Job Title: Single Facer Operator
Department: Corrugator
Reports to: Supervisor Lead
Location: Corrugator Deparement
Position Summary: The Single Facer Operator is responsible for operating the single facer section of the corrugator, where the medium (fluting paper) is heated, formed into the corrugated profile, and bonded to the inner liner to produce single-face web. The quality of the corrugated flute - cell height, flute formation, glue bond, and moisture content - is established at this station and directly determines the strength and performance of the finished board. The Single Facer Operator works in close coordination with the Double Backer Operator and Corrugator Operator (Control Room Operator) to maintain a continuous, stable web with minimal waste and downtime.
Compensation:
The actual base pay offered to the successful candidate will be based on multiple factors, including but not limited to job-related knowledge/skills, experience, geographical location, and internal equity. At ND Paper, it is not typical for an individual to be hired at the high end of the range for their role, and compensation decisions are dependent upon the facts and circumstances of each position and candidate.
About Us
ND Paper is a leading manufacturer of high-quality pulp, paper, and packaging products in the United States, generating over half a billion dollars in annual sales. As a wholly owned subsidiary of Nine Dragons Paper (Holdings) Limited – the largest containerboard producer in the world – ND Paper is part of a global network committed to excellence and innovation. With two integrated pulp and paper mills in Rumford, Maine and Biron, Wisconsin, a packaging plant in Sturtevant, Wisconsin, and two sheeting facilities in Langhorne, Pennsylvania and Fairmont, West Virginia, the ND Paper family produces nearly one million tons of products annually. Our 1,100 dedicated employees are the heart of our operations, and we are committed to fostering positive work environments where individuals can advance and thrive. At ND Paper, we are investing in our future, and that starts with our staff.
Key Responsibilities & Expected Results:
- Demonstrate safety as a core value and establish a safe work environment by actively leading the safe execution of work.
Equipment Operation
- Set up, operate, and monitor the single facer including the corrugating rolls, pressure roll, and preheater drums
- Adjust corrugating roll gap, nip pressure, and wrap angles on preheat drums per grade specifications
- Monitor and control medium and liner preheat temperatures to achieve proper plasticity before fluting
- Maintain belt tension, tracking, and speed synchronization with the double backer section
- Respond promptly to web breaks, misfeeds, or flute formation anomalies to minimize downtime and waste
Flute Quality & Bond
- Inspect single-face web continuously for flute height, flute formation consistency, and bond integrity
- Identify and correct washboarding, rib marking, flute crushing, and poor glue penetration
- Verify flute profile matches the run specification (A, B, C, E, F, or combination flutes)
- Adjust preheater wrap and corrugating roll temperature in response to medium moisture variation
- Communicate web quality issues to the Double Backer Operator and CR Operator in real time
Glue System - Single Facer
- Monitor single facer glue temperature, viscosity, and application roll gap continuously
- Adjust glue gap and roll speed to achieve proper glue bead on flute tips without over-application
- Perform routine glue system cleaning during breaks, roll changes, and order changeovers
- Report abnormal glue consumption, viscosity drift, foam, or starch buildup to Control Room Operator/Lead Supervisor
Paper Splices & Roll Changes
- Perform flying splices on medium and inner liner rolls to maintain continuous web flow
- Stage incoming rolls, inspect for defects (out-of-round, telescoped, wet), and flag non-conforming material
- Coordinate splice timing with Control Room Operator to minimize trim waste and production interruption
- Log all splice events and roll changes, noting paper lot, roll ID, and any quality concerns
Order Changeovers
- Execute medium and liner changes for flute profile or paper weight transitions per the run schedule
- Adjust corrugating roll temperature, preheat, and glue settings for each new specification
- Minimize waste board at changeover through proactive adjustment and communication with the crew
- Confirm run card specifications (flute, basis weight, liner grade) before each new order
Safety & Housekeeping
- Follow all lockout/tagout (LOTO) procedures before clearing jams or performing any maintenance
- Never reach into the corrugating nip or pressure roll area while the machine is in motion
- Maintain a clean work area around the single facer, splice table, and paper roll storage zone
- Identify and report unsafe conditions, near-misses, and equipment abnormalities immediately
- Wear required PPE at all times: safety glasses, ear protection, heat-resistant gloves where applicable
- Comply with all plant safety policies and actively participate in safety meetings
Preventive Maintenance Support
- Perform operator-level Preventative Maintenance tasks per the single facer Preventative Maintenance schedule (roll inspections, bearing checks, lubrication)
- Monitor corrugating roll condition - report tip wear, scoring, or heat distribution issues
- Report equipment wear, unusual vibration, or thermal inconsistency through the downtime log or verbal escalation
