Lead Packaging Design Engineer - Wellness

Haleon; New Jersey; Hybrid; USD 132,000 - 181,000; Full time

Benefits offered by this job

Total rewards

401(k)

Tuition reimbursement

Parental leave

Healthcare coverage

Bonus program

Job summary

Haleon is seeking a Lead Packaging Design Engineer to steward packaging for the Wellness category. You will drive technical development from feasibility to detailed design, partnering with industrial design and engineering teams to deliver innovative packaging solutions within timelines and budgets.

Responsibilities include 3D CAD development, FEA/CFD analyses, DOE leadership, and cost/tolerance estimation, with a strong emphasis on manufacturability and sustainability across Haleon's global

Qualifications

• BS degree in engineering; 10 years in mechanical design engineering.
• Proficiency with 3D design systems and analysis (FEA/CFD).
• Experience with design for packaging, tooling, and manufacturability.
• Knowledge of materials used in packaging equipment and tooling.

Responsibilities

• Invent and develop packaging innovations aligned with product goals.
• Collaborate with design and engineering to execute robust packaging concepts and detailed design.
• Perform 3D CAD development, FEA/CFD analyses, and DOE planning.
• Develop packaging specifications, cost estimates, and supplier recommendations.
• Lead supplier engagement and qualification; scout new technologies.
• Ensure packaging designs meet manufacturing, quality, and sustainability criteria.

Skills

Mechanical design

3D CAD

FEA

CFD

Education

BS in Engineering

MS in Mechanical Engineering

Tools

SolidWorks

3D CAD

FEA

CFD

Job description

Welcome to Haleon. We’re a purpose‑driven, world‑class consumer company putting everyday health in the hands of millions. In just three years since our launch, we’ve grown, evolved and are now entering an exciting new chapter – one filled with bold ambitions and enormous opportunity. Our trusted portfolio of brands – including Sensodyne®, Panadol®, Advil®, Voltaren®, Theraflu®, Otrivin®, and Centrum® – lead in resilient and growing categories. What sets us apart is our unique blend of deep human understanding and trusted science. Now it’s time to fully realise the full potential of our business and our people. We do this through our Win as One strategy. It puts our purpose – to deliver better everyday health with humanity – at the heart of everything we do. It unites us, inspires us, and challenges us to be better every day, driven by our agile, performance‑focused culture.

About the role

The Lead Packaging Design Engineer serves as the packaging steward for the Wellness category, ensuring all deliverables meet or exceed quality, creative, and product requirements within established timelines and budgets.

Key responsibilities

• Innovation Steward Understand that the packaging design and technology development enables rapid creation and development of product innovations.
• Working knowledge in inventing, developing, and creating intellectual property around ownable packaging innovation
• Packaging Concept Feasibility and Detailed Design Partner with Lead Packaging Industrial Designer to execute robust technical engineering and development of packaging and tooling.
• Technical engineering and development including but is not limited to: 3D CAD using good engineering practices
• FEA using first principles to understand tolerance ranges and predict performance of the system
• Statistical dimensional analysis
• FMEA to identify and mitigate technical risks through each step of the product lifecycle
• Specification generation
• Understanding and execution of different prototyping materials and methods for early design evaluation
• Lead / Support development of packaging DOE’s for specific unit operations as part of the overall technical readiness.
• Search new applicable technologies both within and outside our industry to continuously evaluate best practice and support product innovation.
• Understand and provide comprehensive feasibility with data of assigned concept that defines function, manufacturability, component cost, tooling estimates, preliminary development lead time, risk and global consistency.
• Technical Management: supporting all aspects of the development process.
• Technical Feasibility Packaging 3D CAD development.
• Packaging cost estimating and technical profiles.
• Supplier recommendation /selection.
• Failure Mode and Effects Analysis (Pre-Design Turnover and Post Business Award).
• Support / lead value analysis into every new development ensuring the packaging construction and design provides the most cost effective and sustainable way to achieve design criteria but also provide the best function and quality.
• Work with Head of Design and Engineering to execute assigned technical sections of projects through Technical Proof of Manufacturability to ensure design and construction meet all Haleon engineering requirements.
• Execute packaging test plans for all assigned technical sections.
• Work with Package Developers and Engineering to define specifications, design criteria and defect ranges to ensure optimal process flow from manufacture of components through filling and assembly.
• Develop packaging specifications and validate that technical drawings clearly identify all aspects required to define the assigned technical unit operation.
• Work with Engineering to ensure designed packaging components assemble efficiently at optimal rate of production.
• Keep informed through colleagues, vendors, journals, professional affiliations, and seminars of new materials, processes, and procedures.
• Timeline Management Support the Package Developers with design / development schedules and identify risks or ways to mitigate risks to support a component availability requirement.
• Identify and inform of any risks and or delays during development.
• Direct and Indirect Management Work with external suppliers and vendors to develop detailed engineering designs, analysis and custom solutions.
• Build and cultivate relationships with Manufacturing and Engineering.

