Thermoplastic Compounding and Extrusion Consultant

Technical Consultant #1459


  • Thermoplastic resin extrusion and compounding.
  • Single and twin screw extruder design, control and use.
  • Thermoplastic extrusion screw design.
  • Thermoplastic extrusion die design.
  • Thermoplastic extrusion and plastic compounding.
  • Extrusion of sheets, profiles and plastic film.
  • Extrusion process design and layout.
  • Extrusion process control systems.
  • Gravimetric feeding systems.
  • Engineering thermoplastics selection and processing.
  • Thermoplastic compounding, mixing and batching.
  • Thermoplastic extrusion modeling and simulation.
  • Compounding plant business analysis.


Independent Consultant 2003 - Present

  • A sole proprietorship consulting in the area of extrusion process simulation software and related processing equipment.
  • Consulting services process and equipment design; component design; problem solving; and, business analysis.

Director of Operations, Undisclosed Firm, 2001 - 2003

  • Responsible for: Site Management, production, inventory, engineering, customer service, professional recruitment, manufacturing accounting, health, safety and environment.
  • Redesigned the compounding process for a large volume family of products resulting in a 50% production rate increase and significant yield improvement.
  • Implemented significant reductions in operational costs through productivity increases and staff reduction.
  • Managed a successful ISO 9002 registration process.

Independent Consultant, 1997 - 2001

  • Extrusion equipment and software representative.
  • Specializing in extrusion process design and simulation software and related processing equipment.

Dynepco (Subsidiary of Daicel Chemical Industries, Japan), Wharton, NJ, 1979 - 1997

  • Dynepco operates plastic processing equipment facility and processed engineering thermoplastics for major chemical companies.
  • As President of organization of 50 plus employees, responsible for: Profit and loss; strategic direction; professional recruitment; market research; sales and advertising direction; customer negotiations; corporate legal and administrative activities. Member of the Board of Directors and reported to Managing Director of International business in Japan.
  • Established a new strategic direction into 'High End,' sophisticated production.
  • Recruited a team of top professionals to support the new strategy.
  • Improved profitability by 33% in the first year by reducing costs, and increasing sales 25%.
  • Researched the market and uncovered new untapped opportunities for sales.

Engineering Manager 1985 - 1996

  • Responsible for extrusion process design, equipment selection, development, and implementation.
  • Led plant in capital equipment proposal, justification, selection, design, acquisition and installation for extrusion equipment and related equipment.
  • Responsible for production equipment maintenance, and computer hardware, software, and network proposals, justification, selection, design, acquisition and installation.
  • Skilled at process computer simulation and single screw and twin screw extruder compounding screw design.
  • Possess practical and theoretical knowledge of extrusion compounding and used know how to develop numerous process quality improvements and techniques for compounding.
  • A key contributor in a multi million dollar plant relocation and expansion.
  • Designed and installed processes to make optical grade polymer in a dirty environment.
  • Designed, installed, staffed, and operated a sophisticated compounding line for the production of conductive polymer formulations. Wrote QC support software.

Plant Manager 1983 - 1985

  • Responsibilities included: Plastic extrusion and compounding plant management and operations; production and inventory control; work order preparation; customer service; hire and fire; employee training.
  • Designed, proposed, implemented and administered a plant wide incentive program which increased productivity 80 to 100%.
  • Designed and implemented many process improvements for polymer reclaim and recycling.
  • Developed computer software for process simulation, process measurement, process set up, and computer aided design.

Production Manager 1980 - 1983

  • Responsibilities included: Extrusion production and inventory control; work orders; process set up; QC lab management.
  • Organized inventory and production control minimizing stock outs and formulating errors.
  • Wrote custom software to support production and inventory control, minimizing clerical requirements.

Industrial Engineer 1979 - 1980

  • Responsibilities included: Production and process analysis and design; production scheduling; equipment installation.

Honors & Publications

  • Stevens Institute of Technology, Accuracy and Quality in the Extrusion Process.
  • J.T. Baker Chemical Co., Hazardous Chemical Safety School and Workshop.
  • The Center for Professional Advancement, Industrial Moisture Measurement and Control.
  • University of Wisconsin, Process Controls in the Plastics Ind., Focusing on Statistical Methods.
  • Magic Database Programming
  • Scientific Process and Research, Advanced Extrusion
  • Ktron K-10 controller
  • Hardy 2160RC and 2050 weight controller operation
  • Opto 22 Cyrano process control programming
  • Leistritz, Twin Screw Extrusion Workshop


B.S., Industrial Engineering, Lehigh University, Bethlehem, PA

Computer Software Experience:

  • Novell Netware, Basic, Fortran, Progress Data Base, Magic Data Base, Btrieve, DTR Manufacturing Manager.
  • AutoCad, ProDesign, TurboCad, Opto 22 Cyrano, Extrud 2000, TXS.
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