Extrusion Operator

Position Summary

The Foam Extrusion Operator is responsible for setting up, operating, and optimizing foam extrusion lines to produce products that meet dimensional, density, and surface quality specifications. This role requires strong process awareness, attention to detail, and the ability to troubleshoot variations related to gas, temperature, and material blends.

Key Responsibilities

• Set up foam extrusion lines, including dies, calibrators, cooling systems, pullers, and cutters
• Start up and shut down extrusion equipment following established procedures
• Monitor and control critical foam processing parameters such as:
• Barrel and die temperatures
• Screw speed and motor load
• Gas injection and pressure
• Cooling and vacuum settings
• Check and maintain product:
• Density
• Thickness and dimensions
• Cell structure and surface finish
• Make process adjustments to correct issues such as:
• Density variation
• Poor cell structure
• Surface defects
• Thickness inconsistency
• Perform product quality checks using scales, calipers, and other measuring tools
• Record production data, scrap, and process changes accurately
• Assist with material changes, color changes, and cleanouts
• Keep hoppers, feed systems, and blending equipment operating correctly
• Work closely with maintenance and quality teams to resolve line issues
• Maintain a clean, safe, and organized work area

Required Skills & Qualifications

• High school diploma or GED preferred
• Manufacturing experience required; foam or plastics extrusion experience strongly preferred
• Mechanical aptitude and understanding of extrusion equipment
• Understanding of how temperature, speed, and gas affect foam structure
• Ability to read measuring devices (tape measure, calipers, scales)
• Basic math skills (fractions, decimals, conversions)
• Strong attention to detail and quality
• Good troubleshooting and problem-solving skills
• Ability to work independently and as part of a team

Physical Requirements

• Ability to stand for long periods
• Ability to lift up to 50 lbs
• Frequent bending, reaching, and movement around equipment
• Comfortable working near hot equipment and in a warm production environment

Work Environment

• Industrial foam extrusion setting
• Exposure to heat, moving machinery, dust, and production noise
• Shift work may include nights, weekends, and overtime

Safety Requirements

• Follow all lockout/tagout procedures
• Wear required PPE (safety glasses, gloves, hearing protection, etc.)
• Awareness of hot surfaces, rotating equipment, and pressurized systems (gas injection)
• Safe handling of raw materials and additives

Preferred (Not Required)

• Experience with physical or chemical blowing agents
• Knowledge of density control and cell structure optimization
• Forklift certification
• Basic computer and data entry skills