Process Engineer - Blown Film (Mono & 3-Layer) bei None

Process Engineer – Blown Film (Mono & 3-Layer)

Position Summary

We are seeking a skilled Process Engineer to join our extrusion team, specializing in mono-layer and 3-layer blown film production. This role is central to driving process reliability, film quality, and continuous improvement. The ideal candidate combines technical depth in blown film extrusion with strong problem-solving, data analysis, and cross-functional collaboration skills.

Key Responsibilities

Process Control & Optimization

• Develop, monitor, and refine process windows (BUR, FLH, DDR, melt temps, die temps, nip/haul-off settings) to ensure consistent gauge, clarity, and strength.
• Implement SPC, Cp/Cpk, and DOE methods to improve control and capability.

Troubleshooting & Technical Leadership

• Serve as the primary technical resource for extrusion lines; resolve issues related to film defects, resin behavior, or equipment stability.
• Support off-shift teams with rapid diagnosis and corrective actions.

Quality & Compliance

• Partner with QA to validate film properties (dart impact, tensile, haze, COF, OTR/WVTR).
• Ensure compliance with customer specs, food-contact regulations (FDA, EU), and ISO/GMP standards.

Continuous Improvement & KPIs

• Lead Lean/Six Sigma initiatives to reduce scrap, energy usage, and changeover time.
• Deliver measurable improvements in OEE, first-pass yield, and downtime reduction.

Equipment & Technology

• Collaborate with Maintenance and OEMs (W&H, Reifenhäuser, Apline, Macchi, Gloucester, etc.) on PMs, upgrades, and critical spares.
• Support commissioning of new tooling, dies, air rings, and automation systems (IBC, AGC, profile control).

Materials & Trials

• Manage resin qualification, regrind strategy, and additive systems (slip, AB, EVOH, PA, tie layers).
• Lead customer trials and document performance for commercialization.

Training & Documentation

• Create and maintain SOPs, troubleshooting guides, and operator training programs.
• Build operator skill matrices and certification paths to elevate line performance.

Qualifications

• Bachelor’s degree in Chemical, Plastics, or Mechanical Engineering (or related).
• 3+ years of blown film extrusion experience (mono & multi-layer).
• Strong knowledge of polymer rheology, extrusion parameters, and film performance.
• Proficiency in SPC, DOE, Minitab (or similar), and process control systems.
• Hands-on experience with AGC, IBC, oscillating haul-offs, and profile control.
• Excellent analytical, problem-solving, and communication skills.

Preferred Skills

• Familiarity with W&H, Alpine, Reifenhäuser, Macchi, or Gloucester blown film lines.
• Knowledge of food packaging, healthcare, industrial film applications.
• Experience with inline testing and film analysis equipment.
• Green Belt (or higher) in Lean/Six Sigma.
• Experience with bag machine and cleanroom operations is a plus