Packaging Engineer - Dry Business - Concord, NC

Packaging Engineer - Dry Business

Concord, North Carolina, United States

The Packaging Engineer -- Dry Business will be responsible for the design, development, and implementation of primary packaging solutions for Westrock Coffee's Dry Business segment. This role covers two primary packaging formats: flexible film structures (coffee bags) and thermoformed coffee pods. The engineer will apply deep knowledge of material science, barrier technologies, and manufacturing processes to deliver packaging that preserves product freshness and flavor, meets quality and regulatory standards, and supports our sustainability goals.

This individual will also play a key role in First Article Inspection (FAI) processes and inbound raw material quality oversight.

• Design and develop primary packaging solutions for the Dry Business, including flexible film coffee bags and thermoformed single-serve coffee pods, ensuring product integrity, extended shelf life, and environmental sustainability.
• Conduct material selection and testing to identify optimal flexible films and thermoform substrates for coffee packaging applications, balancing performance, cost, and sustainability.
• Develop and maintain detailed specifications for flexible film materials, thermoformed pod structures, lidding films, and related components.
• Evaluate and improve existing packaging designs for cost-effectiveness, performance, manufacturability, and environmental impact.
• Participate in the scale-up process from prototype to full production, ensuring smooth transitions and minimal disruption to operations.

• Lead and execute First Article Inspection (FAI) processes for new packaging components, including flexible films, thermoformed pods, lidding, and other primary materials – verifying conformance to approved specifications prior to full production release.
• Develop FAI protocols, checklists, and acceptance criteria in collaboration with Quality Assurance and Procurement teams.
• Own the inbound raw material quality process for packaging components: define incoming inspection standards, review Certificates of Analysis (COAs), conduct or oversee physical and functional testing, and disposition non-conforming materials.
• Partner with suppliers to address quality issues, drive corrective actions, and ensure continuous improvement in incoming material quality.
• Maintain documentation and traceability records related to FAI and incoming quality inspections.

• Collaborate with cross-functional teams including Product Development, Quality Assurance, Supply Chain, and Production to bring new packaging designs to market efficiently.
• Work closely with packaging material suppliers and converting partners to ensure high-quality materials, on-time delivery, and compliance with Westrock Coffee specifications.
• Troubleshoot and resolve packaging-related issues arising in the production process, including seal integrity, film performance, pod fill/seal quality, and barrier degradation.
• Stay current with industry trends, technologies, and regulations related to flexible film packaging, thermo‑formed pods, food contact materials, and sustainability.

• Bachelor's degree in Packaging Engineering, Materials Science, Chemical Engineering, or a related field.
• Minimum of 3-5 years of experience in packaging engineering, with hands-on experience in flexible films and/or thermo‑formed packaging formats.
• Demonstrated experience in packaging design, material qualification, and manufacturing process support within food, beverage, or consumer goods industries.
• Strong knowledge of flexible film structures, barrier properties, thermoforming processes, lidding materials, and sealing technologies.
• Experience conducting or leading First Article Inspections and managing inbound raw material quality processes.
• Familiarity with packaging machinery, converting processes, and quality management systems (e.g., SPC, FMEA, PPAP).
• Excellent problem-solving skills and attention to detail.
• Strong project management and organizational skills with…