Extrusion & Recycling Process Engineer

Location: Calgary, Alberta

Company: Merlin Plastics

Job Type: Full-Time

Engineer the Next Generation of Recycled Plastics

At Merlin Plastics, engineering drives sustainability. Every process improvement helps recover more valuable plastics, reduce waste, and produce high-quality recycled resins for our customers.

We are seeking a hands-on Extrusion & Recycling Process Engineer to optimize extrusion performance, solve complex processing challenges, and support the development of next-generation recycled plastic products.

The Chance

As the Extrusion & Recycling Process Engineer, you will work closely with Production, Maintenance, Quality, and R&D; teams to maximize the efficiency, reliability, and quality of our extrusion operations—from washed plastic flake through to premium recycled pellets.

This is an ideal opportunity for an engineer who enjoys working directly on the production floor, troubleshooting equipment and processes, analyzing data, and implementing practical improvements.

Key Responsibilities

- Optimize single-screw and twin-screw extrusion processes, with a focus on rPET and recycled polymers.
- Improve melt quality, throughput, filtration efficiency, vacuum degassing, and pelletizing performance.
- Develop and maintain robust processing windows, operating parameters, and production standards.
- Troubleshoot processing issues including contamination, gels, black specks, moisture, and viscosity variation.
- Lead production trials, process improvements, equipment commissioning, and start-up activities.
- Analyze production and process data to improve yield, efficiency, quality, and equipment uptime.
- Collaborate with laboratory and quality teams to monitor IV, MFI, color, and mechanical properties.
- Identify root causes of process and quality issues and implement corrective actions.
- Develop and standardize operating procedures, work instructions, and process documentation.
- Train and support operators on extrusion processes, equipment,



and standardized operating practices.
- Support continuous improvement initiatives across recycling and extrusion operations.
- Work with maintenance and engineering teams to improve equipment reliability and process performance.

Qualifications
- Bachelor's degree in Chemical, Mechanical, Polymer, Process Engineering, or a related discipline.
- 5+ years of hands-on experience in plastics extrusion, polymer processing, or a related manufacturing environment.
- Strong practical knowledge of extrusion, melt filtration, vacuum venting/degassing, and pelletizing systems.
- Experience with PET/rPET extrusion processing is highly preferred.
- Understanding of recycled polymers and material quality considerations.
- Strong analytical, troubleshooting, and problem-solving skills.
- Experience with process optimization, production trials, and continuous improvement.
- Ability to work effectively with production, maintenance, quality, and laboratory teams.
- Strong communication skills and the ability to translate technical concepts into practical operating procedures.

What We Offer
- Market-competitive salary and comprehensive benefits.
- Opportunity to work with advanced recycling and extrusion technologies.
- State-of-the-art recycling and extrusion facilities.
- Collaborative and innovative engineering environment.
- Opportunities to lead meaningful process improvement and equipment projects.
- The opportunity to make a measurable environmental impact through sustainable manufacturing.

Equal Opportunity Employer Merlin Plastics Alberta is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive workplace where everyone is respected, supported, and given the opportunity to succeed.

If you are a hands-on process engineer passionate about plastics, recycling, and manufacturing innovation, we encourage you to apply.

Education

- Bachelor's Degree (preferred)

Experience:
- plastics extrusion or a related manufacturing environment: 5 years (preferred)

Work Location: In person

📌 Extrusion & Recycling Process Engineer (Calgary)
🏢 Merlin plastics
📍 Calgary