- Assist maintenance technicians during corrugating roll changes and scheduled downtime
Reporting & Communication
- Log all downtime events at the single facer (cause, duration, corrective action) on the downtime tracking sheet
- Complete beginning-of-shift and end-of-shift equipment checks per the operator checkout sheet
- Communicate all in-progress quality and equipment issues clearly during shift handoffs
- Report paper quality discrepancies (moisture, caliper, basis weight variation) to supervisor for supplier follow-up
Key Performance Indicators (KPI’s)
Performance in this role is evaluated against the following metrics:
- Single-face web quality - flute formation defects, bond failures, and wash boarding incidents trended over time
- Splice success rate - ratio of clean flying splices to total splice attempts
- Waste generated at single facer section - compared to plant average and trended over time
- Corrugator uptime contribution - downtime events attributable to single facer section
- Safety compliance - zero LOTO violations; active participation in near-miss reporting
- Preventative Maintenance completion rate - operator-level Preventative Maintenance completed on schedule
Role in the Corrugator Crew
Role Interface with Single Facer Operator
CR Operator (Lead) Sets overall corrugator speed; coordinates order changes and splice timing; primary escalation point
Double Backer Operator Receives single-face web; communicates board quality feedback upstream in real time
Dry End Crew Downstream quality issues (warp, delamination) often trace to single facer - collaboration on root cause
Shift Supervisor Reports downtime, safety issues, and paper quality discrepancies
Maintenance Coordinates corrugating roll changes, steam system work, and glue system maintenance
Qualifications and Skills (Performance Oriented) Education and Experience Required
- High school diploma or GED
- Minimum 1–2 years of experience operating equipment in a manufacturing or paper/converting environment
- Mechanical aptitude; ability to make precise adjustments on running equipment under time pressure
- Ability to read and interpret work orders, run cards, and standard operating procedures
- Ability to stand for extended periods and work in a hot, loud, high-speed industrial environment
- Strong situational awareness; able to monitor multiple parameters simultaneously
Preferred
- Prior corrugator experience, specifically at the single facer or wet end
- Familiarity with corrugated flute profiles (A, B, C, E, F, BC, EB) and their quality characteristics
- Experience performing flying splices on a running web
- Understanding of paper properties affecting run ability: moisture content, caliper, MD/CD tensile strength
- Experience with starch-based glue systems
- Bilingual in Mandarin/English/Spanish a plus
Physical Requirements
Requirement
Standing / walking on concrete floors
Lifting up to 50 lbs (paper rolls, glue containers)
Reaching, bending, and stooping around equipment
Working in high-heat environment (hot plates 300°F+)
Exposure to noise levels requiring hearing protection
Use of hand tools and adjustment instruments
Success Profile/Career Development The Single Facer Operator is a technically demanding wet-end position and a key step in corrugator career progression. High-performing operators may advance to:
- Corrugator Operator / Control Room Operator (Lead) - primary operator responsible for full corrugator line
- Double Backer Operator - lateral cross-training for scheduling flexibility and full wet-end mastery
- Corrugator Mechanic - with additional technical and maintenance training
- Corrugator Superintendent - with demonstrated leadership, quality ownership, and operational mastery
Working Conditions Plant site/Corrugator
Attributes for Success
- Hard work – tackle each task with determination, passion and creativity; the willingness to put in whatever effort is required to successfully complete the job at hand.
- Pursuit of Excellence – strive to consistently exceed expectations in our day-to-day work and outperform our competitors in the marketplace, regarding work and company achievements as a collaborative goal with the desire to go above and beyond.
- Integrity - treat the company and teammates with upmost respect, operating on strong moral codes to drive company values and culture.
- Sense of Urgency – drive forward each day with speed, agility, and flexibility to capture unrealized opportunities and avoid potential risks for the business.
- Entrepreneurial Spirit – act like an owner, challenging the status quo, asking the right questions, and actively seeking ways to innovate and improve.
- Adaptability – be fluid with ND Paper’s continuous evolution while driving change in a fast-paced environment, equipped with the ability to acclimate quickly.
- Servant Leadership – set an example by implementing meaningful leadership with heart, empathy, foresight and stewardship.
Enjoy competitive salaries, comprehensive health benefits, and paid time off. Discover more about our benefits and how we support our team by visiting 2025 Benefits. Come be a part of our team and grow with us!
Apply Please submit your resume, and salary requirements to https://us.ndpaper.com/careers
No unsolicited resumes - ND Paper does not accept unsolicited resumes from search firms or employment agencies. Any unsolicited resume you submit to us will immediately become the property of ND Paper. If you would like to become a recruiter for ND Paper, please contact us and we will agree in writing to terms and the specific job roles for which you are authorized to recruit