Sr. Product Development Engineer, Industrial Flexible Films

Novolex is a leading manufacturer of food, beverage, and specialty packaging. The Product Development Engineer for Industrial Flexible Films leads the design, development, and commercialization of blown polyethylene film products serving industrial applications.

Responsibilities:

• Develop new and improved blown film products for industrial applications (e.g., stretch hood, shrink film, heavy-duty FFS sacks, lamination and converting films, agricultural and construction films)
• Design multilayer coextruded film structures, including resin and additive selection, layer architecture, and gauge optimization to meet mechanical, optical, and sealing requirements
• Develop and optimize blown film extrusion processes; establish and document operating windows, and lead scale-up from lab/pilot to commercial lines
• Lead downgauging and cost-out programs that preserve or improve performance (puncture, dart, tear, tensile, elongation, holding force, seal integrity)
• Integrate post-consumer recycled (PCR) content into industrial film structures while maintaining performance and processability
• Advance mono-material PE designs and design-for-recyclability in line with recognized protocols (e.g., APR / RecyClass)
• Evaluate emerging resins, additives, and film technologies for application fit and competitive advantage
• Define test plans and interpret results across mechanical, optical, thermal, and sealing properties
• Apply structure–property relationships and polymer rheology to diagnose issues and guide formulation and process decisions
• Use Design of Experiments (DOE) and statistical methods to drive efficient, data-based development
• Run trials at internal sites and customer/converter locations; support form-fill-seal, slitting, printing, and lamination processes
• Provide technical support to Sales and customers, including troubleshooting field performance
• Manage projects through the stage-gate process, with clear documentation, timelines, and cross-functional alignment
• Partner with Product Management on product roadmaps, specifications, and business cases
• Collaborate with Operations and Quality on manufacturability, specifications, and qualification
• Maintain thorough technical records; contribute to IP, specifications, and knowledge capture

Requirements:

• Bachelor's degree in Chemical Engineering, Polymer/Plastics Engineering, Materials Science, or a related technical field
• 3+ years of experience in polyethylene film extrusion, flexible packaging, or converting [adjust to target level]
• Working knowledge of blown film extrusion and multilayer coextrusion
• Understanding of polyethylene resins (LDPE, LLDPE, mLLDPE, HDPE), additives, and structure–property relationships
• Experience taking products from concept through scale-up and commercialization
• Proficiency with DOE and statistical analysis; comfort interpreting film test data
• Strong problem-solving, communication, and cross-functional collaboration skills
• Willingness to travel up to 50% to manufacturing sites and customers
• Master's degree in a relevant engineering or polymer discipline
• Direct experience with industrial film applications (stretch hood, shrink, FFS, lamination, ag/construction)
• Experience integrating PCR content and developing recyclable mono-material PE structures
• Familiarity with recyclability protocols (APR, RecyClass) and relevant EPR/PCR regulatory drivers
• Six Sigma / Lean certification (Green or Black Belt) and DMAIC project experience
• Hands-on extrusion line and pilot-plant experience