Sr Packaging Engineer

Position Summary

The Senior Packaging Engineer leads the development, qualification, optimization, and commercialization of packaging solutions across multiple product categories and manufacturing platforms. This role partners closely with R&D, Operations, Procurement, Quality, Marketing, and external suppliers to deliver innovative, consumer-focused, cost-effective, and sustainable packaging systems that meet business, regulatory, and manufacturing requirements. As a key technical leader, the Senior Packaging Engineer drives packaging innovation, operational excellence, and continuous improvement initiatives while supporting manufacturing performance and strategic growth objectives. The role requires deep expertise in packaging materials, plastic injection molding, flexible packaging, paperboard, corrugate systems, packaging equipment, testing methodologies, and artwork management processes.

Key Responsibilities

Packaging Development & Commercialization

• Lead the design, development, qualification, and commercialization of primary, secondary, and tertiary packaging solutions for new products, line extensions, renovations, and productivity initiatives.

• Manage packaging projects from concept through launch, ensuring delivery against timelines, performance requirements, quality standards, and cost objectives.

• Create, maintain, and approve detailed packaging specifications for all packaging materials, including plastics, films, labels, paperboard, corrugate, and related components.

• Develop and maintain Bills of Materials (BOMs), packaging standards, testing protocols, and technical documentation.

• Develop trial plans and create packaging trial protocols for plant testing, line validations, commercialization activities, and manufacturing scale-up initiatives.

• Plan and execute packaging trials, line validations, transportation testing, shelf-life studies, and commercialization activities.

• Conduct packaging feasibility assessments to evaluate manufacturability, equipment compatibility, material performance, and operational readiness prior to commercialization.

• Collaborate with Manufacturing and Quality teams to resolve packaging-related production issues and implement sustainable corrective actions.

• Support packaging artwork, labeling, and regulatory compliance activities in partnership with Quality, Regulatory, Legal, and R&D teams.

Packaging Materials & Technical Expertise

• Provide expert technical knowledge and hands-on experience in plastic injection molding, flexible film, paperboard, corrugate systems, and labeling technologies.

• Evaluate, optimize, and select packaging materials, formats, and equipment to improve efficiency, reduce waste, enhance consumer experience, and support new mold development.

• Lead continuous improvement and cost optimization initiatives focused on packaging materials, packaging line performance, conversion efficiency, and resin reduction.

• Define and implement comprehensive packaging testing protocols, including ISTA standards, drop testing, compression testing, seal integrity, and environmental stress testing.

• Partner with equipment manufacturers and packaging suppliers to support equipment selection, setup, commissioning, startup activities, and ongoing performance optimization.

• Develop and maintain packaging standards, testing methodologies, engineering best practices, and design libraries across manufacturing locations.

Supplier Management & Cross-Functional Collaboration

• Lead technical engagement with packaging suppliers, molders, converters, equipment vendors, and contract manufacturing partners.

• Collaborate closely with Strategic Sourcing and Procurement teams to evaluate packaging material costs, identify cost-saving opportunities, support supplier negotiations, and develop total cost optimization strategies.

• Partner with Procurement and Business Development teams to support co-manufacturing qualification, packaging implementation, and supply continuity initiatives.

• Support supplier qualification, capability assessments, and ongoing supplier performance management.

• Lead cross-functional engagement with internal stakeholders including Marketing, Quality, Procurement, and Manufacturing Operations to ensure alignment throughout the packaging lifecycle.

Sustainability & Innovation

• Identify and implement sustainable packaging initiatives aligned with environmental goals and company strategy.

• Evaluate emerging packaging technologies, materials, and trends to drive innovation and competitive advantage.

• Support reduction of packaging waste, resin reduction, recyclability improvements, and alternative material initiatives.

• Conduct competitive benchmarking analyses across packaging materials, systems, graphics, and quality standards to assess market positioning and identify scalable innovation opportunities.

• Champion innovative plastic molding solutions and evaluate new mold technologies to enhance packaging performance and reduce costs.

Manufacturing & Operational Support

• Work closely with plant operations to improve packaging line reliability, throughput, and overall equipment effectiveness (OEE).

• Participate in root cause analysis and corrective action activities for packaging defects and operational downtime.

• Support capital projects involving packaging equipment installation, upgrades, automation improvements, and new line startups.

• Assist with Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and commissioning activities for packaging systems.

• Support shipping, logistics, and packaging performance validation to ensure products arrive in optimal condition.

Qualifications

• Bachelor's degree in Packaging Engineering, Mechanical Engineering, Industrial Engineering, or related technical discipline.

• 7+ years of progressive packaging engineering experience within consumer packaged goods (CPG), confectionery, snack foods, food manufacturing, pharmaceutical, medical device, or related manufacturing environments.

• Strong hands-on experience in plastic injection molding, including mold design, tooling evaluation, resin selection, package development, and manufacturing support.

• Demonstrated expertise in flexible packaging, paperboard, corrugated packaging systems, labels, and packaging equipment.

• Proven experience leading packaging development and commercialization projects from concept through launch.

• Experience creating packaging specifications, BOMs, packaging standards, and technical documentation.

• Experience developing and executing packaging trial plans, trial protocols, and validation programs.

• Solid understanding of packaging testing protocols including ISTA testing, transportation testing, compression testing, drop testing, seal integrity testing, and shelf-life validation.

• Experience developing packaging dielines and structural packaging specifications with suppliers.

• Proficiency with CAPE, TOPS, or equivalent packaging optimization software.

• Experience with Esko WebCenter, or equivalent artwork management and approval systems.

• Knowledge of FDA, FSMA, GMP, and food safety requirements (preferred).

• Experience with packaging specification systems, PLM platforms, and CAD software.

• Lean Six Sigma certification or demonstrated continuous improvement leadership (preferred).

• Strong project management, communication, technical writing, and cross-functional collaboration skills.

Core Competencies

• Packaging engineering and materials science

• Plastic injection molding and tooling expertise

• Packaging commercialization

• Packaging specifications and documentation management

• Packaging testing and validation

• Continuous improvement and Lean manufacturing

• Supplier development and technical collaboration

• Procurement and cost optimization

• Manufacturing operations and equipment systems

• Sustainability and packaging innovation

• Cross-functional leadership

• Results orientation and accountability