Process Engineer

Role details

Role: Process Engineer

Location

Boothwyn, PA (On-site)

Position Type

Full-time (2 Openings: 1 Day Shift | 1 Night Shift)

Position Overview

We are seeking two motivated, hands-on

Process Engineers

to join our manufacturing team in Boothwyn, PA. In this role, you will work directly on the production floor alongside extrusion operators, maintenance personnel, quality teams, and plant leadership to optimize profile extrusion operations, troubleshoot technical challenges, reduce scrap, and establish reliable, repeatable processes.

Whether you are an experienced plastics engineer or a high-potential engineering graduate with strong mechanical aptitude and polymer processing exposure, this role offers direct impact and career growth in high-performance thermoplastic extrusion.

Key Responsibilities

• Hands-on Technical Support:

Provide real-time engineering support for thermoplastic profile, rod, sheet, and slab extrusion lines.

• Process Optimization:

Evaluate and refine process parameters (temperature, pressure, cooling rates, melt flow, line speeds) to maximize product stability, quality, and throughput.

• Scrap & Yield Management:

Identify root causes of material scrap and machine downtime; implement continuous improvement initiatives to improve material yield.

• Troubleshooting:

Diagnose complex processing issues related to raw materials, tooling designs, machinery, heating/cooling zones, and dimensional tolerances.

• Data & Quality Analysis:

Utilize Statistical Process Control (SPC), Design of Experiments (DOE), and Lean/Six Sigma principles to maintain process capability and continuous improvement.

• Standardization & Documentation:

Develop, maintain, and standardize machine setup sheets, standard operating procedures (SOPs), and processing guidelines.

• New Product & Material Validation:

Support new product development (NPD), material trials, tooling modifications, and equipment validation runs.

• Operator Mentorship:

Train and guide extrusion operators in process fundamentals, troubleshooting techniques, and quality control standards.

• Cross-Functional Collaboration:

Partner with Quality, Maintenance, and Production teams to support capital equipment installations and process upgrades.

• Safety & Compliance:

Maintain a safe work environment adhering to plant safety standards and operational protocols.

Qualifications & Requirements

• Education:

Bachelor’s degree in Plastics Engineering, Polymer Science, Mechanical Engineering, Chemical Engineering, Materials Engineering, or a related discipline (or equivalent practical experience).

• Experience:

Hands-on experience in thermoplastic extrusion, polymer processing, or plastics manufacturing is preferred. Recent graduates with relevant coursework/co-op experience and strong mechanical aptitude are encouraged to apply.

• Technical Knowledge:

Familiarity with single/twin-screw extruders, die tooling, vacuum sizing/calibration systems, haul-off pullers, cooling baths, and flying saws/cutters.

• Material Expertise:

Knowledge of standard, engineered, and high-performance thermoplastics (e.g., Nylon, Acetal/POM, Polycarbonate, PEEK, UHMW-PE, HDPE, PVC) is highly valuable.

• Analytical Skills:

Practical understanding of root-cause analysis, SPC, DOE, or Lean/Six Sigma methodologies.

• Attributes:

Strong mechanical aptitude, proactive problem-solving ability, and excellent communication skills to work effectively with floor operators and plant management.