Senior Process Engineer

Dura-Line is hiring for a Senior Process Engineer in Salt Lake City, Utah!Your Role: The Senior Process Engineer serves as the technical subject matter expert for high-density polyethylene (HDPE) conduit manufacturing operations. This role is responsible for driving process efficiency, product quality, machine throughput, and continuous improvement across continuous reel coiling lines and rigid stick extrusion operations. Additionally, the engineer oversees technical operations for offline processes, including scrap/regrind pipe recycling systems, and custom specialty extrusion products such as CIC (cable in conduit).

The ideal candidate possesses deep hands-on expertise in single-screw resin extrusion, tooling design, vacuum sizing, cooling bath dynamics, post-extrusion coiling/cutting automation, and polymer melt behavior. This position collaborates closely with Plant Management, Maintenance, Quality Assurance, and Production Personnel to minimize scrap, eliminate downtime, optimize regrind blending, and ensure strict QC compliance, and customer specifications.

**About Orbia Connectivity Solutions Dura-Line:

Join Dura‑Line, an Orbia Connectivity Solutions business, where we create solutions that connect people and information across the globe. As a leading global manufacturer of conduit products and accessories, Dura‑Line creates the pathways that power connectivity across a wide range of markets worldwide. Quality, safety, and sustainability are at the core of everything we do, with environmentally responsible practices embedded throughout our manufacturing processes. Be part of our shared mission with Orbia to Advance Life Around the World.

Key Responsibilities:

Extrusion & Line Process Optimization (Reels & Stick Form)

• Primary Line Management: Optimize and troubleshoot continuous HDPE extrusion lines producing Standard Duct, Micro duct, and Future path conduit products in continuous coils/reels and straight stick lengths.

• Parameter Standardizations: Establish, document, and standardize optimal processing windows (temperature profiles, melt pressure, screw speeds, vacuum calibration, haul-off/puller speed, and bath cooling controls).

• Tooling & Die Maintenance: Manage die sizing, pin selection, and extrusion die maintenance to ensure wall thickness, ovality, and inner/outer diameter compliance.

• Post-Extrusion Automation: Optimize downstream operations (cutting, reeling, etc.) to maximize line speed and worker safety.

Offline & Specialty Processes (CIC, Regrind & Custom Products)

• Cable-in-Conduit (CIC) Operations: Provide technical leadership for offline CIC manufacturing, ensuring proper tension control, cable feed synchronization, jacket adhesion/jacket temperature, and damage-free cable insertion.

• Scrap & Regrind Processing: Develop and manage technical parameters for offline scrap pipe size reduction (shredding, granulating, and washing), resin blending, and regrind incorporation ratios without compromising product physical standards.

• Specialty Product Line Operations: Lead process design, tooling validation, and setup for customized extrusions, multi-duct bundles, co-extruded color stripes, and smooth-out walls.

• Material Yield Maximization: Establish quality limits for reprocessed materials and optimize compounding/regrind feed systems to minimize raw material waste.

Continuous Improvement, Lean & Root Cause Analysis

• OEE & Scrap Reduction: Lead structured problem-solving (8D, 5-Why, Fishbone) to resolve chronic operational bottlenecks, reduce start-up scrap, and increase Overall Equipment Effectiveness (OEE).

• Capital Projects (CAPEX): Identify equipment upgrade opportunities, develop business cases, write RFPs, and manage installation/commissioning of new extrusion lines, tooling, and scrap processing equipment.

• Standard Operating Procedures (SOPs): Author comprehensive SOPs, process setup sheets, and troubleshooting guides for operators and technicians.

Cross-Functional Collaboration & Quality Assurance

• Quality Compliance: Partner with QA to ensure conduit products meet or exceed industry and customer standards.

• Safety & EHS: Enforce machine guarding, ergonomics, and thermal safety standards on extrusion equipment, scrap processing machines, and other offline equipment.

• Training & Mentorship: Train process technicians and extrusion line operators on fundamental polymer processing techniques and preventive maintenance habits.

• Bachelor’s degree in engineering preferred, ideally Industrial Engineering or Mechanical Engineering.

• Around 2 years of experience in production manufacturing; Plastic or Rubber industry experience is advantageous.

• 3–5 years of hands-on experience managing high-dollar strategic projects, including new plant transformations and relocations.

