Extrusion Process Engineer

Generations People; Chesterfield; On-site; GBP 40,000 - 43,000; Full time

Benefits offered by this job

Salary £40,000

37.5 hours per week

Birthday off

Private healthcare after probation

Employer pension contribution: 5%

Life assurance: 1.75× salary

Free onsite parking

Job summary

Generations People is recruiting an experienced Extrusion Process Engineer to support and optimise HDPE pipe extrusion operations in Chesterfield. You will own process parameters, troubleshoot production issues and drive continuous improvement across extrusion lines, collaborating with Operations, Quality, Maintenance and Production to ensure high efficiency and product reliability.

The role requires hands-on technical engineering expertise, a strong background in plastics extrusion, and a

Qualifications

• 3–5+ years of hands-on process engineering experience in continuous plastics extrusion (pipe extrusion).
• Strong knowledge of HDPE extrusion processes and related materials.
• Experience with process improvement, root-cause analysis and SOP development.

Responsibilities

• Define and optimise extrusion parameters (temperature profiles, melt pressure, screw speed, line speed, cooling rates).
• Lead root-cause analysis for defects and implement corrective actions.
• Improve line speeds, throughput and material yield while maintaining mechanical properties.
• Support scrap reduction and sustainability initiatives including PCR/PIR integration.

Skills

Extrusion engineering

Process optimisation

Problem solving

Automation & PLCs

Education

Materials Science degree

Mechanical Engineering degree

Polymer Engineering degree

Tools

Single-screw extruders

Gravimetric dosing systems

Industrial PLC systems

Job description

Chesterfield — Full‑Time | Permanent

£40,000 + excellent benefits

The Role

We’re recruiting an experienced Extrusion Process Engineer specialising in plastics to support and optimise extrusion operations for a leading manufacturing business in Chesterfield. You’ll take ownership of process parameters, troubleshoot production issues, and drive continuous improvement across HDPE pipe and compression extrusion lines.

This is a technical, hands‑on engineering role working closely with Operations, Quality, Maintenance and Production to ensure high levels of efficiency, product quality and process reliability.

Key Responsibilities

Process Optimisation & Technical Leadership

• Define, standardise and optimise extrusion parameters (temperature profiles, melt pressure, screw speed, line speed, cooling rates) for HDPE
• Lead root‑cause analysis for product defects and implement corrective actions
• Improve line speeds, throughput and material yield without compromising mechanical properties
• Support scrap‑reduction and sustainability initiatives, including PCR/PIR integration and optimisation

Equipment & Tooling Management

• Work with Maintenance and equipment suppliers on preventive maintenance
• Support the design, specification and commissioning of new extrusion lines and associated equipment
• Improve SOPs, setup sheets and troubleshooting guides for operators and technicians

Quality & New Product Introduction (NPI)

• Collaborate with Technical and Quality teams to evaluate and improve process capability
• Oversee trial runs, process validations and scale‑up activities for new product launches
• Ensure processes meet mechanical, dimensional and performance standards

Requirements

• Degree/HNC/HND in Materials Science, Mechanical Engineering, Polymer Engineering or similar
• 3–5+ years’ hands‑on process engineering experience in continuous plastics extrusion (pipe extrusion)
• Strong technical knowledge of Polyethylene (HDPE), melt rheology and thermal behaviour
• Solid understanding of single‑screw extruders and gravimetric dosing systems
• Experience with industrial automation and PLC systems
• Strong analytical, problem‑solving and process‑optimisation skills

Desirable

• Experience with multi‑layer co‑extrusion
• Knowledge of plastics testing standards (ISO/BV/FM) — tensile strength, MFI, density
• Experience improving process capability and statistical process control

Working Conditions

• Engineering / manufacturing environment
• Cross‑functional collaboration with Operations, Quality, Maintenance and Production
• Hands‑on involvement in trials, validations and process optimisation
• Occasional supplier or site visits as required

Benefits

• £40,000 salary
• 37.5 hours per week
• Monday–Friday, 08:30–17:00 (1 hour unpaid lunch)
• 16‑week probation period
• Company sick pay after 6 months
• 25 days holiday + bank holidays + birthday off
• Additional leave for long service
• Christmas shutdown
• Employer pension contribution: 5%
• Life assurance: 1.75× annual salary
• Free onsite parking
• Private healthcare after probation