Process Engineer

Join the ZACROS team

We are seeking a highly skilled and motivated Process Engineer to join our team. As a Process Engineer, you will support the plant manufacturing and technical operations while maintaining a strong focus on continuous Process Improvement, Optimization, and Safety. This role will apply fundamental knowledge of basic principles, theories, and concepts of industry standards and practices to design, automate, modify, or develop facilities, testing, machines, equipment, or processes used in processing or manufacturing products.

Essential Functions:

  • Create and lead optimization projects for the extrusion, thermoforming, and injection molding processes by identifying, validating, and implementing continuous improvement opportunities.
  • Identify and drive projects to reduce cost, eliminate waste, and improve process capabilities, as well as to improve product quality and workplace safety.
  • Establishes process and process capability standards for all plastics processing equipment.
  • Conduct process audits to support process capability in support of product quality efforts.
  • Assist manufacturing & maintenance teams to troubleshoot automation & plastics production equipment issues by identifying root causes and implementing sustainable corrective actions.
  • Investigate process deviations and determine if existing process settings need to be updated.
  • Understand and apply Cpk, FEMA, and Gage R&R analysis for plastics production processes.
  • Create and update documentation related to plastic equipment process capabilities and validations (IQ, OQ, and PQ).
  • Responsible for leading the implementation and validation (IQ, OQ, PQ) of all new plastics processing equipment and tooling projects.
  • Develop specifications and provide technical expertise to purchase new equipment, automation, and tooling.
  • Write Engineering Trial plans to be conducted on Production equipment, execute trials, analyze data, summarize results and provide recommendations.
  • Create seamless linkages between sales, engineering, manufacturing, quality, and maintenance departments to reduce project lead times and to accelerate new products to market.
  • Use ERP system to manage item BOMs, Engineering Change Orders, and create Purchase Orders.
  • Maintain professional and technical knowledge by attending educational workshops, establishing professional networks and participating in professional societies.


  • Bachelor’s Degree in Plastics, Chemical Engineering, Mechanical Engineering, or Materials Engineering with plastics processing experience preferred.
  • A minimum of five (5) years experience as a Process Engineer on a manufacturing line required.
  • Experience with extrusion, injection molding, and thermoforming of plastics highly preferred.
  • Knowledge of thermoplastic raw materials (LDPE, LLDPE, HDPE, Nylon, PET, etc.) preferred.
  • Experience working with or troubleshooting robotic or automated systems preferred.
  • Experience with or knowledge of HMIs, PLCs and coding preferred but not required.
  • Must have the ability to understand how multi-leveled technical systems interact with one another and how changes to one system could affect other parts of the process.
  • Previous experience working in a regulated production environment (i.e., GMP, ISO) preferred.
  • Must have excellent analytical skills and the ability to troubleshoot quickly, safely, and effectively.
  • Must have extensive experience with Microsoft Excel.
  • Must have Lean Five S (5S) knowledge and experience .
  • Knowledge of statistical methods for Process Engineering required. Minitab software preferred.
  • Solidworks experience preferred but not required.
  • Willingness to come in on any of the three shifts to assist Production with technical troubleshooting when urgent.
  • Excellent interpersonal skills and ability to relate to all levels of employees.
  • Be a positive voice while effectively communicating with technical and non-technical employees.

Physical Demands:

  • Ability to walk through all parts of the plant numerous times daily.
  • Ability to stand for long periods of time.
  • Ability to lift 25 pounds regularly.
  • Must be able to walk through department numerous times per day and step up and down from platforms and catwalks.
  • Must be able to bend, stoop, squat, push, pull, and lift objects and/or equipment of various weight, size, and design.

Working Conditions:

  • Combined office, production floor, and warehouse environment – Monday through Friday, starting no later than 9am.
  • Requires exposure to equipment noise and dust.
  • Potential for occasional domestic or international travel (up to 10% annually) to suppliers, customers, and trade shows.

If you are a highly motivated individual with a passion for process optimization, we invite you to apply! Join our team and contribute to the success of our organization through your expertise in improving manufacturing processes. If you would like to apply for this position, please fill out our online job application form.