Senior Process Engineer - HDPE Extrusion

About the role

Dura-Line, an Orbia Connectivity Solutions business, is hiring a Senior Process Engineer in Salt Lake City, Utah. The engineer acts as the technical subject matter expert for high-density polyethylene (HDPE) conduit manufacturing, covering continuous reel coiling lines and rigid stick extrusion, as well as offline processes such as scrap/regrind recycling and custom specialty extrusion products like CIC (cable in conduit). The role works closely with Plant Management, Maintenance, Quality Assurance and Production.

Key responsibilities

• Optimize and troubleshoot continuous HDPE extrusion lines producing Standard Duct, Micro duct and Future path conduit, and set and document processing windows (temperature profiles, melt pressure, screw speeds, vacuum calibration, haul-off speed, bath cooling).
• Manage die sizing, pin selection and die maintenance to ensure wall thickness, ovality and diameter compliance.
• Optimize cutting and reeling operations for line speed and worker safety.
• Lead offline CIC manufacturing, scrap pipe shredding, granulating and washing, regrind blending, and custom extrusion setups.
• Run 8D, 5-Why and Fishbone analyses to reduce scrap and improve OEE, and identify CAPEX projects, write RFPs and manage commissioning.
• Write SOPs, process setup sheets and troubleshooting guides, and partner with QA on quality compliance.
• Enforce machine guarding, ergonomics and LOTO protocols, and train process technicians and operators.

Required profile

• Bachelor's degree in Plastics, Chemical, Mechanical or Manufacturing Engineering (Industrial Engineering or Mechanical Engineering preferred).
• Minimum 5 to 8+ years of hands-on process engineering experience in plastics extrusion (pipe, conduit or profile extrusion preferred).
• Profound knowledge of HDPE resin properties, melt flow index, screw design and die head geometry.
• Experience with granulators, resin conveyance and gravimetric blenders, and with process scale-up, validation and equipment qualification.
• Lean Six Sigma Green Belt preferred; hands-on approach and ability to lead small teams.

Required skills

• Statistical process control (SPC) and Minitab
• SolidWorks or AutoCAD for tooling design; PLC unit operations (Siemens, Allen-Bradley)
• Project management and CAPEX budget management
• Data management, document control and ISO process auditing
• Preferred: SAP/ODEN ERP/CRM, CAD assembly drawings, automation and digitalization experience