Rubber Compounding & Mixing Optimization
Monitor and optimize mixing parameters in internal mixers (Banbury / Kneader) and open two-roll mills (ram pressure, rotor speed, fill factor, dumping temperature, and cycle time).
Track Mooney viscosity, rheometer cure curves (M_L, M_H, t_{s2}, t_{90}), and scorch safety to maintain batch-to-batch compounding consistency.
Conduct material balance audits across raw elastomer handling, carbon black/filler feeding, plasticizers, and curing/blowing agent masterbatches to reduce compound scrap.
Extrusion, Foaming & Vulcanization Line Control
Fine-tune continuous cold-feed / pin-barrel extruder parameters (screw L/D ratios, temperature profiles across barrel zones, die pressure, and head tooling design).
Control continuous hot-air/microwave/infrared vulcanization and expansion tunnel ovens to achieve uniform cell expansion, target wall thickness, and specified thermal/mechanical properties.
Supervise cooling, precision cutting, and packaging line integration to prevent deformation or surface blemishes on finished goods.
Quality Troubleshooting & Yield Improvement
Perform structured Root Cause Analysis (RCA using 5-Why, Fishbone, 8D) on typical elastomeric defects (e.g., blister formation, uneven foaming/pore size distribution, under-cure, surface tearing, scorch, or dimensional shrinkage).
Establish and monitor Statistical Process Control (SPC) charts for Critical-to-Quality (CTQ) parameters (C_p / C_{pk} tracking for density, wall thickness, and elongation).
Partner with Quality Assurance to execute CAPAs and ensure compliance with international thermal/acoustic standards (e.g., ASTM, EN, BS).
Standardization & Process Engineering Governance
Draft, update, and audit Standard Operating Conditions (SOCs) and Standard Operating Procedures (SOPs) for compounding, extrusion, and vulcanization.
Champion Management of Change (MOC) procedures for compound reformulation, raw material supplier qualifications, or tooling redesign.
Conduct operator training on standard line set-up, die changeovers, and emergency stoppage recovery protocols.
Continuous Improvement & Operational Excellence
Drive Lean Manufacturing initiatives (Kaizen, SMED for die/mold changeovers, 5S in compounding/weighing areas, and scrap reduction taskforces).
Support capacity expansion, line revamping, Factory Acceptance Tests (FAT), and equipment commissioning for new mixing, dosing, or extrusion lines.
Maintain rigorous process safety standards regarding chemical handling, dust collection (carbon black/fillers), and thermal hazard mitigation.
Requirements
Education: Bachelor’s degree in Chemical Engineering, Polymer/Materials Science & Engineering, Mechanical Engineering, or Industrial Engineering.
Experience:
3–6 years of hands-on process engineering experience in rubber, elastomer, or polymer compounding and extrusion plants.
Direct experience in NBR/PVC elastomeric foam insulation, EPDM profiles, or continuous rubber vulcanization processes is strongly preferred.
Technical Competencies:
In-depth understanding of rubber vulcanization chemistry, blowing/foaming agents, and rheological testing (MDR / Mooney Viscometer).
Strong foundation in Lean manufacturing, 6S, line balancing, and scrap reduction methodologies.
Proficiency in SPC data analysis (Minitab / Advanced Excel) and mechanical CAD/tooling drawings (AutoCAD).
Familiarity with ERP production modules (e.g., SAP) and plant SCADA/PLC interfaces.
Key Attributes:
Strong shop-floor presence and practical troubleshooting mindset.
Ability to communicate clearly across cross-functional teams (mixing operators, maintenance, QA, and management).
Professional working proficiency in English and Arabic.