Packaging Engineer - Dry Business

The Packaging Engineer -- Dry Business will be responsible for the design, development, and implementation of primary packaging solutions for Westrock Coffee's Dry Business segment. This role covers two primary packaging formats: flexible film structures (coffee bags) and thermoformed coffee pods. The engineer will apply deep knowledge of material science, barrier technologies, and manufacturing processes to deliver packaging that preserves product freshness and flavor, meets quality and regulatory standards, and supports our sustainability goals. This individual will also play a key role in First Article Inspection (FAI) processes and inbound raw material quality oversight.

Job Duties:

Packaging Design & Development

• Design and develop primary packaging solutions for the Dry Business, including flexible film coffee bags and thermoformed single-serve coffee pods, ensuring product integrity, extended shelf life, and environmental sustainability.
• Conduct material selection and testing to identify optimal flexible films and thermoform substrates for coffee packaging applications, balancing performance, cost, and sustainability.
• Develop and maintain detailed specifications for flexible film materials, thermoformed pod structures, lidding films, and related components.
• Evaluate and improve existing packaging designs for cost-effectiveness, performance, manufacturability, and environmental impact.
• Participate in the scale-up process from prototype to full production, ensuring smooth transitions and minimal disruption to operations.

First Article Inspection (FAI) & Quality

• Lead and execute First Article Inspection (FAI) processes for new packaging components, including flexible films, thermoformed pods, lidding, and other primary materials -- verifying conformance to approved specifications prior to full production release.
• Develop FAI protocols, checklists, and acceptance criteria in collaboration with Quality Assurance and Procurement teams.
• Own the inbound raw material quality process for packaging components: define incoming inspection standards, review Certificates of Analysis (COAs), conduct or oversee physical and functional testing, and disposition non-conforming materials.
• Partner with suppliers to address quality issues, drive corrective actions, and ensure continuous improvement in incoming material quality.
• Maintain documentation and traceability records related to FAI and incoming quality inspections.

Cross-Functional Collaboration & Supplier Management

• Collaborate with cross-functional teams including Product Development, Quality Assurance, Supply Chain, and Production to bring new packaging designs to market efficiently.
• Work closely with packaging material suppliers and converting partners to ensure high-quality materials, on-time delivery, and compliance with Westrock Coffee specifications.
• Troubleshoot and resolve packaging-related issues arising in the production process, including seal integrity, film performance, pod fill/seal quality, and barrier degradation.
• Stay current with industry trends, technologies, and regulations related to flexible film packaging, thermoformed pods, food contact materials, and sustainability.