom flute geometries, transitioning new designs seamlessly from pilot to full production.
Customer Resolution:

Collaborate with QA to conduct failure analyses on customer returns or packaging defects, implementing permanent corrective actions (CAPA).
Safety, Compliance & Plant Modernization
Maintain rigorous adherence to plant OSHA protocols, machine guarding, and applicable food-contact packaging standards (e.g., FDA/IMS requirements).
Identify automation and line-upgrade opportunities; specify instrumentation, sensors, and downstream handling equipment to enhance line stability.
Qualifications & Competencies
Minimum Requirements
Education:

Bachelor of Science in Plastics Engineering, Chemical Engineering, Mechanical Engineering, Materials Science, or a related discipline.
Experience:

3+ years of dedicated process engineering experience in a continuous plastics manufacturing environment.
Technical Depth:

Proven technical proficiency in polyolefin processing (PP/PE), including practical familiarity with single/twin-screw extruders, gear pumps, sheet dies, and profile calibration systems.
Data-Driven Problem Solving:

Demonstrated capability in statistical process control (SPC), design of experiments (DOE), and structured root-cause analysis.
Presence:

Strong interpersonal and communication skills with a willingness to spend significant time on the production floor working alongside operating crews.
Preferred Assets
Direct experience with hollow-fluted sheet extrusion (corrugated plastic/twin-wall profile lines) or carton converting machinery.
Six Sigma Green Belt or Black Belt certification.
Familiarity with food-contact packaging regulations and circular economy initiatives (handling high-ratio regrind/PCR blends).