Overview
Process Engineer – Blown Film (Mono & 3-Layer)
We are seeking a skilled Process Engineer to join our extrusion team, specializing in mono-layer and 3-layer blown film production. This role is central to driving process reliability, film quality, and continuous improvement. The ideal candidate combines technical depth in blown film extrusion with strong problem-solving, data analysis, and cross-functional collaboration skills.
Responsibilities
- Process Control & Optimization
Develop, monitor, and refine process windows (BUR, FLH, DDR, melt temps, die temps, nip / haul-off settings) to ensure consistent gauge, clarity, and strength.
Implement SPC, Cp / Cpk, and DOE methods to improve control and capability.Troubleshooting & Technical LeadershipServe as the primary technical resource for extrusion lines; resolve issues related to film defects, resin behavior, or equipment stability.
Support off-shift teams with rapid diagnosis and corrective actions.Quality & CompliancePartner with QA to validate film properties (dart impact, tensile, haze, COF, OTR / WVTR).
Ensure compliance with customer specs, food-contact regulations (FDA, EU), and ISO / GMP standards.Continuous Improvement & KPIsLead Lean / Six Sigma initiatives to reduce scrap, energy usage, and changeover time.
Deliver measurable improvements in OEE, first-pass yield, and downtime reduction.Equipment & TechnologyCollaborate with Maintenance and OEMs (W&H, Reifenhäuser, Alpine, Macchi, Gloucester, etc.) on PMs, upgrades, and critical spares.
Support commissioning of new tooling, dies, air rings, and automation systems (IBC, AGC, profile control).Materials & TrialsManage resin qualification, regrind strategy, and additive systems (slip, AB, EVOH, PA, tie layers).
Lead customer trials and document performance for commercialization.Training & DocumentationCreate and maintain SOPs, troubleshooting guides, and operator training programs.
Build operator skill matrices and certification paths to elevate line performance.Qualifications
Bachelor’s degree in Chemical, Plastics, or Mechanical Engineering (or related).3+ years of blown film extrusion experience (mono & multi-layer).Strong knowledge of polymer rheology, extrusion parameters, and film performance.Proficiency in SPC, DOE, Minitab (or similar), and process control systems.Hands-on experience with AGC, IBC, oscillating haul-offs, and profile control.Excellent analytical, problem-solving, and communication skills.Preferred Skills
Familiarity with W&H, Alpine, Reifenhäuser, Macchi, or Gloucester blown film lines.Knowledge of food packaging, healthcare, industrial film applications.Experience with inline testing and film analysis equipment.Green Belt (or higher) in Lean / Six Sigma.Experience with bag machine and cleanroom operations is a plusJob Function & Industry
Job function : Management and ManufacturingIndustries : Packaging and Containers ManufacturingNote : This description reflects the role responsibilities and qualifications without extraneous job-board boilerplate.
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