Process Engineer

Description

We are seeking an experienced Process Engineer with a strong background in plant engineering to support our extruded polystyrene (XPS) manufacturing operations at our new Brantford, Ontario facility. The successful candidate will be responsible for optimizing production processes, supporting plant startup activities, and tuning equipment to ensure operational efficiency and high-quality XPS products.

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Benefits

• Competitive salary - $91,000 - $110,000

• Health Insurance (includes Virtual Health, and HCSA), Dental Insurance, Vision Insurance
• Life Insurance, Long-term Disability, Short-term Disability
• RRSP Match
• Paid Vacation
• Floating Days
• Employee Assistance Program
• Employee Engagement Events
• Awards and Recognition
• Tuition reimbursement
• Service Awards
• Employee Perks & Discounts

Job Responsibilities

• Optimize manufacturing processes specific to the Brantford Ontario facility for extruded polystyrene production, including extrusion, foaming, and finishing stages.
• Lead plant startup initiatives at the facility, ensuring smooth commissioning of new equipment or processes from installation to full production capacity.
• Tune and calibrate plant-specific equipment (e.g., extruders, molds, and auxiliary systems) to achieve peak performance, product consistency, and energy efficiency.
• Monitor and troubleshoot process parameters (e.g., temperature, pressure, material flow) to maintain quality and minimize downtime during regular operations and startup phases.
• Conduct root cause analysis and implement corrective actions for process deviations, equipment failures, or quality issues unique to the plant.
• Develop and maintain standard operating procedures (SOPs) and work instructions tailored to the plant’s startup, equipment tuning, and production needs.
• Analyze plant production data to identify trends, reduce waste, and improve yield for XPS manufacturing at the facility.
• Support plant-specific capital projects, including equipment upgrades, installations, and commissioning, with a focus on cost-effectiveness and reliability.
• Ensure compliance with environmental, health, and safety regulations, including proper handling of blowing agents and raw materials at the site.
• Train and guide plant operators and maintenance staff on startup procedures, equipment tuning, and process optimization specific to the facility.
• Collaborate with R&D and quality assurance teams to support new product trials and process validation at the plant.

Qualifications

• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, or a related field.
• 5+ years of experience as a Process Engineer or Plant Engineer in a manufacturing environment, ideally in extruded polystyrene (XPS), polymer extrusion, or foam production.
• Proven experience with plant startups and equipment tuning in a single-facility setting.
• Strong knowledge of extrusion processes, polymer chemistry, and plant equipment (e.g., extruders, pumps, heat exchangers) relevant to XPS production.
• Ability to troubleshoot process and equipment issues in a hands-on, plant-specific context.
• Experience with process optimization tools (e.g., Six Sigma, Lean Manufacturing) is a plus.
• Proficiency in data analysis and process simulation software (e.g., Aspen, MATLAB, or similar).
• Strong communication skills and the ability to work effectively with the plant’s cross-functional team.
• Familiarity with OSHA, EPA, and other regulatory standards applicable to the facility.
• Direct experience with XPS manufacturing processes, including blowing agents (e.g., HFC, HFO, blended blowing agents) and foam density control.
• Manufacturing leadership experience or potential to advance to Sr leadership position.
• Prior involvement in plant-specific projects, such as equipment tuning or process enhancements at a single site.
• Knowledge of energy efficiency and sustainability practices tailored to a manufacturing plant.

Note: This is a Safety Sensitive position

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Benefits of Employment: IKO recognizes that its success is due to the strength of its employees. A primary goal of IKO is to promote individual employee's sense of accomplishment and contribution so that employees enjoy their association with IKO. The Company invests in its employees so that they are the most knowledgeable in the industry, and undertakes great efforts to nurture loyalty to, and teamwork at, IKO. We are pleased to offer competitive compensation, health care, a progressive and challenging workplace and a commitment to teamwork and integrity.

Diversity and Equal Opportunity Employment: IKO Industries Ltd. is an equal opportunity employer. We are committed to diversity and inclusion and are pleased to consider all qualified applicants for employment without consideration to race, religion, creed, color, national origin, age, gender, sexual orientation, marital status, veteran status or disability. IKO Industries Ltd. encourages and welcomes applications from people with disabilities. Accommodations are available on request for candidates taking part in all aspects of the selection process.