Printing Press Process Engineer (Offset Web / UV Lithographic)

Salary range $80,000-$100,000 based on experience

Position Summary

The Printing Press Process Engineer is responsible for optimizing and controlling printing processes to ensure consistent print quality, maximize equipment performance, reduce waste, and support operational excellence initiatives. This position serves as the technical expert for web offset printing, UV curing technology, color management, and print process troubleshooting.

Key Responsibilities

Process Optimization & Performance

• Optimize web offset lithographic printing processes, including:
  • Ink-water balance
  • Plate performance
  • Blanket condition
  • Web handling and tension control
• Improve UV curing performance through optimization of curing parameters and lamp performance.
• Drive improvements in:
  • Color consistency
  • Print sharpness
  • Registration accuracy
• Reduce spoilage, startup waste, and downtime through process standardization and continuous improvement initiatives.
• Monitor and improve printing-related KPIs, including OEE, waste, and print quality performance.

UV Ink Systems & Print Chemistry

• Manage and optimize UV ink, coating, and varnish systems.
• Monitor critical process variables including ink viscosity, rheology, and temperature.
• Support qualification and implementation of new UV formulations, coatings, and low-migration ink technologies.
• Ensure compliance with food packaging requirements and migration standards.

Production Support & Troubleshooting

• Provide technical support and guidance to printing press operators.
• Troubleshoot and resolve printing issues, including:
  • Ghosting
  • Scumming
  • Toning
  • Misting
  • Ink and water balance issues
  • Registration drift
  • UV curing defects
• Lead root cause investigations and implement corrective and preventive actions.

Quality Assurance & Control

• Establish and maintain print quality standards and specifications.
• Utilize densitometry, spectrophotometry, and color measurement systems to control color performance.
• Implement Statistical Process Control (SPC) methodologies for key printing variables.
• Partner with Quality teams to reduce customer complaints and improve process capability.
• Ensure compliance with customer, regulatory, and food safety requirements.

Equipment & Technology Management

• Partner with Maintenance to improve press reliability and preventive maintenance programs.
• Support installation, commissioning, and qualification of:
  • Web offset printing presses
  • UV curing systems
  • Inspection and color measurement systems
• Evaluate emerging technologies including LED UV curing, automation, and inline inspection systems.

Continuous Improvement

• Lead Lean Manufacturing and Six Sigma projects focused on:
  • OEE improvement
  • Waste reduction
  • Process stability
  • Energy efficiency
• Develop and standardize best practices across shifts and production lines.
• Identify opportunities for cost savings and productivity improvements.

Cross-Functional Collaboration

• Support new product launches and artwork transitions.
• Collaborate with:
  • Prepress teams
  • Quality teams
  • Maintenance teams
  • Suppliers
  • Operations leadership
• Provide technical expertise during product trials and customer qualification activities.

Health, Safety & Sustainability

• Ensure safe handling and use of UV inks, coatings, solvents, and curing systems.
• Maintain compliance with company safety standards and regulatory requirements.
• Support sustainability initiatives through waste reduction, process optimization, and energy-efficient technologies.

Qualifications

Education

• Bachelor's degree in Printing Technology, Chemical Engineering, Mechanical Engineering, or a related technical discipline.

Experience

• 3 to 7+ years of experience in web offset lithographic printing.
• Experience within folding carton, packaging, or high-speed manufacturing environments preferred.
• Hands-on experience with UV-curable ink systems and curing technologies.
• Experience supporting high-speed web-fed printing operations.

Technical Skills

Strong knowledge of:

• Web-fed offset lithography
• Ink-water balance and dampening systems
• Web handling and tension control
• UV curing systems (Mercury UV and/or LED UV)
• Color management systems
• Print quality measurement techniques
• Densitometry and spectrophotometry
• SPC and process control methodologies

Preferred knowledge of:

• Low-migration inks and food packaging applications
• Lean Manufacturing and Six Sigma tools
• Root cause analysis methodologies

Systems & Software

• Microsoft Office Suite
• ERP and MES systems
• Print inspection and color measurement systems
• Statistical analysis tools preferred

Soft Skills

• Strong analytical and troubleshooting abilities
• Excellent problem-solving skills
• Ability to communicate effectively with operators, maintenance personnel, suppliers, and leadership
• Detail-oriented with a strong focus on quality and continuous improvement
• Ability to thrive in a fast-paced manufacturing environment

Key Performance Indicators (KPIs)

• Reduction in print waste and spoilage
• OEE improvement and press uptime
• Color consistency and Delta E performance
• Reduction in customer quality complaints
• UV curing efficiency and defect reduction
• Cost savings generated through process improvements
• Safety and compliance performance