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