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Job Position: Blown Film Extrusion

Location: Rockwall, TX 75032

Pay Rate: DOE

Shift: A/B/C/D Shifts

Blown Film Extrusion Operator is a skilled manufacturing professional responsible for setting up, operating, and maintaining machinery that produces plastic film through the blown film extrusion process. This role is critical in ensuring the efficient production of high-quality plastic films used in various applications, such as packaging (shrink wrap, stretch wrap, food packaging, shopping bags) and industrial films.

Here's a comprehensive job description for a Blown Film Extrusion Operator:

Job Title: Blown Film Extrusion Operator

Job Summary: The Blown Film Extrusion Operator is responsible for the safe and efficient operation of blown film extrusion equipment to produce plastic film products that meet specified quality standards. This role involves machine setup, continuous monitoring of the extrusion process, quality control, troubleshooting, and routine maintenance to minimize downtime and ensure production goals are met.

Key Responsibilities:

• Machine Setup and Operation:

  • Set up and prepare blown film extrusion machinery, including the extruder, die, cooling system, and winding equipment, according to production orders and specifications.

  • Load appropriate plastic resins and additives into the extruder, ensuring correct material types and quantities for desired film properties.

  • Adjust machine controls, resin feed rates, barrel and die temperatures, bubble cage, nip rollers, and air ring to achieve consistent film thickness, width, and quality.

  • Perform setup, operation, and shutdown procedures for the blown film extrusion line and related converting equipment (e.g., corona treaters, flexographic print stations, bag machines, rewinders, folders).

• Process Monitoring and Quality Control:

  • Continuously monitor the extrusion process, observing gauges, dials, and other indicators to ensure consistent extrusion performance.

  • Conduct regular quality checks on film products, including measuring gauge (thickness), length, width, tensile strength, seal strength, and inspecting for film color and print quality.

  • Identify and troubleshoot issues such as inconsistent film quality, machine malfunctions, or variations from specifications, making real-time adjustments as necessary.

  • Transfer production and quality control data to daily logs and other required documentation.

• Maintenance and Troubleshooting:

  • Perform routine maintenance tasks, including cleaning dies, replacing filters, and maintaining extruder and cooling equipment.

  • Diagnose and resolve minor operational issues or malfunctions (mechanical and electrical) to minimize production downtime.

  • Communicate line malfunctions or complex issues to maintenance personnel in a timely manner.

• Safety and Compliance:

  • Adhere to all safety protocols, company policies, and relevant regulations (e.g., GMP, OSHA, SQF) at all times, including wearing required PPE (safety shoes, safety glasses, hearing protection).

  • Maintain a clean and orderly work environment ("clean as you go"policy).

  • Report any food safety problems immediately to a supervisor or QA team member where applicable.

• Teamwork and Communication:

  • Collaborate with other team members, including supervisors, maintenance, and other operators, to ensure smooth production flow and address issues effectively.

  • Communicate key information about the line status during shift changes.

  • Assist with the training of other employees as needed.

Qualifications:

• Education: High school diploma or equivalent required. Additional technical training, vocational training, or certifications in machine operation, plastics technology, or a related manufacturing field is a strong asset (e.g., ITI, Diploma (Plastic), CIPET).

• Experience:

  • 1-2 years of manufacturing experience required; at least 2-5 years of experience in blown film extrusion operation is often preferred, especially with mono-layer and multi-layer (e.g., 3-layer, 5-layer) blown film lines.

  • Experience with specific machine brands (e.g., W&H, Reifenhauser) can be a plus.

  • Flexographic printing experience is also beneficial.

• Skills & Abilities:

  • Mechanical Aptitude: Strong understanding of machinery, its components, and how to operate and adjust complex equipment.

  • Technical Expertise: Knowledge of raw materials (resins, additives) and their properties, the blown film extrusion process, and ability to interpret technical drawings and specifications.

  • Problem-Solving: Ability to identify, diagnose, and quickly resolve operational issues and troubleshoot machine problems.

  • Attention to Detail: Meticulous in monitoring the process, inspecting products, and ensuring all specifications are met.

  • Quality Focus: Commitment to producing high-quality output and adherence to quality standards.

  • Basic Math Skills: Ability to perform calculations and measurements (length, gauge, weight).

  • Computer Skills: Prior computer experience for data entry and monitoring systems is preferred.

  • Communication: Effective oral and written communication skills for reporting, collaboration, and training.

  • Teamwork: Ability to work effectively in a team-oriented, fast-paced manufacturing environment.

  • Physical Requirements:

    • Ability to stand and walk for extended periods (e.g., 100% of a 12-hour shift).

    • Ability to lift and/or carry 35-40 lbs or more consistently.

    • Frequent pushing and pulling with arms and legs.

    • Occasional stooping, bending, kneeling, squatting, climbing ladders, and reaching overhead.

    • Constant use of hands for light and firm grasping.

    • Ability to work in a noisy environment requiring hearing protection.

    • Ability to operate cranes, hoists, hand trucks, and roll manipulators.

    • Balance required for some tasks.

  • Flexibility: Willingness to work various shifts (day/night, weekends, overtime) as needed.

Work Environment:

• Manufacturing plant setting with exposure to noise, heat, moving machinery, and plastic materials.

• Requires adherence to strict safety protocols and use of personal protective equipment (PPE).

This job description can be customized based on the specific needs of the company and the complexity of their blown film extrusion operations.