Sr. Packaging Engineer

About Pregis IQ

Pregis IQ is the innovation, testing, and technical solutions center for Pregis. Our team of packaging engineers helps customers optimize product protection, distribution performance, sustainability, and operational efficiency through package testing, material science, automation consulting, and packaging design.

As a material-neutral solutions provider, Pregis works collaboratively with customers to identify the most effective packaging systems for their products and supply chains. We support a wide range of industries, including food, pharmaceutical, life sciences, healthcare, medical device, industrial, e-commerce, and consumer products.

Company: Pregis LLC
Location: Pregis IQ Innovation Headquarters, Aurora, Illinois
Reports To: Senior Manager, Packaging Services

Pregis is seeking a Senior Packaging Engineer to lead the design, testing, and commercialization of cold chain and protective packaging solutions. Based within Pregis IQ, this role combines hands‑on laboratory work, thermal and distribution testing, packaging engineering, and cross‑functional project leadership to ensure products perform effectively throughout the distribution environment.

Working closely with customers, sales, product management, manufacturing, and operations teams, the Senior Packaging Engineer will develop scalable packaging systems that meet performance, regulatory, and business requirements.

The ideal candidate brings expertise in cold chain packaging, thermal qualification, package testing, and technical problem‑solving, and will play a key role in advancing Pregis’ growth across food, pharmaceutical, healthcare, life sciences, and other temperature‑sensitive markets.

• Lead development of innovative passive cold chain systems utilizing Pregis Thermal Solutions materials, , flexible materials, cushioning, and other protective packaging technologies.
• Design packaging solutions that meet customer requirements for temperature control, shock and vibration protection, damage reduction, sustainability, and cost optimization.
• Evaluate new materials, protective packaging formats, and system configurations to improve thermal and distribution performance and market competitiveness.
• Develop customer‑specific thermal packaging solutions and commercialization plans.

• Design and execute thermal testing programs utilizing environmental chambers, thermal mapping, profile analysis, and distribution simulation testing.
• Develop and manage qualification protocols aligned with ISTA, ASTM, and customer‑specific requirements.
• Conduct packaging performance evaluations to validate thermal, cushioning, containment, compression, and operational performance objectives.
• Design and lead experimentation programs supporting new material evaluation and solution development.
• Support operation of the ISTA and APASS‑certified package testing laboratories.

• Serve as a primary technical resource for customers, sales teams, distributors, and strategic partners.
• Consult with customers on cold chain best practices, packaging optimization strategies, and thermal qualification requirements.
• Participate in customer meetings, site visits, tours, technical presentations, and packaging reviews.
• Translate customer thermal and distribution challenges into engineered cold chain and protective packaging solutions.
• Deliver technical reports, recommendations, and presentations to both technical and executive audiences.

• Analyze thermal performance, distribution test data, damage risks, and customer requirements to generate actionable packaging recommendations.
• Develop…