Extrusion Manager

Dangote Packaging Limited

Job Purpose:

The Extrusion Manager is responsible for leading and managing the extrusion department to ensure the efficient, safe, and high-quality production of PP tapes used for DPL sacks. The role includes managing manpower, ensuring product quality, reducing waste, maintaining machines, and coordinating with weaving, lamination, and quality departments to ensure smooth production flow.

Duties & Reponsibilities

1. Production & Process Management

• Plan, schedule, and monitor daily extrusion production activities to meet output targets.
• Oversee the operation of tape extrusion lines, including Lamination/Coating lines if applicable.
• Optimize extrusion parameters (temperature, L/D ratio, die gap, quench, stretching ratios, winders) to ensure consistent tape quality.
• Monitor raw material consumption (PP, HDPE, additives, masterbatch) and ensure optimal usage and mixing ratios.
• Ensure smooth flow of materials from compounding to winding and onward to weaving.

2. Quality Control

• Maintain quality standards for tensile strength, elongation, denier consistency, shrinkage, and tape uniformity.
• Coordinate with the QA team to address quality deviations and implement corrective actions.
• Conduct root-cause analysis for defects such as tape breakage, inconsistent denier, melt flow issues, and color variations.

3. Manpower & Team Leadership

• Supervise extrusion operators, helpers, and shift-in-charge staff.
• Conduct training on machine operation, safety, and productivity improvement.
• Ensure proper shift handovers and performance management of team members.

4. Machine Maintenance & Upkeep

• Coordinate with the maintenance team for preventive and breakdown maintenance of extrusion lines.
• Ensure proper condition of dies, heaters, godets, chill rollers, T-Die, stretching units, AC motors/inverters, and winding systems.
• Maintain spare parts inventory (heaters, thermocouples, filters, blades, bearings, etc.).

5. Productivity & Cost Control

• Drive initiatives to reduce wastage, power consumption, and downtime.
• Track KPIs such as output kg/hr, waste %, tape breakage rate, and energy usage.
• Implement lean manufacturing practices and continuous improvement initiatives.

6. Documentation & Compliance

• Maintain production logs, shift reports, material tracking sheets, and downtime analyses.
• Ensure compliance with safety, environmental, and statutory guidelines.
• Support ISO, GMP, or other audits as applicable.

Job Requirements:

• Education: Bachelor's degree in Polymer Science, Chemical Engineering, Mechanical Engineering, or a related technical field.

• Experience: Minimum of 5-12 years of progressive experience in PP woven sacks industry, with at least 2 - 5 years in an extrusion supervisory or managerial role. Added Advantage: Hands-on experience with high-speed extrusion/tape lines

• Technical Knowledge: Proven expertise in the operation, maintenance, and process optimization of modern PP Tape Extrusion lines.

Competencies:

• In-depth knowledge of PP extrusion process, polymers, additives, and tape production.
• Strong understanding of extrusion machinery (Lohia, Starlinger, Yongming, etc.).
• Problem-solving and troubleshooting skills in process and machine issues.
• Ability to lead and motivate a large team across multiple shifts.
• Strong analytical, planning, and communication skills.
• Familiarity with lean, 5S, and Kaizen practices is a plus.