Senior Extrusion Process Engineer

Job Overview

Working alongside our client, we are seeking an Extrusion Senior Process Engineer join their bespoke manufacturing facility

• Auto enrolled into the companies Stakeholder Pension Scheme (10% company contribution)
• Holiday entitlement increases dependent on length of service
• Life assurance covering 2x annual salary
• Private medical cover
• Subsidised canteen offering freshly cooked meals and sandwiches daily
• Free car parking
• Access to Employee Assistance Programme offering counselling support, legal guidance and medical advice for you and immediate family
• Mental Health First Aiders available to provide support and guidance
• Discounted gym memberships
• Discounted company products upon successful completion of probationary period
• Peer to Peer recognition programme
• Free Flu Jab voucher
• Christmas Savings scheme
• NHS Health checks

As an Extrusion Senior Process Engineer, you will help support the company through the next period of development and growth. Playing a key role in developing, optimising and maintaining extrusion processes to ensure consistent product quality, high operational efficiency and safe manufacturing performance.

This role combines hands-on technical expertise with analytical problem-solving to support production, improvement throughput and drive continuous improvement initiatives.

• Develop, refine, and document extrusion processes to improve product quality, reduce waste and increase efficiency
• Analyse process data to identify trends, root causes and improvement opportunities
• Lead trials, experiments and validation activities for new materials, tooling and equipment
• Provide day-to-day technical support to extrusion operators and shift teams
• Troubleshoot process deviations, equipment issues and quality concerns
• Establish and maintain process parameters and standard operating procedures (SOPs)
• Ensure all extrusion processes meet product specifications, regulatory requirements and internal quality standards
• Collaborate with Quality teams to resolve non-conformance and implement corrective actions
• Support customer audits and documentation or industry-specific standards
• Work with maintenance and engineering teams to improve equipment reliability and uptime
  
  Specify, test and implement new dies, screws, tooling and auxiliary equipment
• Participate in capital projects, equipment upgrades and commissioning activities
• Lead Lean, Six Sigma or Kaizen initiatives to reduce scrap, improve cycle times and enhance process stability
• Develop training materials and coach operators on best practices and process understanding
• Drive innovation in materials, technology and automation

• Degree in Mechanical Engineering, Chemical Engineering, Materials Science or Polymer Science
• Understanding of Rheology (material flow, viscosity, sheer thinning temperatures and speed)
• Strong understanding of extrusion principles (single screw, twin-screw, profile or relevant type)
• Experience with process troubleshooting, data analysis and root-cause investigation
• Ability to interpret technical drawings, specifications and material data sheets
• Strong communication skills and ability to work cross-functionally

• Experience in plastics, rubber or metal extrusion
• Knowledge of Lean Manufacturing, Six Sigma or similar methodologies
• Familiarity with all aspects of extrusion production equipment and material feed systems
• Hands-on experience with die-design, screw-design and rheology

“Senior Process Engineer”, “Extrusion Senior Process Engineer”, “Extrusion Technician”, “Process Setter”, “Process Technician”,“Plastics”, “Profile Extrusion