Extruder Operator

Department: Manufacturing / Production
Reports To: Production Supervisor
Classification: Hourly, Non-Exempt
Work Schedule: Assigned Shift; overtime, weekends, and holidays may be required

Position Summary

The Extruder Operator is responsible for safely operating, monitoring, and maintaining plastic extrusion and pelletizing equipment. This position ensures recycled plastic materials are processed according to production schedules, customer specifications, quality standards, and Sunrise safety requirements.

The Extruder Operator monitors temperatures, pressures, feed rates, screen conditions, cooling systems, and pellet quality while identifying and correcting production issues. This role requires strong attention to safety, equipment performance, product quality, and production efficiency.

Essential Duties and Responsibilities

• Safely start, operate, monitor, adjust, and shut down extrusion and pelletizing equipment.
• Review production orders, material specifications, work instructions, and shift priorities.
• Verify that the correct raw materials, additives, colorants, and regrind materials are being used.
• Inspect materials for contamination, moisture, incorrect labeling, or other quality concerns before processing.
• Monitor extrusion temperatures, pressures, screw speed, amperage, feed rates, cooling systems, vacuum systems, screens, and pelletizer performance.
• Adjust operating settings within approved parameters to maintain product quality and production efficiency.
• Perform screen changes, die cleaning, line changeovers, purging, and equipment setup according to established procedures.
• Monitor pellets for proper size, color, consistency, moisture level, contamination, and overall appearance.
• Collect product samples and coordinate required testing with Quality Control or the laboratory.
• Properly identify, label, segregate, and document finished products, work-in-process materials, scrap, and nonconforming material.
• Record production totals, downtime, scrap, quality results, equipment settings, and material usage accurately.
• Immediately report equipment malfunctions, unusual noises, temperature or pressure changes, leaks, contamination, and safety hazards.
• Assist Maintenance with troubleshooting while following Lockout/Tagout requirements.
• Maintain a clean and organized work area, including the extruder, pelletizer, platforms, stairs, floors, tools, and surrounding production area.
• Complete shift handoffs by communicating machine conditions, production status, quality concerns, downtime, and pending work.
• Support other production areas when needed and perform additional duties assigned by management.

Safety Responsibilities

• Follow all company safety policies, procedures, and work instructions.
• Wear required personal protective equipment, including safety glasses, gloves, hearing protection, safety shoes, and any task-specific protection.
• Follow Lockout/Tagout procedures before entering, cleaning, adjusting, or servicing hazardous equipment.
• Never remove machine guards or bypass safety devices.
• Use approved tools and procedures when working near heated equipment, dies, screens, and molten plastic.
• Follow forklift and powered industrial truck requirements when authorized to operate equipment.
• Immediately report injuries, near misses, unsafe conditions, spills, and equipment damage.
• Maintain safe clearance around operating equipment and emergency exits.
• Participate in safety meetings, inspections, training, and incident-prevention activities.

Quality Responsibilities

• Follow product specifications and approved operating parameters.
• Prevent cross-contamination by verifying materials and thoroughly completing required cleanouts and changeovers.
• Identify and isolate questionable or nonconforming material.
• Maintain accurate traceability, labeling, lot numbers, and production records.
• Notify the Supervisor and Quality Control immediately when material does not meet specifications.
• Do not continue processing known nonconforming material without management or Quality approval.

Minimum Qualifications

• High school diploma or GED preferred.
• Previous extrusion, plastics, recycling, manufacturing, or machine-operation experience preferred.
• Ability to understand basic machine controls, measurements, production instructions, and safety procedures.
• Basic mechanical aptitude and troubleshooting ability.
• Ability to perform basic math and accurately complete production documents.
• Ability to communicate effectively with Production, Quality, Maintenance, and other team members.
• Ability to work independently while remaining accountable to production and safety expectations.
• Ability to work rotating shifts, overtime, weekends, or holidays when required.
• Forklift certification preferred or ability to obtain company certification.

Preferred Experience

• Plastic extrusion or pelletizing equipment.
• Recycled polyethylene or polypropylene processing.
• Screen changers, grinders, blenders, feeders, vacuum systems, cooling systems, and pelletizers.
• Material changeovers, line purging, and contamination control.
• Lockout/Tagout and machine-guarding procedures.
• Quality inspections and production documentation.

Physical Requirements

• Regularly stand and walk for extended periods.
• Frequently bend, reach, climb stairs, push, pull, and use hand tools.
• Lift and carry up to 50 pounds, with assistance or lifting equipment when required.
• Work around heat, noise, moving machinery, dust, odors, and plastic-processing materials.
• Use required PPE throughout the assigned work area.
• Maintain sufficient vision, hearing, coordination, and mobility to operate equipment safely.

Performance Expectations and KPIs

Performance will be evaluated based on:

• Compliance with safety procedures and PPE requirements.
• Production output compared with established shift targets.
• Product quality and conformance to specifications.
• Scrap, waste, and material-loss percentages.
• Equipment uptime and avoidable downtime.
• Accuracy of production, quality, and material records.
• Proper completion of changeovers, cleanouts, and screen changes.
• Housekeeping and organization of the assigned work area.
• Attendance, punctuality, and reliability.
• Communication and effectiveness of shift handoffs.
• Timely reporting of mechanical, safety, and quality concerns.
• Teamwork and cooperation with Production, Quality, Maintenance, and Warehouse personnel.

Success in This Role

A successful Extruder Operator consistently produces quality material, protects employees and equipment, follows approved procedures, maintains accurate records, communicates production concerns promptly, and takes ownership of the assigned extrusion line.

Management reserves the right to modify duties, responsibilities, schedules, and performance expectations based on operational needs. This job description does not constitute an employment contract.