Development Engineer I

About the Role

TekniPlex is seeking a highly motivated Development Engineer I to join our Flexible Packaging Product Development team in Winston-Salem, NC. This entry-level engineering position offers an exciting opportunity to develop innovative flexible packaging solutions and support their commercialization from concept through full-scale production. In this collaborative role, you will work closely with experienced Product Development Engineers, Manufacturing, Sales, Quality, Procurement, Operations, Regulatory, and customers to design, develop, test, validate, scale-up, and commercialize flexible packaging structures—including lidding substrates, pouching substrates, and closure liners—for a variety of applications in consumer products, food & beverage, healthcare, and industrial markets.

Responsibilities

• Product Development
  • Lead the development of new flexible packaging structures from concept through commercialization.
  • Design materials configurations to meet performance, manufacturing, regulatory, sustainability, and cost objectives.
  • Supervise pilot and production line trials; generate technical recommendations based on laboratory, pilot, and production trial results.
  • Document trial results accurately and in a timely manner in the Lotus Notes Trial Request Database.
  • Maintain contact with raw material suppliers and identify, evaluate, and recommend new materials for improved performance or reduced cost.
  • Use ERP system to create raw materials part codes and finished goods recipes.
  • Conduct engineering cost calculations (costing) and provide to the pricing analyst.
• Product Commercialization
  • Coordinate production trials and assist in scale-up activities to commercial production.
  • Prepare technical reports summarizing development work, trial results, conclusions, and recommendations.
  • Work with Operations to optimize manufacturability and process capability.
  • Provide assistance in the field to customers and other company representatives in the successful conversion to new products.
• Laboratory Testing & Data Analysis
  • Conduct laboratory testing of flexible packaging materials, including:
    • Seal strength and peel force
    • Lamination bond strength
    • Coefficient of friction (COF)
    • Mechanical properties such as burst strength
    • Barrier properties
    • Microscopy
    • Product compatibility testing
  • Analyze test data and communicate findings clearly.
  • Conduct statistical analysis using Excel (Minitab a plus).
  • Maintain laboratory data files and technical documentation.
• Converting Process
  • Write and execute trial and test plans involving flexible packaging converting operations, including:
    • Flexographic printing
    • Gravure printing
    • Adhesive lamination
    • Extrusion lamination
    • Extrusion coating
    • Slitting
    • Gravure coating
    • Wax bonding
    • Coextrusion processes
    • Paper, polymer film, and aluminum foil converting
  • Support investigations related to:
    • Material and substrate performance
    • Process capability
    • Product quality (Critical to Quality – CTQ)
    • Manufacturing efficiency
    • Customer technical issues
• Cross-Functional Collaboration
  • Work closely with:
    • Product Development Team members
    • Manufacturing
    • Sales
    • Marketing
    • Quality
    • Regulatory
    • Procurement
    • Operations (logistics, supply chain, other functions)
    • Equipment suppliers
    • Raw material suppliers
    • Customers

Requirements

• Up to 15% overnight travel may be required.
• Able to work extended hours as required.
• Valid driver’s license with acceptable driving record.
• Ability to effectively communicate in-person or virtually, both orally and in writing.
• Bachelor’s Degree in: Chemical Engineering (preferred), Materials Science (preferred), Packaging Engineering, Polymer Science, Polymer Engineering, Mechanical Engineering, or other Engineering or related scientific discipline.
• 1–3 years of engineering or product development experience in flexible packaging, converting, packaging materials, or related industries. Internship, co-op, undergraduate research, or industrial experience in flexible packaging is highly desirable.

Skills

• Flexible Packaging Materials: Knowledge of and experience with polymer films, paper, aluminum foil, extrusion resins, adhesives, coatings, sealant technologies, and sustainable/recyclable packaging structures.
• Flexible Packaging Manufacturing Processes: Knowledge of and experience with flexographic printing, gravure printing, adhesive lamination, extrusion lamination, extrusion coating, slitting, gravure coating, wax bonding, coextrusion, and web handling/converting operations.
• Basic project management skills with the ability to navigate complex projects through a global organization while managing risk, contingency plans, timelines, and results.
• Capable of understanding and using analytical (infrared spectroscopy, gas chromatography, differential scanning calorimetry, optical microscopy, etc.) and mechanical/physical test methods; experience with statistical analysis, experimental design, and interpreting results to drive product development.
• Hands-on experience performing routine physical tests (heat-seal, tensile, COF, barrier, burst, peel, etc.) and interpreting results to drive product development.
• Testing method development and test protocol (SOP) writing (if/as necessary).
• Knowledge of product development Stage/Gate process, Design of Experiments, Six Sigma methodology, and statistical analysis (e.g., Minitab).
• Excellent written and verbal communication skills.
• Capable of communicating with customers and operations personnel under stressful or adverse conditions.
• Proven ability to work with minimal direction, analytical thinking, and problem-solving ability.
• Proficient computer literacy with established basic knowledge in general applications: word processing, spreadsheets, PowerPoint, and ERP systems.

Pay

The compensation package will pay up to $75,000 plus a target bonus incentive.