Process Engineer

Process Engineer

IKO Industries Ltd. is a market leader in the manufacturing of roofing and building materials. IKO is a Canadian owned and operated business with production facilities worldwide and has many years of unparalleled success in the roofing materials industry. Quality, integrity, and trustworthiness are the values that underlie this success, and we have built this company by hiring people who hold these values.

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We are seeking an experienced Process Engineer with a strong background in plant engineering to support our extruded polystyrene (XPS) manufacturing operations at our new Brantford, Ontario facility. The successful candidate will be responsible for optimizing production processes, supporting plant startup activities, and tuning equipment to ensure operational efficiency and high-quality XPS products.

• Optimize manufacturing processes specifically to the Brantford Ontario facility for extruded polystyrene production, including extrusion, foaming, and finishing stages.
• Lead plant startup initiatives at the facility, ensuring smooth commissioning of new equipment or processes from installation to full production capacity.
• Tune and calibrate plant-specific equipment (e.g., extruders, molds, and auxiliary systems) to achieve peak performance, product consistency, and energy efficiency.
• Monitor and troubleshoot process parameters (e.g., temperature, pressure, material flow) to maintain quality and minimize downtime during regular operations and startup phases.
• Conduct root cause analysis and implement corrective actions for process deviations, equipment failures, or quality issues unique to the plant.
• Develop and maintain standard operating procedures (SOPs) and work instructions tailored to the plant’s startup, equipment tuning, and production needs.
• Analyze plant production data to identify trends, reduce waste, and improve yield for XPS manufacturing at the facility.
• Support plant-specific capital projects, including equipment upgrades, installations, and commissioning, with a focus on cost-effectiveness and reliability.
• Ensure compliance with environmental, health, and safety regulations, including proper handling of blowing agents and raw materials at the site.
• Train and guide plant operators and maintenance staff on startup procedures, equipment tuning, and process optimization specifically to the facility.
• Collaborate with R&D and quality assurance teams to support new product trials and process validation at the plant.

• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, or a related field.
• 5+ years of experience as a Process Engineer or Plant Engineer in a manufacturing environment, ideally in extruded polystyrene (XPS), polymer extrusion, or foam production.
• Proven experience with plant startups and equipment tuning in a single-facility setting.
• Strong knowledge of extrusion processes, polymer chemistry, and plant equipment (e.g., extruders, pumps, heat exchangers) relevant to XPS production.
• Ability to troubleshoot process and equipment issues in a hands‑on, plant‑specific context.
• Experience with process optimization tools (e.g., Six Sigma, Lean Manufacturing) is a plus.
• Proficiency in data analysis and process simulation software (e.g., Aspen, MATLAB, or similar).
• Strong communication skills and the ability to work effectively with the plant’s cross‑functional team.
• Familiarity with OSHA, EPA, and other regulatory standards applicable to the facility.
• Direct experience with XPS manufacturing processes, including blowing agents (e.g., HFC, HFO, blended blowing agents) and foam density control.
• Manufacturing leadership experience or potential to advance to Sr leadership position.
• Prior involvement in plant‑specific projects, such as equipment tuning or process enhancements at a single site.
• Knowledge of energy efficiency and sustainability practices tailored to a manufacturing plant.

• Competitive salary - $91,000 - $107,000
• Health Insurance (includes Virtual Health, and HCSA), Dental Insurance, Vision Insurance
• Life Insurance, Long‑term Disability, Short‑term Disability
• RRSP Match
• Paid Vacation
• Floating Days
• Employee…