Senior Process Engineer - Plastic Extrusion Expertise Required

Hi-Cone; Itasca (IL); On-site; USD 120,000 - 150,000; Full time

Job summary

Hi-Cone, a division of ITW, seeks a Senior Process Engineer to lead extrusion, conversion, and labeling processes across its global manufacturing network. The role drives process capability, equipment reliability, and sustainability initiatives while partnering with operations, maintenance, quality, and product development teams to improve safety, quality, delivery, and cost.

You will develop and implement manufacturing standards, lead capital projects, and shepherd new product

Qualifications

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, Plastics Engineering, Industrial Engineering, or related technical field.
• 7+ years of manufacturing process engineering experience with demonstrated expertise in plastic extrusion, polymer processing, flexible packaging, converting, film manufacturing, or related industries.
• Hands-on troubleshooting and optimization of cast film, sheet extrusion, blown film, or similar continuous manufacturing processes.
• Proven experience optimizing manufacturing processes, improving equipment reliability, and driving productivity in a production environment.
• Experience supporting capital projects, equipment installations, commissioning activities, and process validation.
• Strong understanding of process capability analysis, SPC, root cause analysis, and Lean Manufacturing principles.
• Experience with recycled material processing, sustainability initiatives, and continuous improvement methodologies preferred.
• Experience with CAD, SolidWorks or AutoCAD preferred.

Responsibilities

• Serve as global SME for extrusion, material conversion, and labeling operations.
• Establish global process standards, operating windows, control plans, and best practices across all facilities.
• Lead troubleshooting and resolution of complex manufacturing issues impacting safety, quality, throughput, waste, and reliability.
• Establish, monitor, and improve process capability metrics and benchmarks for global assets.
• Provide technical leadership, coaching, and training in process optimization and problem-solving techniques.
• Lead root cause investigations and corrective actions for extrusion performance and product consistency.

Skills

Plastic extrusion

Polymer processing

Process optimization

Lean manufacturing

Root cause analysis

Cross-functional collaboration

Education

Bachelors degree in Mechanical / Chemical / Plastics / Industrial Engineering

Tools

CAD

SolidWorks

AutoCAD

Job description

Company Overview

Hi-Cone, a division of ITW (NYSE: ITW), is a global leader in sustainable multipackaging solutions for the Alcohol and Non-Alcoholic Ready to Drink (NARTD) beverage markets. We partner with major Consumer Packaged Goods (CPG) companies to deliver innovative, environmentally responsible secondary packaging systems. As part of ITW’s decentralized structure, Hi-Cone leverages the ITW Business Model to drive customer-focused innovation, operational excellence, and market leadership.

Job Description

Position Summary

The Senior Process Engineer serves as the technical leader for extrusion, material conversion, and labeling processes across Hi-Cone's global manufacturing network. This role is responsible for driving process capability, operational excellence, equipment reliability, material utilization, and technology advancement initiatives. Leveraging extensive hands-on manufacturing experience, the Senior Process Engineer develops and implements global manufacturing standards, leads process optimization efforts, supports capital investment projects, and provides technical leadership for strategic initiatives including PCR integration, sustainability objectives, and new product commercialization. The position acts as a subject matter expert for polymer processing, die-cutting/punch press operations, and labeling technologies while partnering with operations, maintenance, quality, and product development teams to improve safety, quality, delivery performance, and cost.

Key Responsibilities

• Serve as global Subject Matter Expert (SME) for extrusion, material conversion, and labeling operations.
• Establish global process standards, operating windows, control plans, and best practices across all manufacturing facilities.
• Lead troubleshooting and resolution of complex manufacturing issues impacting safety, quality, throughput, waste, and equipment reliability.
• Establish, monitor, and improve process capability metrics and operational benchmarks to drive consistency and performance across global production assets.
• Provide technical leadership, coaching, and training to plant engineering, operations, maintenance, and quality teams in process optimization, root cause analysis, and problem-solving methodologies.
• Lead root cause investigations and corrective actions for chronic process issues related to extrusion performance, material conversion, labeling quality, and product consistency.

Asset & Performance Management

• Develop and maintain a comprehensive global equipment inventory and manufacturing capability matrix for extrusion, conversion, and labeling assets.
• Establish maintenance standards, critical spare parts strategies, and equipment care plans for extrusion, punch press, and labeling operations.
• Conduct global audits of extrusion, punch press, and labeling assets to identify reliability risks, capacity constraints, and equipment rebuild priorities.
• Partner with operations and maintenance teams to identify and execute asset improvement opportunities that increase productivity, quality, and equipment uptime.
• Support capital planning, equipment upgrades, and technology implementations through technical evaluation and performance analysis.
• Develop and deploy a global preventive maintenance framework and asset care strategy in collaboration with maintenance, quality, and engineering teams.
• Establish maintenance standards and critical spare parts strategies for extrusion, tooling, conversion, and labeling equipment.
• Drive continuous improvement initiatives focused on safety, quality, throughput, material utilization, waste reduction, and operational efficiency utilizing ITW Toolbox principles.

