{"id":2383459,"url":"https://alion.io/job/pregis-sr-packaging-engineer","title":"Sr. Packaging Engineer","company":{"id":1804630,"name":"Pregis","domain":"pregis.com","url":"https://alion.io/company/pregis","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Dayforce","truth_index":{"grade":"B","score":75,"open_postings":13,"ghost_share":0,"stale_share":1,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-10-13T05:45:00Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Aurora, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":110000,"max":145000,"currency":"USD","period":"year","gross":null,"usd_annual":145000},"salary_estimate":null,"experience_years_min":3,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-10-05T05:00:00Z","employer_posted_date":"2026-10-12","last_verified_at":"2026-10-13T09:28:45Z","board_verified":true,"closed_at":null,"days_open":8,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":8},"description":"About Pregis IQ\nPregis 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.\nAs 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.\n\nSenior Packaging Engineer\nCompany: Pregis LLCLocation: Pregis IQ Innovation Headquarters, Aurora, IllinoisReports To: Senior Manager, Packaging Services\nPosition Summary\nPregis 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.\nWorking 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.\nThe 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.\n\nKey Responsibilities\nCold Chain Solution Development\nLead development of innovative passive cold chain systems utilizing Pregis Thermal Solutions materials, , flexible materials, cushioning, and other protective packaging technologies.\nDesign packaging solutions that meet customer requirements for temperature control, shock and vibration protection, damage reduction, sustainability, and cost optimization.\nEvaluate new materials, protective packaging formats, and system configurations to improve thermal and distribution performance and market competitiveness.\nDevelop customer-specific thermal packaging solutions and commercialization plans.\nTesting & Technical Validation\nDesign and execute thermal testing programs utilizing environmental chambers, thermal mapping, profile analysis, and distribution simulation testing.\nDevelop and manage qualification protocols aligned with ISTA, ASTM, and customer-specific requirements.\nConduct packaging performance evaluations to validate thermal, cushioning, containment, compression, and operational performance objectives.\nDesign and lead experimentation programs supporting new material evaluation and solution development.\nSupport operation of the ISTA and APASS-certified package testing laboratories.\n Customer Consulting & Technical Leadership\nServe as a primary technical resource for customers, sales teams, distributors, and strategic partners.\nConsult with customers on cold chain best practices, packaging optimization strategies, and thermal qualification requirements.\nParticipate in customer meetings, site visits, tours, technical presentations, and packaging reviews.\nTranslate customer thermal and distribution challenges into engineered cold chain and protective packaging solutions.\nDeliver technical reports, recommendations, and presentations to both technical and executive audiences.\n Data Analysis & Reporting\nAnalyze thermal performance, distribution test data, damage risks, and customer requirements to generate actionable packaging recommendations.\nDevelop customer-ready validation reports including methodologies, assumptions, analysis, conclusions, and recommendations.\nMonitor industry trends related to cold chain, pharmaceutical packaging, sustainability, and thermal technologies.\nSupport creation of design guidelines, best practices, technical papers, and training materials.\nParticipate in structured product development activities including concept development, design reviews, feasibility evaluations, verification and validation testing, and commercialization.\nSupport manufacturing transfer activities, specifications, work instructions, and product launch readiness.\n Project Leadership\nManage multiple customer development programs and internal innovation projects simultaneously.\nProvide technical mentorship and guidance to fellow engineers and laboratory staff.\nContribute to continuous improvement initiatives related to testing methodologies, reporting tools, digital technologies, and laboratory operations.\nSupport training and educational programs for internal teams, customers, and industry partners.\n\nRequired Qualifications\nBachelor of Science in Packaging, Mechanical Engineering, Materials Science, or related engineering discipline.\n3 to 7 years of experience in packaging engineering, cold chain or protective packaging, package testing, or product development.\nExperience managing technical projects and customer-facing engineering initiatives.\nExperience developing packaging solutions from concept through validation and commercialization.\nTechnical Expertise\nStrong understanding of heat transfer principles including conduction, convection, radiation, and thermal resistance.\nExperience with thermal packaging systems including refrigerants, phase change materials (PCMs), insulated shippers, corrugated systems, foams, and emerging sustainable insulation technologies.\nHands-on experience with environmental chambers, thermocouples, thermal mapping equipment, and data acquisition systems.\nKnowledge of ISTA and ASTM test methods for thermal performance and distribution hazards, including shock, vibration, and compression.\nExperience designing and executing engineering experiments and interpreting large data sets.\nExperience with SolidWorks, ArtiosCAD, Cape Pack, TOPS Pro, or comparable engineering software.\nExperience with statistical analysis and data visualization tools preferred.\nPreferred Qualifications\nExperience in pharmaceutical, life sciences, healthcare, biologics, food, meal-kit, or temperature-sensitive distribution environments.\nExperience with ISTA 7D, ISTA 7E, and thermal qualification methodologies.\nExperience supporting customer-facing technical consulting engagements.\nKnowledge of sustainability initiatives and life-cycle assessment methodologies.\nManufacturing, converting, or operations experience.\nExperience with digital simulation, thermal modeling, or predictive engineering tools.\nISTA Thermal Certification or willingness to obtain certification.\n\nCompensation\n 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.\n\nBenefits & Rewards\nAt 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.\nComprehensive Benefits\nMedical plan options through Blue Cross Blue Shield\nDental and Vision coverage\nHealth Savings Account (HSA) and Flexible Spending Accounts (FSA)\nCompany-paid Life Insurance\nShort-Term and Long-Term Disability coverage\nCareer Development & Education Assistance\n401(k) with company match and immediate vesting\nPaid Time Off, Holiday Pay, and Excellent Work-Life Balance\nPaid Parental Leave & Paid Military Leave","description_format":"text","description_chars":8043,"description_truncated":false,"requirements":{"experience_years_min":3,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":false,"languages":[]},"benefits":["Education assistance","Life insurance","Parental leave"],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":true,"industries":["Manufacturing","Vaccines","Packaging & Labeling","Packaging Design"],"lifecycle":[{"event":"open","at":"2026-10-12T19:50:25Z"}],"visa":[],"liveness":{"score":57,"band":"ok","label":"Likely open","p_open":1,"p_active":0.573,"p_room":1,"age_days":8,"expected_fill_days":28,"reasons":["conf:2","stale_co","win:early","comp:brand"],"computed_at":"2026-10-13T05:45:00Z"},"pay":{"stated_usd_annual":145000,"is_top_pay":true},"html_url":"https://alion.io/job/pregis-sr-packaging-engineer","json_url":"https://alion.io/job/pregis-sr-packaging-engineer.json","meta":{"generated_at":"2026-10-13T09:48:58Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":14838,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-10-14T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":1804630},"rest":"https://alion.io/mcp/rest/get_company?id=1804630"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fpregis-sr-packaging-engineer"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fpregis-sr-packaging-engineer"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fpregis-sr-packaging-engineer"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/pregis-sr-packaging-engineer\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fpregis-sr-packaging-engineer"}]}