Polypropylene Extrusion Process Engineer (Greater Phoenix Area)

Company: SeaCa Plastic Packaging, LLC

Salary: $87,500–$100,000 annually, depending on experience

Department: Operations / Manufacturing Engineering

Reports To: Production Manager

Role Description The Polypropylene Extrusion Process Engineer is a full-time, on-site role located in the Surprise, AZ. This position will focus on optimizing the production of hollow form polypropylene (PP) sheets and carton products. The ideal candidate will bring hands-on extrusion experience, strong troubleshooting abilities, and a passion for improving manufacturing efficiency, product quality, and equipment performance.

Process Engineering & Production Optimization

• Monitor and optimize polypropylene extrusion processes to improve productivity, quality, and efficiency.
• Troubleshoot extrusion equipment and resolve production-related issues.
• Develop and improve processing parameters, including temperature profiles, screw speeds, melt pressures, line speeds, and cooling conditions.
• Analyze production data to identify opportunities to increase throughput, reduce scrap, and minimize downtime.
• Conduct root cause analysis and implement corrective actions to address recurring manufacturing issues.
• Lead continuous improvement projects using Lean Manufacturing, Six Sigma, or similar methodologies.

Quality & Product Development

• Ensure products meet specifications for thickness, weight, flute geometry, stiffness, and dimensional stability.
• Partner with Quality Assurance to address quality concerns and customer complaints.
• Evaluate raw materials, additives, resin formulations, and recycled content.
• Support new product development, process validation, customer trials, and production scale-up.

Qualifications

• Strong foundation in Chemical Engineering and Process Engineering, with experience in polymer or plastics processing, preferably polypropylene extrusion.
• Proficiency in Process Design, including the development and optimization of extrusion lines, equipment layouts, and process flows.
• Experience with Process Control, including setting and maintaining operating parameters, implementing control strategies, and working with instrumentation and automation systems.
• Advanced Analytical Skills to interpret process data, perform root-cause analysis, and drive data-based improvements in quality, throughput, and efficiency.
• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, or a related field; advanced degree or relevant certifications in plastics or extrusion engineering are a plus.
• Knowledge of safety, environmental, and food-contact packaging regulations and standards; experience in a manufacturing environment is preferred.
• Ability to work collaboratively on-site with cross-functional teams, communicate technical information clearly, and manage multiple projects in a fast-paced setting.
• Commitment to sustainability, continuous improvement, and maintaining a safe work environment.