Senior Packaging EngineerCompany: Pregis LLC
Location: Pregis IQ Innovation Headquarters, Aurora, Illinois
Reports To: Senior Manager, Packaging Services
Position SummaryPregis is seeking a Senior Packaging Engineer to lead the design, testing, and commercialization of cold chain and protective packaging solutions. Based within Pregis IQ, this role combines hands-on laboratory work, thermal and distribution testing, packaging engineering, and cross-functional project leadership to ensure products perform effectively throughout the distribution environment.
Working closely with customers, sales, product management, manufacturing, and operations teams, the Senior Packaging Engineer will develop scalable packaging systems that meet performance, regulatory, and business requirements.
The ideal candidate brings expertise in cold chain packaging, thermal qualification, package testing, and technical problem-solving, and will play a key role in advancing Pregis' growth across food, pharmaceutical, healthcare, life sciences, and other temperature-sensitive markets.
Key ResponsibilitiesCold Chain Solution Development- Lead development of innovative passive cold chain systems utilizing Pregis Thermal Solutions materials, , flexible materials, cushioning, and other protective packaging technologies.
- Design packaging solutions that meet customer requirements for temperature control, shock and vibration protection, damage reduction, sustainability, and cost optimization.
- Evaluate new materials, protective packaging formats, and system configurations to improve thermal and distribution performance and market competitiveness.
- Develop customer-specific thermal packaging solutions and commercialization plans.
Testing & Technical Validation- Design and execute thermal testing programs utilizing environmental chambers, thermal mapping, profile analysis, and distribution simulation testing.
- Develop and manage qualification protocols aligned with ISTA, ASTM, and customer-specific requirements.
- Conduct packaging performance evaluations to validate thermal, cushioning, containment, compression, and operational performance objectives.
- Design and lead experimentation programs supporting new material evaluation and solution development.
- Support operation of the ISTA and APASS-certified package testing laboratories.
Customer Consulting & Technical Leadership- Serve as a primary technical resource for customers, sales teams, distributors, and strategic partners.
- Consult with customers on cold chain best practices, packaging optimization strategies, and thermal qualification requirements.
- Participate in customer meetings, site visits, tours, technical presentations, and packaging reviews.
- Translate customer thermal and distribution challenges into engineered cold chain and protective packaging solutions.
- Deliver technical reports, recommendations, and presentations to both technical and executive audiences.
Data Analysis & Reporting- Analyze thermal performance, distribution test data, damage risks, and customer requirements to generate actionable packaging recommendations.
- Develop customer-ready validation reports including methodologies, assumptions, analysis, conclusions, and recommendations.
- Monitor industry trends related to cold chain, pharmaceutical packaging, sustainability, and thermal technologies.
- Support creation of design guidelines, best practices, technical papers, and training materials.
- Participate in structured product development activities including concept development, design reviews, feasibility evaluations, verification and validation testing, and commercialization.
- Support manufacturing transfer activities, specifications, work instructions, and product launch readiness.
Project Leadership- Manage multiple customer development programs and internal innovation projects simultaneously.
- Provide technical mentorship and guidance to fellow engineers and laboratory staff.
- Contribute to continuous improvement initiatives related to testing methodologies, reporting tools, digital technologies, and laboratory operations.
- Support training and educational programs for internal teams, customers, and industry partners.
Required Qualifications- Bachelor of Science in Packaging, Mechanical Engineering, Materials Science, or related engineering discipline.
- 3 to 7 years of experience in packaging engineering, cold chain or protective packaging, package testing, or product development.
- Experience managing technical projects and customer-facing engineering initiatives.
- Experience developing packaging solutions from concept through validation and commercialization.
Technical Expertise- Strong understanding of heat transfer principles including conduction, convection, radiation, and thermal resistance.
- Experience with thermal packaging systems including refrigerants, phase change materials (PCMs), insulated shippers, corrugated systems, foams, and emerging sustainable insulation technologies.
- Hands-on experience with environmental chambers, thermocouples, thermal mapping equipment, and data acquisition systems.
- Knowledge of ISTA and ASTM test methods for thermal performance and distribution hazards, including shock, vibration, and compression.
- Experience designing and executing engineering experiments and interpreting large data sets.
- Experience with SolidWorks, ArtiosCAD, Cape Pack, TOPS Pro, or comparable engineering software.
- Experience with statistical analysis and data visualization tools preferred.
Preferred Qualifications- Experience in pharmaceutical, life sciences, healthcare, biologics, food, meal-kit, or temperature-sensitive distribution environments.
- Experience with ISTA 7D, ISTA 7E, and thermal qualification methodologies.
- Experience supporting customer-facing technical consulting engagements.
- Knowledge of sustainability initiatives and life-cycle assessment methodologies.
- Manufacturing, converting, or operations experience.
- Experience with digital simulation, thermal modeling, or predictive engineering tools.
- ISTA Thermal Certification or willingness to obtain certification.
CompensationThe listed annualized base pay range is primarily based on analysis of similar positions. Actual base pay could vary and may be above or below the listed range based on factors including but not limited to performance, proficiency and demonstration of competencies required for the role. The base pay is just one component of Pregis' total compensation package. The base pay range for this role is estimated to be $110,000 to $145,000, depending on experience and skills.
Benefits & RewardsAt Pregis, we invest in our employees' success both professionally and personally. In addition to a competitive compensation package, eligible employees may qualify for a sign-on incentive, relocation package, or gain-sharing programs. We also offer a comprehensive benefits package designed to support your health, financial well-being, and work-life balance.
Comprehensive Benefits- Medical plan options through Blue Cross Blue Shield
- Dental and Vision coverage
- Health Savings Account (HSA) and Flexible Spending Accounts (FSA)
- Company-paid Life Insurance
- Short-Term and Long-Term Disability coverage
- Career Development & Education Assistance
- 401(k) with company match and immediate vesting
- Paid Time Off, Holiday Pay, and Excellent Work-Life Balance
- Paid Parental Leave & Paid Military Leave
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Diversity and InclusionWe believe in diversity of thought and bringing together other traits and characteristics that make an individual bring a unique experience to Pregis. We strive to foster an inclusive environment where behaviors and social norms ensure people are welcome.
