Process Technician

Company Description

CastAlum is an internationally acclaimed aluminium die casting and machining centre located in Welshpool, UK. The site was a Greenfield development in the winter of 2000‑2001, serving one customer only. 20 years on, the company supplies parts to the UK, Europe, Canada, and Mexico. We have grown from die casting aluminium parts only to supplying a range of products (using high‑pressure die casting, squeeze die casting, and machining). We can supply aluminium components as cast, cast & machined, or assembled & tested according to the needs of our customers.

Job Description

The Process Technician is responsible for ensuring stable, efficient, and capable manufacturing processes across High Pressure Die Casting (HPDC) cells. The role supports daily production by optimizing machine parameters, diagnosing process issues, improving product quality, and ensuring safe and reliable operation of equipment. Working for the Process Engineer and alongside the Production team, the Process Technician acts as the first line of technical support on shift.

Key Responsibilities

• Set, adjust, and verify HPDC machine parameters according to approved process documentation.
• Monitor critical process variables (shot profiles, intensification, vacuum levels, metal temperature, die temperature, cooling circuits, accumulator performance).
• Ensure all die casting, trimming, and automation processes are running to validated standards.
• Identify and implement on‑shift process adjustments to maintain cycle stability and scrap reduction.
• Analyse SPC data and look for trends.

Technical Support & Troubleshooting

• Act as the primary technical resource for production teams during the shift.
• Diagnose and resolve casting issues (porosity, short shots, flash, cold shuts, soldering, dimensional drift, surface defects).
• Effectively escalation of complex issues to Process Engineer / Process Supervisor.
• Work with the Maintenance team on machine issues.
• Support die changes, start‑ups, trials, and first‑off approvals.

Skills, Experience & Qualifications

• Experience in high‑pressure die casting, manufacturing, or a technical manufacturing environment.
• Good problem‑solving and analytical skills.
• Ability to work independently on 12‑hour shifts.
• Basic understanding of hydraulics, pneumatics, and high‑temperature processes.

What We Offer

• The salary for this position will be dependent on the candidate’s experience, with opportunities for progression through a structured three‑grade pay system.
• Ongoing training and development.
• Supportive and skilled team environment.
• Opportunities for progression within the company.

Shift Pattern

12‑hour shifts – 3 shifts per week (Early / Nights rotation) 24/6 operation.

Benefits

• Life insurance
• On‑site parking
• Sick pay