Foam Operator I - Nights

Pregis LLC.; Hopkinsville (KY); On-site; USD 42,000 - 54,000; Full time

Job summary

Pregis LLC in Kentucky is seeking a PE Foam Extrusion Line Operator for the 12-hour night shift. You will operate extrusion lines, monitor temperatures, pressures, and line speed to produce high-quality PE foam products.

The role requires mechanical aptitude, ability to read SOPs, and a safety-focused mindset. Experience in plastics manufacturing is preferred, and forklift certification is a plus.

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.

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, 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

Extrusion experience

Mechanical aptitude

SOP reading

Safety conscious

Education

High school diploma

Tools

PLC/HMI

Forklift certified

Job description

We’re Not Just in the Packaging Business–We’re in the "Wow" Business

Pregis is Hiring!

Why Join Pregis?

Pregis is in the packaging business to protect what matters. We are committed to providing our customers and employees sustainable growth through purpose-driven innovation and customer‑centric packaging solutions. If you are looking for a company that is thriving across various high growth industries and is innovative, customer focused, high integrity, believes in strong teamwork and collaboration, Pregis is the company for you. Check out the Pregis Purpose to learn how sustainability and social responsibility is at the very core of our company DNA.

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

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

• Problem‑solving and troubleshooting
• Teamwork and communication
• Reliability and time management
• Strong safety focus

Diversity and Inclusion

We believe in diversity of thought and bringing together other traits and characteristics that make an individual bring a unique experience to Pregis. We strive to foster an inclusive environment where behaviors and social norms ensure people are welcome.

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.