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Plastic Extrusion Process Engineer - PSR3926

Salary Range: $90,000 – $126,000
Industry: Plastics / Polymer Extrusion / Advanced Manufacturing
Location: Near Hendersonville, TN
Schedule: Full-Time / First Shift 

Position Summary

We are partnering with an established manufacturer to identify an experienced Plastic Extrusion Process Engineer to support the development, optimization, and continuous improvement of precision plastics extrusion processes.

This is a true hands-on engineering role, with an anticipated balance of approximately 50% hands-on extrusion/process work and 50% engineering, research, and process-development activities. The selected individual should be equally comfortable working directly with extrusion equipment and production personnel on the manufacturing floor as they are analyzing processes, developing solutions, conducting research, and managing engineering projects.

This individual will play an important role in new product and process development while also supporting existing production. Responsibilities will range from extrusion trials, equipment setup, tooling development, and process optimization to troubleshooting, root cause analysis, scrap reduction, and the development of stable, repeatable manufacturing processes.

The position requires someone who is self-directed, technically hands-on, collaborative, and comfortable operating within a structured ISO-certified manufacturing environment. The successful candidate must communicate effectively across all levels of the organization, from working directly with operators on the manufacturing floor to collaborating with engineering teams and senior leadership.

Responsibilities

• Develop and optimize precision plastics extrusion processes from initial concept and prototyping through production release. 

• Develop, implement, and maintain robust extrusion processes for high-performance thermoplastics, engineered resins, polyolefins, and other specialty polymer materials.

• Set up extrusion equipment, conduct product and process trials, evaluate performance, and establish repeatable processing parameters.

• Work directly on the manufacturing floor to troubleshoot extrusion issues involving equipment settings, process parameters, tooling, material behavior, and finished-product performance.

• Identify root causes of extrusion defects, process variation, scrap, and production inefficiencies.

• Apply structured problem-solving and process-development methodologies including DOE, PFMEA, process control plans, statistical process control, and root cause analysis.

• Work directly with production personnel to ensure extrusion processes consistently meet customer specifications, dimensional tolerances, quality requirements, and internal standards.

• Collaborate with Production, R&D, Engineering, Quality, Manufacturing, and other internal teams on new and existing products.

• Support the development and improvement of extrusion tooling, fixtures, and related production equipment.

• Work with internal resources and outside vendors on tooling and equipment improvements.

• Evaluate relationships between extrusion equipment settings, process instrumentation, polymer behavior, and resulting product quality.

• Support extrusion process improvements involving polymer rheology, heat transfer, screw design, tooling, and material handling.

• Troubleshoot processing challenges associated with specialty, engineered, and high-temperature polymer materials.

• Develop and maintain process documentation, operating parameters, traceability records, and related manufacturing documentation.

• Provide technical guidance and training to production personnel regarding extrusion processes, troubleshooting, best practices, and established operating procedures.

• Lead or support continuous improvement initiatives focused on scrap reduction, setup-time reduction, productivity, material optimization, cost savings, and quality improvement.

• Manage multiple engineering and process-improvement projects while adapting to changing production and business priorities.

• Support Lean Manufacturing, Six Sigma, and other continuous improvement initiatives.

• Maintain compliance with applicable quality, safety, environmental, QMS, EMS, and ISO-related requirements.

Qualifications

• 3+ years of hands-on precision plastics extrusion experience strongly preferred.

• Professional experience as an Extrusion Engineer, Process Engineer specializing in extrusion, Plastics Engineer, Polymer Engineer, or similar technical role.

• Demonstrated experience working directly with extrusion equipment in a manufacturing environment.

• Hands-on experience with extrusion equipment setup, process development, production trials, troubleshooting, and process optimization.

• Experience supporting production teams and resolving real-time extrusion and manufacturing issues.

• Strong understanding of plastics/polymer extrusion principles and material behavior.

• Working knowledge of polymer rheology, heat transfer, extrusion tooling, screw design, and statistical process control.

• Ability to analyze process parameters and understand how equipment settings and material characteristics affect finished-product quality.

• Experience troubleshooting extrusion defects and identifying root causes of process variation.

• Experience with DOE, PFMEA, root cause analysis, Lean Manufacturing, Six Sigma, or similar structured problem-solving methodologies.

• Comfortable working within a structured ISO-certified manufacturing environment.

• Strong communication skills with the ability to effectively interact with shop floor operators, technicians, engineering teams, cross-functional departments, and senior leadership.

• Self-directed and capable of independently managing multiple projects and priorities simultaneously.

• Collaborative working style with the ability to build effective partnerships across manufacturing, engineering, quality, and operational teams.

• Strong analytical and technical problem-solving abilities.

• Strong written and verbal communication skills.

• Strong computer skills, including Microsoft Office applications.

• Post-secondary education in an engineering or technical discipline, or equivalent relevant technical experience.

Preferred Experience

• Precision plastics extrusion experience within a tight-tolerance or technically demanding manufacturing environment.

• Experience processing high-performance thermoplastics, high-temperature polymers, engineered resins, specialty polymers, and/or polyolefins.

• Experience troubleshooting complex polymer-processing challenges involving material behavior, thermal characteristics, melt stability, drying, or material handling.

• Extrusion tooling and die development experience.

• Experience with extrusion screw design and process optimization.

• New product introduction and process-development experience from prototype through production.

• Experience establishing or improving extrusion process parameters and control plans.

• Experience reducing scrap, improving setup times, increasing process capability, or improving material utilization.

• Mechanical Engineering, Chemical Engineering, Plastics Engineering, Polymer Science, Materials Engineering, or related technical education.

• Lean Manufacturing and/or Six Sigma experience.

• Previous experience balancing hands-on manufacturing support with engineering, R&D, or process-development responsibilities.

Culture & Work Style

The organization is seeking an engineer who enjoys being directly involved with both the technical and operational sides of manufacturing. Success in this position will require:

• Comfort operating within a structured ISO-certified environment where process discipline, documentation, quality, and traceability are important.

• The ability to communicate effectively across all organizational levels, from operators on the production floor through senior leadership.

• A self-directed approach with the ability to manage multiple projects and priorities without losing focus on day-to-day production needs.

• A collaborative partnership mindset when working with Production, Quality, R&D, Engineering, Manufacturing, and other internal stakeholders.

• A willingness to remain hands-on with extrusion equipment and processes, rather than approaching the position solely from a desk-based engineering perspective.

Confidential Application

If your background aligns with this Plastic Extrusion Process Engineer opportunity and you are interested in learning more, we encourage you to apply for confidential consideration.

Qualified candidates will be contacted to discuss the company and opportunity in greater detail. No information will be shared with our client without your knowledge and approval.

Maria Abelardo, Recruiting Director
Plastic Staffing | A Division of National Search Group, Inc.
Direct: (754) 241-9507
Email: maria@plasticstaffing.com

Plastic Staffing is an equal opportunity employer committed to providing equal employment opportunities to all qualified candidates.

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