Basic Qualifications

• BS degree in Engineering.
• 10 years’ experience in mechanical design engineering.
• Proficiency in computer systems including 3D Design Systems and Analysis, MS Excel, Word, Outlook and Timeline management systems.
• Computer Aided Engineering – FEA and / or CFD, demonstrated ability to generate and interpret results
• Demonstrated knowledge of fundamental mechanical design and / or tooling design
• Ability to demonstrate strong fundamental engineering skills
• Technical competency in analysis of geometric objects in 2D and 3D dimensions including understanding of clearances, fit and finish of assemblies and sub‑assemblies.
• Fundamental knowledge of materials used in the construction and manufacturing of equipment and packages including but not limited to injection molding, blow molding, tool design and assembly of components.

Preferred Qualifications

• MS degree in Mechanical Engineering or equivalent Engineering Degree.
• Course concentration in solid mechanics, design and manufacturing, parts design, plastics processing, robotics and / or thermal sciences.
• SolidWorks.

Location: Hybrid in Warren, NJ or Richmond, VA; 3 days on‑site required.

The salary range for this role is: $131,518 - $180,838 plus an 18% target bonus.

Benefits

• Haleon offers a robust Total Reward package that consists of competitive pay and a comprehensive benefits program.
• This includes a generous 401(k) plan, tuition reimbursement and time off programs including 6 months paid parental leave.
• On day one, you are eligible for benefits, including our healthcare programs where the company pays for the majority of your medical coverage for you and your family.
• We also offer the opportunity to receive a discretionary bonus based on the achievement of key business performance and other incentive/recognition programs as part of the offering.

Equal Opportunities

Haleon are committed to mobilising our purpose in a way that represents the diverse consumers and communities who rely on our brands every day. It guides us in creating an inclusive culture, where different backgrounds and views are valued and respected – all in support of understanding and best serving the needs of our consumers and unleashing the full potential of our people. It’s important to us that Haleon is a place where all our employees feel they truly belong. During the application process, we may ask you to share some personal information, which is entirely voluntary. This information ensures we meet certain regulatory and reporting obligations and supports the development, refinement, and execution of our inclusion and belonging programmes that are open to all Haleon employees. The personal information you provide will be kept confidential, used only for legitimate business purposes, and will never be used in making any employment decisions, including hiring decisions. Please note that if you are a US Licensed Healthcare Professional or Healthcare Professional as defined by the laws of the state issuing your license, Haleon may be required to capture and report expenses Haleon incurs, on your behalf, in the event you are afforded an interview for employment. This capture of applicable transfers of value is necessary to ensure Haleon’s compliance to all federal and state US Transparency requirements.

Note to candidates

The Haleon recruitment team will contact you using a Haleon email account (@haleon.com). If you are not sure whether the email you received is from Haleon, please get in touch.