Remote Extrusion Materials Engineer

Requisition
521656
-Posted
- Architectural Products Group

- Oldcastle APG (Fence, Rail, Deck)
- Full Time

- Engineering

- United States

- Pennsylvania

Oldcastle, a CRH company, is reinventing what's possible in building solutions. We are the leading provider of innovative outdoor living products and utility infrastructure solutions for the water, energy, and communications markets throughout North America. We're a trusted and strategic partner to engineers, contractors, distributors, specifiers, retailers, and homeowners alike as the manufacturer of precast concrete, polymer concrete, and plastic infrastructure products.

Our portfolio of brands includes Oldcastle APG, Oldcastle Infrastructure, Belgard® hardscape, Echelon® Masonry, RDI® railing, Catalyst™ Fence Solutions, Sakrete® packaged concrete, Amerimix® mortar, Pebble Technology International® pool finishes, and Techniseal® sands and sealant technologies.

The Materials Science Engineer (Extrusion) provides technical expertise in polymer behavior, formulation development, and process optimization for plastic extrusion operations. This role supports production, quality, and R&D by ensuring that materials, additives, and processing conditions deliver consistent product performance, cost efficiency, and manufacturability.

This is a remote role when not traveling locally or nationally to our manufacturing sites. This person must reside in the greater Philadelphia, PA, Charlotte, NC, Dover, DE, Bulls Gap, TN or Tampa, FL area.

• Optimize extrusion parameters including melt temperature, screw speed, and line speed.
• Support design and optimization of extrusion dies, screws, and downstream equipment.
• Perform DOE studies to improve throughput, quality, and dimensional stability.
• Develop and optimize compound formulations including color masterbatch, fillers, stabilizers, and additives.
• Evaluate resin properties affecting extrusion behavior such as MFI, rheology, fusion, and thermal stability.
• Creates and documents clear, concise and accurate reports under guidance of direct management, providing insights on results and conclusions based upon data sets.
• Define resin specifications, incoming material requirements, and in‑process quality checks (dimensions, gloss, haze, tensile, melt flow, density, impact).
• Use analytical tools to diagnose material or process issues.
• Troubleshoot problems such as:
  Melt fracture / sharkskin, Gels or black specks, Die lines or surface roughness, Bubbles / voids, Warpage or dimensional instability, Color streaking or contamination, Excessive die drool or buildup.
• Work closely with extrusion operators to implement material or recipe changes, adjust settings, and improve process robustness.
• Conduct root‑cause analysis for scrap or downtime events using tools such as 5‑Why, Ishikawa, and statistical analysis.
• Maintain and update work instructions, material handling procedures, resin drying guidelines, and hopper loading practices.
• Creates procedures to ensure all safety concerns and hazards are properly addressed in compliance with company and regulatory requirement.
• Manage resin trials, supplier evaluations, and approval of alternative materials to reduce cost or improve performance.
• Reduce material usage and scrap through formulation refinement, tighter process control, and resin substitution.
• Collaborate with Purchasing and R&D on resin cost‑reduction and qualification projects.
• Support Lean, Six Sigma, and process capability improvement (Cp/Cpk) initiatives.
• Travel up to 50% of the time.

• Bachelor’s degree in Materials Science, Polymer Engineering, Chemical Engineering, or related field.
• Hands‑on experience with thermoplastic extrusion (single‑screw, twin‑screw, profile, sheet, pipe, film, tubing, or wire & cable).
• Strong understanding of polymer behavior: melt rheology, thermal transitions, degradation mechanisms, and stabilization chemistry. PVC experience preferred.
• Familiarity with quality systems, lab testing methods, and statistical analysis. Strong analytical and troubleshooting skills, especially in dynamic production environments.
• Excellent communication with operators,…