Extrusion Senior Process Engineer

🔒 Confidential Employer
Posted 25 March 2026
LOCATION
Not specified
TYPE
Full-time
LEVEL
Mid-Senior level
CATEGORY
Manufacturing
This employer holds a UK Home Office sponsor license — sponsorship for this specific role is at the employer’s discretion

SKILLS

Extrusion principles Process troubleshooting Data analysis Root cause investigation Technical drawings Communication skills Rheology Lean Manufacturing

FULL DESCRIPTION

Extrusion Senior Process Engineer

We are recruiting for an Extrusion Senior Processor to help steer the [Employer hidden — view at passion-project.co.uk] group through the next period of development and growth. The Extrusion Process Engineer plays 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, improve throughout and drive continuous improvement initiatives.

Main Responsibilities & Duties

  • 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.

Production Support

  • 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).

Quality & Compliance

  • Ensure all extrusion processes meet product specifications, regulatory requirements and internal quality standards.
  • Collaborate with quality control teams to resolve non-conformances and implement corrective actions..
  • Support customer audits and documentation or industry-specific standards

Equipment & Tooling

  • Work with maintenance and engineering teams to improve equipment reliability and uptime.
  • Specify, test and implement new dies, screws, tooling and auxiliary activities.
  • Participate in capital projects, equipment upgrades and commissioning activities.

Continuous Improvement

  • 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.

Essential Criteria

  • Degree in Mechanical Engineering, Chemical Engineering, Material Science, Polymer Science.
  • Understanding of Rheology (material flow, viscosity, shear thinning temperatures and speed).
  • Strong understanding of extrusion principles (single-screw, thin-crew, 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.

Desirable Criteria

  • 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.
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