Senior Extrusion Process Engineer

Recruitment Partner

Reference number: 40362

	Denton, Hyde, Stockport, Bolton, Wythenshawe, Rochdale
	Full Time (Permanent)
	£65,000 - £70,000
	Sierra 57 Consult
	Manufacturing
	27/03/2026
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Working alongside our client, we are seeking an Extrusion Senior Process Engineer join their bespoke manufacturing facility.

As an Extrusion Senior Process Engineer, you will help support the company through the next period of development and growth. Playing a key role in developing, optimising and maintaining extrusion processes to ensure consistent product quality, high operational efficiency and safe manufacturing performance.
This role combines hands-on technical expertise with analytical problem-solving to support production, improve throughput and drive continuous improvement initiatives.

Develop, refine, and document extrusion processes to improve product quality, reduce waste and increase efficiency
Analyse process data to identify trends, root causes and improvement opportunities
Lead trials, experiments and validation activities for new materials, tooling and equipment
Provide day-to-day technical support to extrusion operators and shift teams
Troubleshoot process deviations, equipment issues and quality concerns
Establish and maintain process parameters and standard operating procedures (SOPs)
Ensure all extrusion processes meet product specifications, regulatory requirements and internal quality standards
Collaborate with Quality teams to resolve non-conformance and implement corrective actions
Support customer audits and documentation or industry-specific standards
Work with maintenance and engineering teams to improve equipment reliability and uptime
Specify, test and implement new dies, screws, tooling and auxiliary equipment
Participate in capital projects, equipment upgrades and commissioning activities
Lead Lean, Six Sigma or Kaizen initiatives to reduce scrap, improve cycle times and enhance process stability
Develop training materials and coach operators on best practices and process understanding
Drive innovation in materials, technology and automation

Auto-enrolled into the company's Stakeholder Pension Scheme (10% company contribution)
Holiday entitlement increases dependent on length of service
Life assurance covering 2x annual salary
Private medical cover
Subsidised canteen offering freshly cooked meals and sandwiches daily
Free car parking
Access to Employee Assistance Programme offering counselling support, legal guidance and medical advice for you and your immediate family
Mental Health First Aiders available to provide support and guidance
Discounted gym memberships
Discounted company products upon successful completion of probationary period
Peer-to-Peer recognition programme
Free Flu Jab voucher
Christmas Savings scheme
NHS Health checks

Degree in Mechanical Engineering, Chemical Engineering, Materials Science or Polymer Science
Understanding of Rheology (material flow, viscosity, sheer thinning temperatures and speed)
Strong understanding of extrusion principles (single screw, twin-screw, profile or relevant type)
Experience with process troubleshooting, data analysis and root-cause investigation
Ability to interpret technical drawings, specifications and material data sheets
Strong communication skills and ability to work cross-functionally

Desirable Requirements:

Experience in plastics, rubber or metal extrusion
Knowledge of Lean Manufacturing, Six Sigma or similar methodologies
Familiarity with all aspects of extrusion production equipment and material feed systems
Hands-on experience with die-design, screw-design and rheology