Senior Process Engineer

About the role

The Senior Process Engineer will lead process development, optimisation, and continuous improvement initiatives within a high-performance manufacturing environment. This position combines hands-on engineering expertise, project management, and new product commercialisation responsibilities to improve safety, quality, productivity, and profitability.

Responsibilities

• Serve as the technical lead for twin-screw extrusion processes and equipment.
• Optimise screw designs, barrel configurations, feeder performance, processing parameters, and throughput.
• Lead troubleshooting efforts related to product quality, process stability, equipment performance, and material variability.
• Partner with Production, Quality, Maintenance, and Product Development teams to identify and implement sustainable process improvements.
• Evaluate and support capital investment projects involving extrusion lines, automation systems, material handling equipment, feeders, and pelletisers.
• Support equipment start-up, commissioning, validation, and qualification activities.
• Develop and maintain SOPs, process flow diagrams, PFMEAs, control plans, and manufacturing process specifications.
• Drive Lean Manufacturing initiatives focused on scrap reduction, OEE improvement, and capacity expansion.
• Lead manufacturing support activities from laboratory formulation through full-scale commercial production.
• Coordinate scale-up trials, product qualification runs, customer samples, and production launches.
• Collaborate with Sales, Quality, Product Development, and Operations teams on new product introductions.
• Manage cross-functional projects and external vendors to ensure successful execution within budget and timeline requirements.

Qualifications

• Bachelor's degree in Chemical Engineering, Plastics Engineering, Materials Science, Mechanical Engineering, Manufacturing Engineering, or a related engineering discipline.
• 5-8 years of manufacturing, process engineering, or production support experience.
• Minimum 3 years of experience supporting plastics compounding and twin-screw extrusion operations.
• Strong knowledge of polymer processing, extrusion technology, and process optimisation methodologies.
• Proven experience leading technical projects and cross-functional initiatives.

Preferred skills and experience

• Experience with engineered thermoplastics, masterbatch manufacturing, or specialty compounding operations is highly preferred.
• Familiarity with equipment such as Coperion, Leistritz, Entek, KraussMaffei Berstorff, or similar extrusion systems is a plus.
• Knowledge of polymer rheology, material characterisation, and advanced material technologies is desirable.
• Lean Six Sigma experience preferred.
• Experience working within ISO 9001 quality systems and utilising DOE and SPC methodologies.

What the role offers

• Opportunity to lead critical process optimisation and manufacturing improvement initiatives.
• Significant exposure to advanced polymer technologies and innovative product development projects.
• High level of collaboration across engineering, operations, quality, and commercial teams.
• Direct impact on business growth, operational efficiency, and new product success.
• Strong opportunity for professional growth, leadership development, and long-term career advancement.