Job Description

Job Summary

The Senior Plastic Extrusion Machine Operator leads and oversees the operation of plastic extrusion lines. This role ensures smooth line startups, color/gauge changes on the fly, precise quality control, and strict safety compliance. As a senior operator, you will monitor output metrics, perform die maintenance, operate downstream equipment like Deco systems, and train incoming crew members.

Key Responsibilities

• Line Startup & Machine Operation- Execute safe, proper startups and shut-offs of extrusion lines.

  • Perform gauge changes up or down without dropping the line.
  • Conduct orderly color changes without causing product overruns or material waste.
  • Calibrate and adjust calibrators, flow bars, choke bars, and die lips as needed.
  • Change screens on the screen changer while the line is running or idle.
  • Clean vacuum systems and understand their full operating functions.

• Tooling & Die Maintenance- Safely change, clean, disassemble, reassemble, and store dies.

  • Disassemble die ends to clear material lodged in air chambers.
  • Install, maintain, and change the Deco System on the fly per order specifications.

• Quality Assurance & Technical Reporting- Interpret work orders and adjust masterbatches to meet exact production targets.

  • Perform continuous quality checks for gram weight, color, corona, size (length/width), and squareness; record metrics on every sheet.
  • Clean and maintain the blender and loader systems to prevent cross-contamination.
  • Accurately calculate production metrics, including pieces per hour and pounds per hour.
  • Verify and complete production reports, count sheets, raw material consumption logs, purge reports, and downtime logs.

• Leadership & Team Support- Master all duties of the Back-End Helper and Assistant Operator positions.

  • Train, mentor, and guide team members willing to learn the process.
  • Lead by example regarding safety procedures, site cleanliness, and required PPE usage.

Qualifications & Requirements

• Education & Experience- High school diploma or equivalent required; vocational or technical training in machinery/manufacturing is a plus.

  • Certified forklift operator with hands-on experience.
  • Fluent bilingual communication skills required to effectively train and coordinate with crew members.

• Technical Skills & Tools- Strong mechanical aptitude with hands-on experience using precision measurement tools (calipers, bow gauges, tape measures, feeler gauges) and hand/power tools (ratchets, torque wrenches, power drills, utility knives).

  • In-depth understanding of blending, loading, and filtration systems.

• Physical Requirements & Working Conditions- Ability to stand for long shifts and regularly lift materials weighing up to 50 lbs.

• Flexibility to work various shifts, weekends, and overtime as needed.

• Commitment to wearing full Personal Protective Equipment (PPE) and maintaining an organized work area.

You should be proficient in:

• Tape Measure Reading
• Plastic Extrusion Experience