Materials Science Engineer (Extrusion)
Oldcastle APG, Inc., Dover, DE, United States
Oldcastle APG, a CRH Company, is North America's leading provider of innovative outdoor living solutions that enable customers to Live Well Outside. The manufacturer's portfolio of premier building products inspires endless possibilities while providing enduring outdoor spaces where people can connect, reflect and recharge. Award-winning brands include Belgard hardscape, Echelon Masonry, MoistureShield composite decking, RDI railing, Catalyst Fence Solutions, Sakrete packaged concrete, Amerimix mortar, Pebble Technology International pool finishes, Lawn & Garden mulches and landscape features, and Techniseal sands and sealant technologies.
Job Summary
The Materials Science Engineer (Extrusion) provides technical expertise in polymer behavior, formulation development, and process optimization for plastic extrusion operations. This role supports production, quality, and R&D by ensuring that materials, additives, and processing conditions deliver consistent product performance, cost efficiency, and manufacturability.
Job Location
This is a remote role when not traveling locally or nationally to our manufacturing sites. This person must reside in the greater Philadelphia, PA, Charlotte, NC, Dover, DE, Bulls Gap, TN or Tampa, FL area.
Job Responsibilities
Optimize extrusion parameters including melt temperature, screw speed, and line speed.
Support design and optimization of extrusion dies, screws, and downstream equipment.
Perform DOE studies to improve throughput, quality, and dimensional stability.
Develop and optimize compound formulations including color masterbatch, fillers, stabilizers, and additives.
Evaluate resin properties affecting extrusion behavior such as MFI, rheology, fusion, and thermal stability.
Creates and documents clear, concise and accurate reports under guidance of direct management, providing insights on results and conclusions based upon data sets.
Define resin specifications, incoming material requirements, and in-process quality checks (dimensions, gloss, haze, tensile, melt flow, density, impact).
Use analytical tools to diagnose material or process issues.
Troubleshoot problems such as: Melt fracture / sharkskin, Gels or black specks, Die lines or surface roughness, Bubbles / voids, Warpage or dimensional instability, Color streaking or contamination, Excessive die drool or buildup.
Work closely with extrusion operators to implement material or recipe changes, adjust settings, and improve process robustness.
Conduct root-cause analysis for scrap or downtime events using tools such as 5-Why, Ishikawa, and statistical analysis.
Maintain and update work instructions, material handling procedures, resin drying guidelines, and hopper loading practices.
Creates procedures to ensure all safety concerns and hazards are properly addressed in compliance with company and regulatory requirement.
Manage resin trials, supplier evaluations, and approval of alternative materials to reduce cost or improve performance.
Reduce material usage and scrap through formulation refinement, tighter process control, and resin substitution.
Collaborate with Purchasing and R&D on resin cost-reduction and qualification projects.
Support Lean, Six Sigma, and process capability improvement (Cp/Cpk) initiatives.
Travel up to 50% of the time.
Job Requirements
Bachelor's degree in Materials Science, Polymer Engineering, Chemical Engineering, or related field.
Hands-on experience with thermoplastic extrusion (single-screw, twin-screw, profile, sheet, pipe, film, tubing, or wire & cable).
Strong understanding of polymer behavior: melt rheology, thermal transitions, degradation mechanisms, and stabilization chemistry. PVC experience preferred.
Familiarity with quality systems, lab testing methods, and statistical analysis. Strong analytical and troubleshooting skills, especially in dynamic production environments.
Excellent communication with operators, supervisors, quality teams, and customers.
Practical, hands-on approach to materials and process experimentation.
Ability to manage multiple projects and meet deadlines in a high-volume manufacturing setting.
Overnight travel up to 50%.
Compensation
Base salary is $70,000 - $110,000
401(k) / retirement savings program
Short-term and long-term disability benefits
Life insurance
Health, Dental, and Vision insurance
Paid time off
Paid holidays
What CRH Offers You
Highly competitive base pay
Comprehensive medical, dental and disability benefits programs
Group retirement savings program
Health and wellness programs
An inclusive culture that values opportunity for growth, development, and internal promotion
Oldcastle APG, a CRH Company, is an affirmative action and equal opportunity employer.
