Extrusion Process Engineer

Chesterfield — Full‑Time | Permanent £40,000 + excellent benefits The Role We’re recruiting an experienced Extrusion Process Engineer specialising in plastics to support and optimise extrusion operations for a leading manufacturing business in Chesterfield. You’ll take ownership of process parameters, troubleshoot production issues, and drive continuous improvement across HDPE pipe and compression extrusion lines. This is a technical, hands‑on engineering role working closely with Operations, Quality, Maintenance and Production to ensure high levels of efficiency, product quality and process reliability. Key Responsibilities Process Optimisation & Technical Leadership Define, standardise and optimise extrusion parameters (temperature profiles, melt pressure, screw speed, line speed, cooling rates) for HDPE Lead root‑cause analysis for product defects and implement corrective actions Improve line speeds, throughput and material yield without compromising mechanical properties Support scrap‑reduction and sustainability initiatives, including PCR/PIR integration and optimisation Equipment & Tooling Management Work with Maintenance and equipment suppliers on preventive maintenance Support the design, specification and commissioning of new extrusion lines and associated equipment Improve SOPs, setup sheets and troubleshooting guides for operators and technicians Quality & New Product Introduction (NPI) Collaborate with Technical and Quality teams to evaluate and improve process capability Oversee trial runs, process validations and scale‑up activities for new product launches Ensure processes meet mechanical, dimensional and performance standards Requirements Degree/HNC/HND in Materials Science, Mechanical Engineering, Polymer Engineering or similar 3–5+ years’ hands‑on process engineering experience in continuous plastics extrusion (pipe extrusion) Strong technical knowledge of Polyethylene (HDPE), melt rheology and thermal behaviour Solid understanding of single‑screw extruders and gravimetric dosing systems Experience with industrial automation and PLC systems Strong analytical, problem‑solving and process‑optimisation skills Desirable Experience with multi‑layer co‑extrusion Knowledge of plastics testing standards (ISO/BV/FM) — tensile strength, MFI, density Experience improving process capability and statistical process control Working Conditions Engineering / manufacturing environment Cross‑functional collaboration with Operations, Quality, Maintenance and Production Hands‑on involvement in trials, validations and process optimisation Occasional supplier or site visits as required Benefits £40,000 salary 37.5 hours per week Monday–Friday, 08:30–17:00 (1 hour unpaid lunch) 16‑week probation period Company sick pay after 6 months 25 days holiday + bank holidays + birthday off Additional leave for long service Christmas shutdown Employer pension contribution: 5% Life assurance: 1.75× annual salary Free onsite parking Private healthcare after probation Apply Today