Senior Manager, Product Development

Novolex; Northern (KY); Hybrid; USD 135,000 - 150,000; Full time

Benefits offered by this job

401(k) with company match

Medical, dental, vision insurance

Paid vacation and sick days

Paid parental leave

Job summary

Novolex is seeking a Product Development Engineer for Industrial Flexible Films to lead design, development, and commercialization of blown polyethylene film products for industrial applications.

You will work hands-on from lab to commercial scale, partnering with Product Management, Operations, Quality, Procurement, and Sales to deliver on time and within cost targets.

Qualifications

• Bachelor’s degree in a relevant technical field as listed.
• 10+ years of experience in polyethylene film extrusion, flexible packaging, or converting.
• Knowledge of blown film extrusion and multilayer coextrusion.
• Understanding of PE resins, additives, and structure–property relationships.
• Experience taking products from concept through scale‑up and commercialization.
• Proficiency with DOE and statistical analysis; ability to interpret film test data.

Responsibilities

• Lead product and process development for blown film products for industrial applications.
• Design multilayer coextruded film structures and optimize gauge.
• Develop and optimize blown film extrusion processes and scale-up from lab to commercial lines.
• Lead cost-out programs while preserving performance.
• Integrate PCR content and recyclable mono-material PE designs.
• Define test plans and interpret results across mechanical, optical, thermal, and sealing properties.
• Support commercialization and customer trials; provide technical support to Sales and customers.

Skills

Problem solving

Communication

Cross-functional collaboration

DOE & statistics

Travel willingness

Education

Bachelor’s degree in Chemical Engineering, Polymer/Plastics Engineering, Materials Science, or related field

Job description

Company Overview

Why Choose Us?

Novolex is a leading manufacturer of food, beverage, and specialty packaging that supports multiple industries including foodservice, restaurant delivery and carryout, food processing, grocery and retail, and industrial sectors. Novolex manufacturing and sourcing expertise spans a diverse range of substrates including resin, paper, molded fiber, aluminum and more. We provide customers a broad array of stock and customized solutions with 120 product categories, 250 brands and over 39,000 SKUs.

Our Sustainability Commitment

The Novolex sustainability vision is built upon three pillars: our products, our operations and our people. Each is critically important to our growth and future as a business. These pillars form the foundation of our company-wide commitment to sustainability, helping us achieve our ambitious goals through our wide-ranging initiatives.

Job Description

Position Summary

The Product Development Engineer for Industrial Flexible Films leads the design, development, and commercialization of blown polyethylene film products serving industrial applications. This role owns the technical work from concept through scale-up, translating customer and market needs into manufacturable film structures, driving performance and cost improvements on existing products, and advancing sustainability goals through PCR integration and mono-material recyclable designs. The engineer works hands‑on at lab, pilot, and commercial scale, and partners closely with Product Management, Operations, Quality, Procurement, and Sales to bring robust products to market on time and within cost targets.

This is a remote position with travel requirements, ideal candidates would be west‑coast based due to sites being supported within this role.

Key Responsibilities

Product & Process Development

• Develop new and improved blown film products for industrial applications (e.g., stretch hood, shrink film, heavy‑duty FFS sacks, lamination and converting films, agricultural and construction films).
• Design multilayer coextruded film structures, including resin and additive selection, layer architecture, and gauge optimization to meet mechanical, optical, and sealing requirements.
• Develop and optimize blown film extrusion processes; establish and document operating windows, and lead scale‑up from lab/pilot to commercial lines.
• Lead downgauging and cost‑out programs that preserve or improve performance (puncture, dart, tear, tensile, elongation, holding force, seal integrity).

Sustainability & Innovation

• Integrate post‑consumer recycled (PCR) content into industrial film structures while maintaining performance and processability.
• Advance mono‑material PE designs and design‑for‑recyclability in line with recognized protocols (e.g., APR / RecyClass).
• Evaluate emerging resins, additives, and film technologies for application fit and competitive advantage.

Testing & Characterization

• Define test plans and interpret results across mechanical, optical, thermal, and sealing properties.
• Apply structure–property relationships and polymer rheology to diagnose issues and guide formulation and process decisions.
• Use Design of Experiments (DOE) and statistical methods to drive efficient, data‑based development.