• Proficiency in project management to ensure timely delivery of projects related to scrap & productivity goals, product introduction, OEE, conversion cost, and CAPEX projects.

• Technology-savvy with experience in automation, digitalization procedures, CAD assembly drawings, Tooling Design, Solid Works, AutoCAD 2D, ERP/CRM systems (SAP/ODEN is a plus).

• Expertise in managing CAPEX budget and capital projects.

• Analytical mindset with the ability to diagnose processes and equipment, implementing sustainable solutions.

• Experience in data management, document control, and ISO process auditing.

• Strong leadership skills to train and coach peer employees.

• Experience with process scale-up, process optimization, cleaning, and validation.

• Experience with equipment specification, qualification, and automation.

• Ability to lead small teams and projects. Lean Six Sigma Green Belt preferred.Expectations:

• Hands-on Approach: Must be a hands-on engineer that can develop strong floor presence and rapport with production associates and operators.

• Technical Leadership: Demonstrate deep technical domain knowledge of HDPE processing and single-screw extrusion mechanics.

• Scrap & Material Loss Reduction: Achieve measurable continuous reduction in scrap rates across all product lines.

• Equipment Uptime & Efficiency: Improve overall plant capacity utilization through setup time reduction (SMED) and standard operating procedures.

• Regrind Utilization: Maintain maximum sustainable blend ratios of internal regrind without negatively impacting tensile strength, environmental stress crack resistance (ESCR), or impact requirements.

• Safety First Mindset: Maintain zero lost-time incidents on modified or new process lines and uphold strict lockout/tagout (LOTO) protocols.

Qualifications, Education & Skills:

• Required Education: Bachelor of Science (B.S.) in Plastics Engineering, Chemical Engineering, Mechanical Engineering, Manufacturing Engineering, or a related technical degree.

• Years of Experience: Minimum 5 to 8+ years of hands-on process engineering experience in plastics extrusion manufacturing (profile, pipe, conduit, or sheet extrusion preferred).

• HDPE Extrusion Expertise: Profound knowledge of HDPE resin properties, melt flow index (MFI), thermal behavior, screw design (barrier screws, mixing elements), die head geometry, and process parameter tuning.

• Offline Process Familiarity Desired: Proven working experience with heavy-duty granulators/shredders, resin conveyance, and gravimetric blender systems.

• Analytical & Technical Tools: Proficiency in statistical process control (SPC), Minitab, SolidWorks or AutoCAD (for tooling design), and PLC unit operations (Siemens, Allen-Bradley).

• Certifications (Preferred): Six Sigma Green Belt or Black Belt certification; Lean Manufacturing training.

Working Conditions & Physical Demands:

• Work Environment: Split time between a professional office setup and a fast-paced 24/7 heavy industrial extrusion floor with heat, noise, dust from regrind, and heavy machinery operations.

• Physical Capabilities: Must be able to stand, walk, bend, climb platforms, and lift up to 40 lbs. when conducting trial runs, line troubleshooting, or tooling inspections.

• Travel Requirements: Occasional travel (up to 10-15%) for equipment acceptance testing (FAT), supplier visits, or technical industry conferences.

Our Offer:

The compensation for this position is typically range from $100,000 to $125,000 annually.

The actual base pay offered to the successful candidate will be based on multiple factors, including but not limited to job-related knowledge/skills, experience, geographical location, and internal equity. The compensation package may also include short and long-term incentive compensation. We offer a comprehensive benefits package that includes healthcare coverage, USA 401(k) retirement savings plan, paid company holidays, paid vacation time, paid sick time, parental leave, short- and long-term disability leave, education reimbursement, and an employee assistance program. At Orbia, we are committed to taking care of our employees and believe in providing comprehensive support so you can thrive at work and home.

JOIN OUR GROWING TEAM TODAY!

As part of Orbia Connectivity Solutions, Dura-Line offers an exciting work environment and career opportunities in a continuously growing company. We are committed to attracting, developing, and retaining a diverse workforce that reflects our global customer base.

Acquisition based on this vacancy is not appreciated and unsolicited applications from third parties will not be accepted.

All employees are subject to pre-employment Background Check and Drug Screening, and employment is contingent upon successful clearance of both.

Orbia is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity or expression, marital status, national origin, age, disability, genetic information, veteran status, or any other status protected by applicable federal, state, or local law.