Process Technician
Genpak LLC

Middletown, New York

The Process Technician is responsible for working with Process Engineering to resolve ongoing problems, supporting set-up and changeovers in bringing lines into production, working with corporate engineers on new product development and R&D trial requests, and working to maintain accurate and up-to-date process sheets. Appropriately communicate information clearly and accurately whether by emails, reports or meetings. Lead efforts on the production floor to develop improved process capabilities by reviewing data, contributing to programs, looking at new technologies and acting upon the findings.

  • Be the plant expert in fields of our work, whether it is extrusion or thermoforming
    • Perform changeovers with minimal downtime
    • Ensure all products are running at correct production rate
    • Update, review and manage process sheets within the plant
    • Develop, implement and execute programs to improve overall product quality and line efficiencies.
    • Ability to operate and troubleshoot processes and equipment at an elevated level to resolve complex issues.
  • Lead efforts on the production floor to develop improved process capabilities by reviewing data, contributing to programs, looking at new technologies and acting upon the findings.
    • Clearly document all findings and data gathered while working on projects and improvements, with clear communication via reports, emails and/or meetings,
    • Utilize problem-solving and troubleshooting techniques to find root cause
    • Provide root cause problem identification and recommend equipment and process modifications to resolve.
  • Train all levels of operators on proper operation of equipment.
    • Verify operator level achievement for pay-for-skills advancement
    • Develop and conduct training programs for line operators and process technicians.
  • Provide process input to new product development teams.
    • Work with corporate engineers on new project development, lead plant start-up of these jobs and develop stable process conditions.
  • Work with material suppliers on understanding material behavior throughout the whole process.
  • Other duties as necessary to operate the plant in a safe and efficient manner.


  • Ability to communicate effectively and work closely and productively as part of a cross-functional team.
  • Ability to prioritize multi-task duties without loss of efficiency or composure.
  • Effective written and verbal communication and the ability to disseminate information in a timely and diplomatic manner.
  • Ability to work under pressure, meet scheduled deadlines, respond to emergency situations without loss of efficiency or composure.
  • Communicate regularly and pro-actively with all levels of employee regarding problems or issues impacting processes.
  • Strong record keeping and training skills will be key in successfully implementing consistent processes.
  • Ability to motivate and train and delegate responsibility to indirect reports.
  • Demonstrated ability to work without supervision.
  • Ability to create and/or exhibit an atmosphere of openness, honesty, trust, and teamwork.
  • Demonstrates understanding of product development process.
  • Strong analytical skills with a high level of initiative and trouble shooting skills
  • Excellent planning, organizational, leadership and assessment skills

Technical Knowledge:

  • Process expert in the areas of sheet extrusion, different materials, forming and trimming of thermoformed products and automation.
  • Good understanding of mechanical and electrical principles and applications.
  • Ability to read and understand schematics and blueprints
  • Ability to operate thermoforming and extrusion equipment and peripherals.
  • Demonstrates knowledge of company specific product, material and/or production technological methods and procedures, and capabilities of machines and equipment in manufacturing facilities.
  • Demonstrates a fundamental understanding of standard manufacturing business processes.
  • Demonstrates an advanced comprehensive knowledge of entire process from concept to commercialization.
  • Demonstrates advanced mechanical aptitude and abilities.
  • Demonstrates ability to troubleshoot and efficiently identify appropriate course of action.


  • Demonstrate ability to initiate and perform root cause analysis and implement corrective action to drive improvement.
  • Ability to meet or exceed performance standards and continuously improve upon them.


  • Demonstrated ability to comply with all Company policies and procedures and to uphold, support and exemplify the safety programs and standards.


  • Ability to develop and maintain processes that are ISO compliant.


  • Minimum 5-8 years relevant experience (or similar combination of education and experience). Two or four year technical degree or certification desirable.
  • Experience in plastics processing, including forming and extrusion required
  • Knowledge of both conventional and OMV equipment and processes required
  • Experience working with machinery
  • Strong interpersonal skills to be able to train, communicate, and lead effectively.
  • Knowledge of MS Office and familiarity with database applications.
  • Knowledge of physical properties and behaviors
  • Demonstrated analytical thinking and problem-solving skills.
  • Speaking and presentation skills to conduct effective meetings.


Must be able to:

  • Work an 8-hour shift with overtime as required.
  • Sit constantly, stand and/or walk frequently
  • Speak and hear constantly
  • Use of fingers, hands and arms constantly

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