Commercialization & Customer Support

• Run trials at internal sites and customer/converter locations; support form‑fill‑seal, slitting, printing, and lamination processes.
• Provide technical support to Sales and customers, including troubleshooting field performance.
• Manage projects through the stage‑gate process, with clear documentation, timelines, and cross‑functional alignment.

Cross‑Functional & Documentation

• Partner with Product Management on product roadmaps, specifications, and business cases.
• Collaborate with Operations and Quality on manufacturability, specifications, and qualification.
• Maintain thorough technical records; contribute to IP, specifications, and knowledge capture.

Required Qualifications

• Bachelor’s degree in Chemical Engineering, Polymer/Plastics Engineering, Materials Science, or a related technical field.
• 10+ years of experience in polyethylene film extrusion, flexible packaging, or converting [adjust to target level].
• Working knowledge of blown film extrusion and multilayer coextrusion.
• Understanding of polyethylene resins (LDPE, LLDPE, mLLDPE, HDPE), additives, and structure–property relationships.
• Experience taking products from concept through scale‑up and commercialization.
• Proficiency with DOE and statistical analysis; comfort interpreting film test data.
• Strong problem‑solving, communication, and cross‑functional collaboration skills.
• Willingness to travel to manufacturing sites and customers.

Preferred Qualifications

• Master’s degree in a relevant engineering or polymer discipline.
• Direct experience with industrial film applications (stretch hood, shrink, FFS, lamination, ag/construction).
• Experience integrating PCR content and developing recyclable mono‑material PE structures.
• Familiarity with recyclability protocols (APR, RecyClass) and relevant EPR/PCR regulatory drivers.
• Six Sigma / Lean certification (Green or Black Belt) and DMAIC project experience.
• Hands‑on extrusion line and pilot‑plant experience.

Key Competencies

• Technical depth in polymer science and film processing
• Bias for action and hands‑on experimentation
• Customer‑and commercially‑minded engineering judgment
• Disciplined project execution and documentation
• Collaboration across a matrixed, cross‑functional organization

A reasonable estimate of the current range is $135,000 - $150,000 + bonus + benefits. The range displayed on each job posting reflects the minimum and maximum target salaries for the position across all US locations. Within the range, individual pay is determined by job‑related skills, experience, and relevant education or training. At Novolex, it is not typical for an individual to be hired at the top of the range for their role and compensation decisions are dependent on the facts and circumstances of each case.

The benefits for this role include 401(k) plan with company match, comprehensive medical, dental, and vision insurance, flexible spending and health savings accounts, paid vacation, and sick days, paid parental leave, paid holidays and wellness program.

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Company Benefits

What You’LL Get From Us

Benefits

With safety as our top priority and a commitment to employee well‑being an important focus, we offer comprehensive and competitive benefits that include medical, dental and vision insurance as well as a variety of other well‑being resources focused on mental, physical and financial health. Specific benefits and well‑being programs may vary depending on where you work.

Community Engagement

At Novolex, giving back to the local communities that support us is important. Our Focused Giving Program prioritizes support for organizations whose missions promote sustainability initiatives or address food and hunger needs. We also encourage facility level support of activities in the communities where our employees live and work.

Training and Development

We offer constant opportunities for advancement. From skills development to advanced education programs, training and development programs and courses are available through MyLearning. Programs include company and industry training curricula, support for formal education through the Tuition Reimbursement Program (Non-Union), and a Learning Management System that supports and enhances employee skills at all levels of the organization.

Novolex is committed to providing equal employment opportunity in all employment practices, including but not limited to selection, hiring, promotion, transfer, and compensation to all qualified applicants and employees without regard to age, race, color, national origin, sex, pregnancy, sexual orientation, gender identity, religion, handicap or disability, genetics, citizenship status, service member or veteran status, or any other category protected by federal, state, or local law. Any individual who, because of his or her disability, needs an accommodation in connection with an aspect of the Company's application process should contact [e-mail].

Formerly Pactiv Evergreen