Process Monitoring & Innovation Support

• Implement process monitoring and condition-tracking systems to identify deviations, improve process stability, and ensure consistent product quality.
• Assess manufacturing capability and process readiness to support 55% PCR processing requirements under varying material and supply chain conditions.
• Lead process trials and evaluate the manufacturing impacts of alternate materials, new product developments, and CBI initiatives.
• Support qualification, validation, and commercialization of new products, materials, and manufacturing technologies.
• Evaluate emerging technologies, automation opportunities, and process improvements that enhance safety, productivity, quality, and sustainability across the global manufacturing network.

Education And Experience

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, Plastics Engineering, Industrial Engineering, or related technical field required.
• 7+ years of manufacturing process engineering experience with demonstrated expertise in plastic extrusion, polymer processing, flexible packaging, converting, film manufacturing, or related industries, required.
• Demonstrated hands-on experience troubleshooting and optimizing cast film, sheet extrusion, blown film, or similar continuous manufacturing processes.
• Proven experience optimizing manufacturing processes, improving equipment reliability, and driving productivity improvements in a production environment.
• Experience supporting capital projects, equipment installations, commissioning activities, and process validation.
• Strong understanding of process capability analysis, SPC, root cause analysis, and Lean Manufacturing principles.
• Experience with recycled material processing, sustainability initiatives, and continuous improvement methodologies preferred.
• Experience with CAD, SolidWorks or AutoCAD preferred.

Character Capabilities Required

• Learning Agility: Quickly understand and apply new concepts to drive execution.
• Analytical Thinking: Evaluate and interpret complex data to define desired outcomes and potential solutions.
• Collaborative: Strong team-oriented approach to problem analysis and resolution.
• Adaptability: Ability to adjust to changing project requirements, emerging technologies, and evolving industry trends.
• Strategic Mindset: Ability to anticipate future trends, align decisions with long—term objectives, and prioritize actions that create sustainable value.

Credibility Capabilities Required

• Project Management: Demonstrated ability to consistently execute projects and meet objectives/timelines.
• Manufacturing Methods: Strong background in manufacturing processes with capability to identify key requirements in method selection.
• Standardization: Clear, focused approach to aligning processes and products to reduce variability and ensure consistency across lines/facilities.
• Product Testing: Proficient in evaluation, instrumentation, and data analysis to ensure compliance with specifications and standards.

Physical Demands

• Frequently required to reach with hands and arms.
• Regularly required to sit and walk.
• Occasionally required to stoop, kneel, crouch, or crawl.
• The employee must frequently lift and/or move up to 35 pounds.
• Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception and ability to adjust focus.

Working Conditions

• Regularly will work in an office setting
• Regularly will work in a manufacturing setting and required to wear personal protective equipment (hearing protection, safety shoes, safety gloves, safety glasses, hi—viz apparel).

Hours of Work

• Normal business hours with occasional extended hours as needed
• Flexibility with schedule to meet critical deadlines
• Travel to other divisional and vendor locations, domestic and international, up to 20% as needed

Compensation Information

The base salary range for this position is $120,000 – $150,000 annually. Actual compensation will be determined based on factors such as the candidate’s skills, qualifications, experience, and geographic location (this range is for successful candidates in the Chicago, Illinois metro area), and may fall outside of this range in certain circumstances.

Additionally, the successful and their eligible family members will be eligible for ITW’s generous benefits. Our comprehensive plans currently include Medical and Prescription Drug, Dental, Flexible Spending, Wellness, Basic and Voluntary Life and Accident Insurance, Dependent Life, Disability, and more. Learn more about our full benefit offerings by visiting https://myitwhr.com/.

ITW is an equal opportunity employer. We value our colleagues’ unique perspectives, experiences and ideas and create workplaces where everyone can develop their careers and perform to their full potential.

As an equal employment opportunity employer, ITW is committed to equal employment opportunity and fair treatment for employees, beginning with the hiring process and continuing through all aspects of the employment relationship.

All qualified applicants will receive consideration for employment without regard to race, color, sex, gender identity, sexual orientation, religion, national origin, age, disability, protected Veteran status or any other characteristic protected by applicable federal, state, or local laws.