Foam Operator I - Nights

Pregis Corporation; Hopkinsville (KY); On-site; USD 42,000 - 60,000; Full time

Job summary

Pregis Corporation is seeking a PE Foam Extrusion Line Operator for the 2-2-3 12 hour night shift to operate and maintain polyethylene foam extrusion equipment, ensuring quality and safety compliance.

You will set up lines, monitor process parameters, perform changeovers, inspect density and surface quality, and coordinate with maintenance and quality teams to sustain uptime in a hot, noisy manufacturing environment.

Qualifications

• High school diploma or equivalent required.
• Experience in extrusion or plastics manufacturing preferred.
• Strong mechanical aptitude with ability to troubleshoot process/equipment.
• Ability to read and understand work instructions, specs and SOPs.
• Basic math skills for measurements and production calculations.
• Ability to safely operate manufacturing equipment.
• Willingness to work in a fast-paced production environment.

Responsibilities

• Set up and operate PE foam extrusion lines, including extruders, dies, cooling systems, and downstream equipment.
• Monitor and adjust process parameters such as temperature profiles, pressure, blowing agents, screw speed, and line speed.
• Perform product changeovers, start-ups, and shutdowns efficiently for various PE foam products.
• Inspect finished foam for density, thickness, cell structure, and surface quality to meet specifications.
• Troubleshoot quality issues such as shrinkage, collapse, uneven cell structure, or surface defects.
• Perform routine maintenance, cleaning, and die conditioning to ensure optimal extrusion performance.
• Accurately complete production records, batch logs, and quality documentation.
• Follow safety procedures for handling heated materials, pressurized systems, and blowing agents.
• Coordinate with maintenance, quality, and production teams to optimize uptime and efficiency.
• Maintain a clean, organized, and safe work environment.

Skills

Mechanical aptitude

Problem solving

Reading SOPs

Basic math

Equipment operation

Fast-paced environment

Quality awareness

Teamwork

Safety

Production records

Operational troubleshooting

Lean/continuous improvement

Education

High school diploma or equivalent

Job description

PE Foam Extrusion Line Operator - 2-2-3 12 hour night shift

Position Summary

The PE Foam Extrusion Line Operator is responsible for operating, monitoring, and maintaining polyethylene (PE) foam extrusion equipment to produce high-quality foam products in compliance with company specifications and safety standards. This role requires strong technical aptitude, attention to detail, and the ability to troubleshoot process and equipment issues specific to PE foam production.

Key Responsibilities

• Set up and operate PE foam extrusion lines, including extruders, dies, cooling systems, and downstream equipment
• Monitor and adjust process parameters such as temperature profiles, pressure, blowing agents, screw speed, and line speed
• Perform product changeovers, start-ups, and shutdowns efficiently for various PE foam products
• Inspect finished foam for density, thickness, cell structure, and surface quality to meet specifications
• Troubleshoot quality issues such as shrinkage, collapse, uneven cell structure, or surface defects
• Perform routine maintenance, cleaning, and die conditioning to ensure optimal extrusion performance
• Accurately complete production records, batch logs, and quality documentation
• Follow safety procedures for handling heated materials, pressurized systems, and blowing agents
• Coordinate with maintenance, quality, and production teams to optimize uptime and efficiency
• Maintain a clean, organized, and safe work environment

Required Qualifications

• High school diploma or equivalent
• Experience in extrusion or plastics manufacturing preferred
• Strong mechanical aptitude and problem‑solving skills
• Ability to read and understand work instructions, specifications, and SOPs
• Basic math skills for measurements and production calculations
• Ability to safely operate manufacturing equipment
• Willingness to work in a fast‑paced production environment

Preferred Qualifications

• Experience with polyethylene (PE) foam extrusion
• Familiarity with blowing agents and foam expansion processes
• Experience with PLC/HMI control systems
• Forklift certification (or willingness to obtain)
• Lean manufacturing or continuous improvement experience

Physical Requirements

• Ability to stand for extended periods
• Ability to lift up to 50 lbs
• Comfortable working in a hot, noisy manufacturing environment
• Manual dexterity and hand-eye coordination

Work Environment

Manufacturing environment with exposure to heat, noise, moving machinery, and chemical blowing agents. Required use of personal protective equipment (PPE).

Key Competencies

• Attention to detail
• Problem-solving and troubleshooting
• Teamwork and communication
• Reliability and time management
• Strong safety focus

Affirmative Action/EEO Statement/Inclusion

We offer equal employment opportunities to all employees and applicants for employment and prohibit discrimination and harassment of any type based on race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. We support inclusion and believe in welcoming a collective sum of individual differences, thoughts, traits, and characteristics to represent Pregis' culture and achievements.