Senior Extrusion Process Engineer

Job Overview: Working alongside our client, we are seeking an Extrusion Senior Process Engineer join their bespoke manufacturing facility Benefits: * 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 Remit: * 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. Responsibilities: * 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 Experience Requirements: * 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 Desirable Requirements: * 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 Key Words: “Senior Process Engineer”, “Extrusion Senior Process Engineer”, “Extrusion Technician”, “Process Setter”, “Process Technician”,“Plastics”, “Profile Extrusion