EOE/Vet/Disability
CRH is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, status as a protected veteran or any other characteristic protected under applicable federal, state, or local law.
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Job Summary
The Materials Science Engineer (Extrusion) provides technical expertise in polymer behavior, formulation development, and process optimization for plastic extrusion operations. This role supports production, quality, and R&D by ensuring that materials, additives, and processing conditions deliver consistent product performance, cost efficiency, and manufacturability.
Job Location
This is a remote role when not traveling locally or nationally to our manufacturing sites. This person must reside in the greater Philadelphia, PA, Charlotte, NC, Dover, DE, Bulls Gap, TN or Tampa, FL area.
Job Responsibilities
Optimize extrusion parameters including melt temperature, screw speed, and line speed.
Support design and optimization of extrusion dies, screws, and downstream equipment.
Perform DOE studies to improve throughput, quality, and dimensional stability.
Develop and optimize compound formulations including color masterbatch, fillers, stabilizers, and additives.
Evaluate resin properties affecting extrusion behavior such as MFI, rheology, fusion, and thermal stability.
Creates and documents clear, concise and accurate reports under guidance of direct management, providing insights on results and conclusions based upon data sets.
Define resin specifications, incoming material requirements, and in-process quality checks (dimensions, gloss, haze, tensile, melt flow, density, impact).
Use analytical tools to diagnose material or process issues.
Troubleshoot problems such as: Melt fracture / sharkskin, Gels or black specks, Die lines or surface roughness, Bubbles / voids, Warpage or dimensional instability, Color streaking or contamination, Excessive die drool or buildup.
Work closely with extrusion operators to implement material or recipe changes, adjust settings, and improve process robustness.
Conduct root-cause analysis for scrap or downtime events using tools such as 5-Why, Ishikawa, and statistical analysis.
Maintain and update work instructions, material handling procedures, resin drying guidelines, and hopper loading practices.
Creates procedures to ensure all safety concerns and hazards are properly addressed in compliance with company and regulatory requirement.
Manage resin trials, supplier evaluations, and approval of alternative materials to reduce cost or improve performance.
Reduce material usage and scrap through formulation refinement, tighter process control, and resin substitution.
Collaborate with Purchasing and R&D on resin cost-reduction and qualification projects.
Support Lean, Six Sigma, and process capability improvement (Cp/Cpk) initiatives.
Travel up to 50% of the time.
Job Requirements
Bachelor's degree in Materials Science, Polymer Engineering, Chemical Engineering, or related field.
Hands-on experience with thermoplastic extrusion (single-screw, twin-screw, profile, sheet, pipe, film, tubing, or wire & cable).
Strong understanding of polymer behavior: melt rheology, thermal transitions, degradation mechanisms, and stabilization chemistry. PVC experience preferred.
Familiarity with quality systems, lab testing methods, and statistical analysis. Strong analytical and troubleshooting skills, especially in dynamic production environments.
Excellent communication with operators, supervisors, quality teams, and customers.
Practical, hands-on approach to materials and process experimentation.
Ability to manage multiple projects and meet deadlines in a high-volume manufacturing setting.
Overnight travel up to 50%.
Compensation
Base salary is $70,000 - $110,000
401(k) / retirement savings program
Short-term and long-term disability benefits
Life insurance
Health, Dental, and Vision insurance
Paid time off
Paid holidays
What CRH Offers You
Highly competitive base pay
Comprehensive medical, dental and disability benefits programs
Group retirement savings program
Health and wellness programs
An inclusive culture that values opportunity for growth, development, and internal promotion
Oldcastle APG, a CRH Company, is an affirmative action and equal opportunity employer.
EOE/Vet/Disability
CRH is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, status as a protected veteran or any other characteristic protected under applicable federal, state, or local law.
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