Sr. Packaging Engineer
Confirmed on the employer's own hiring board on Oct 13, 2026. First seen by Alion on Oct 5, 2026.
About Pregis IQ
Pregis IQ is the innovation, testing, and technical solutions center for Pregis. Our team of packaging engineers helps customers optimize product protection, distribution performance, sustainability, and operational efficiency through package testing, material science, automation consulting, and packaging design.
As a material-neutral solutions provider, Pregis works collaboratively with customers to identify the most effective packaging systems for their products and supply chains. We support a wide range of industries, including food, pharmaceutical, life sciences, healthcare, medical device, industrial, e-commerce, and consumer products.
Senior Packaging Engineer
Company: Pregis LLCLocation: Pregis IQ Innovation Headquarters, Aurora, IllinoisReports To: Senior Manager, Packaging Services
Position Summary
Pregis 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 Responsibilities
Cold 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.
Compensation
The 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 & Rewards
At 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