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