Senior Extrusion Engineering Leader

Full Circle Recruiting•Ellendale, MN

1d•Onsite

About The Position

We are seeking a highly experienced Senior Extrusion Engineering Leader to drive operational excellence across twin screw profile extrusion operations. This role is ideal for a hands-on technical expert with deep expertise in foamed PVC processing and profile manufacturing, particularly within fencing or structural profile applications. The ideal candidate will bring a minimum of 20 years of total plastics extrusion experience, with significant time spent leading twin screw extrusion lines, optimizing foamed PVC processes, and overseeing tooling design and line performance. This is a high-impact leadership role responsible for process optimization, tooling strategy, production efficiency, and continuous improvement across extrusion operations. Candidates must be located within a reasonable commuting distance to W Highway 30, Ellendale, MN. Relocation assistance is not available for this position.

Requirements

Minimum 20+ years of total plastics extrusion experience
Extensive hands-on experience with twin screw extrusion systems (counter-rotating or co-rotating)
Demonstrated experience in foamed PVC processing
Strong background in profile extrusion manufacturing, preferably fencing or similar structural profiles
Proven expertise in extrusion tooling design and optimization
Experience balancing production lines to increase throughput and reduce bottlenecks
Track record of measurable operational improvements (scrap reduction, startup time improvement, downtime reduction)
Deep understanding of foam structure control, density management, and process stabilization
Experience with extrusion line setup, commissioning, and troubleshooting

Nice To Haves

Mechanical or Plastics Engineering background (degree preferred but not required with strong hands-on experience)
Experience leading extrusion teams in a manufacturing environment
Strong understanding of downstream equipment (calibrators, vacuum sizing tanks, pullers, cutters)
Lean Manufacturing and Continuous Improvement experience
Ability to work cross-functionally with production, maintenance, and engineering teams

Responsibilities

Lead and optimize twin screw extrusion operations, specifically in rigid and foamed PVC applications
Oversee profile extrusion manufacturing, including fencing and structural profiles
Drive line balancing initiatives to improve throughput and reduce scrap
Serve as a setup expert for new and existing extrusion lines, reducing startup time and stabilizing production
Design, evaluate, and optimize extrusion tooling, including dies and downstream calibration systems
Monitor and adjust foaming parameters to control density, cell structure, and product consistency
Improve process stability, reduce downtime, and enhance overall equipment effectiveness (OEE)
Support commissioning of new extrusion equipment and upgrades
Partner with maintenance and production teams to troubleshoot mechanical and process-related issues
Develop SOPs and best practices for twin screw extrusion and foamed profile production
Lead continuous improvement initiatives to reduce scrap and increase efficiency