Thermoforming Process Technician

Sun America LLC; Alliance (OH); On-site; USD 52,000 - 76,000; Full time

Job summary

Sun America / Central Coated Products seeks a mechanically strong Thermoforming Process Technician to operate, troubleshoot, and maintain GN800 and AMUT lines. You will lead tooling and die changeovers, diagnose faults, and perform repairs to keep production running.

This hands-on role requires reading process data, validating first-off parts, and documenting changes. Shifted on second and third shift, you will work with a safety-first mindset and contribute to uptime, quality, and lean

Qualifications

• Strong mechanical aptitude with proven ability to troubleshoot and repair production equipment.
• Hands-on experience with thermoforming machinery (GN, AMUT, or comparable form/trim systems strongly preferred).
• Working knowledge of forming tooling and trim/cut dies, including changeovers, alignment, and setup.
• Comfortable with pneumatics, hydraulics, mechanical drives, and reading the HMI/PLC interface for fault diagnosis.
• Skilled with precision measuring instruments (calipers, micrometers, dial indicators) and able to read mechanical drawings.

Responsibilities

• Plan and execute tooling changeovers on GN800 and AMUT thermoformers, including forming molds, plug-assist tooling, and trim/cut dies, with minimal downtime.
• Install, align, and set tooling: shut height/daylight, form-to-trim registration and timing, plug depth and centering, and mold cooling connections.
• Verify first-off parts after each changeover and dial in tooling to spec before releasing the line to run.
• Document changeover steps, settings, and tooling condition; flag worn or damaged tooling for repair or replacement.
• Diagnose and correct mechanical, pneumatic, hydraulic, and basic electrical faults across the thermoforming line — drive systems, indexing/chain rails, sheet feed, vacuum and pressure forming systems, trim press, and conveyors.
• Repair and replace components such as bearings, bushings, seals, cylinders, valves, belts, and gears; perform alignments and adjustments to restore proper operation.

Skills

Mechanical aptitude

Thermoforming experience

Reading drawings

Precision measurement

Team communication

Tools

HMI/PLC interface

Calipers

Micrometers

Dial indicators

Job description

We are seeking a mechanically strong Thermoforming Process Technician to operate, troubleshoot, and maintain our GN800 and AMUT thermoforming systems. This is a hands-on technical role for someone who can run the equipment, lead tooling and die changeovers, diagnose mechanical and process faults, and make repairs that keep the lines producing quality parts. The ideal candidate understands forming tooling and trim dies inside and out, reads the process to solve part-quality problems, and takes ownership of equipment uptime.

This is for second & third shift only

Key Responsibilities

• Plan and execute tooling changeovers on GN800 and AMUT thermoformers, including forming molds, plug-assist tooling, and trim/cut dies, with minimal downtime.
• Install, align, and set tooling: shut height/daylight, form-to-trim registration and timing, plug depth and centering, and mold cooling connections.
• Verify first-off parts after each changeover and dial in tooling to spec before releasing the line to run.
• Document changeover steps, settings, and tooling condition; flag worn or damaged tooling for repair or replacement.
• Diagnose and correct mechanical, pneumatic, hydraulic, and basic electrical faults across the thermoforming line — drive systems, indexing/chain rails, sheet feed, vacuum and pressure forming systems, trim press, and conveyors.
• Repair and replace components such as bearings, bushings, seals, cylinders, valves, belts, and gears; perform alignments and adjustments to restore proper operation.
• Use the HMI/PLC interface to read fault codes, sensor states, and timing, and trace issues to root cause; support controls and maintenance on more complex electrical/PLC repairs.
• Maintain mold temperature control units, chillers, vacuum pumps, and water/air systems supporting the forming process.

Process Problem-Solving & Quality

• Read the process to resolve part-quality defects — wall-thickness distribution, webbing, chill marks, poor part definition, warpage, thin spots/holes, registration, and trim/flash issues.
• Adjust heater (oven) zone profiles, plug and vacuum timing, forming pressures, mold and plug temperatures, and web indexing to bring parts back into spec.
• Conduct dimensional inspections with calipers, micrometers, and indicators to confirm specifications are met.

Maintenance & Safety

• Perform preventive maintenance: lubrication, inspection, cleaning, and scheduled component replacement to maximize uptime.
• Fabricate or modify simple fixtures, spare parts, and guarding using hand tools, power tools, and basic machining as needed.
• Maintain a clean, organized, and safe work area; follow all safety protocols and lockout/tagout procedures.
• Support continuous-improvement and lean initiatives to improve changeover times, reduce scrap, and increase line efficiency.

Required Qualifications

• Strong mechanical aptitude with proven ability to troubleshoot and repair production equipment.
• Hands-on experience with thermoforming machinery (GN, AMUT, or comparable form/trim systems strongly preferred).
• Working knowledge of forming tooling and trim/cut dies, including changeovers, alignment, and setup.
• Comfortable with pneumatics, hydraulics, mechanical drives, and reading the HMI/PLC interface for fault diagnosis.
• Skilled with precision measuring instruments (calipers, micrometers, dial indicators) and able to read mechanical drawings.
• Solid shop math for measurements, tolerances, and process calculations.
• Effective problem-solver who works well on a team and communicates clearly.

Preferred Qualifications

• Experience with extrusion, injection molding, or blow molding processes.
• Machining and fabrication background (CNC lathe, press brake, mill).
• Forklift certification and materials-handling experience.
• Familiarity with PLC troubleshooting and basic electrical work.

Physical Requirements

• Ability to lift and handle tooling and components, stand for extended periods, and work in a manufacturing environment around moving equipment, heat, and noise.

Sun America / Central Coated Products is an Equal Opportunity Employer.

We are committed to providing equal employment opportunities to all employees and applicants without regard to race, color, religion, sex (including pregnancy, gender identity, and sexual orientation), national origin, age, disability, genetic information, veteran status, or any other characteristic protected by applicable federal, state, or local law. This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, compensation, training, and discipline.

We are committed to providing reasonable accommodations to qualified individuals with disabilities and to applicants and employees with sincerely held religious beliefs. If you need an accommodation to participate in the application or interview process, please contact Human Resources.