Polymer and Rubber Polymerization and Processing Expert

Technical Consultant #955


Expertise

  • Nylon polymer polymerization and extrusion compounding.
  • Polyester polymerization and extrusion compounding and solid phase polymerization.
  • Acrylic polymerization and extrusion.
  • Ethylene copolymers polymerization and extrusion.
  • Rubber polymerization and extrusion.
  • Bulk plastic material handling, solids flow and pneumatic conveying.
  • Packaging and filling systems for plastics.
  • Plant safety analyses, including bulk storage and conveying of plastic resin.
  • Recycling of plastics, industrial waste and consumer waste.
  • Product development of plastics.
  • Plastics plant design, construction and startup (built 6; moved 2).
  • Plant cost reduction and operations optimization.

Experience

Independent Consultant, 2009 - Present

  • Clients Include ADM, Metabolix, DuPont, Davis Standard, Barnet Polymers and Gala Industries.
  • Built, dismantled, enlarged, relocated plants in USA, Holland, India, Hungary (all DuPont experience.)
  • Specialist in plastics extrusion and compounding.
  • Product and process development in plastics
  • Developed a new trade marked plastic product using recycled materials.
  • Business analysis, market studies, manufacturing cost analysis, process optimization and cost and savings.
  • Computer modeling of polymer manufacturing operation.
  • Capital project design, estimation and management.
  • Chemical and plastics process optimizations.
  • Scope of work preparation for capital projects.
  • Training operations crews for start up and operations.

Safety Resources, Senior Consultant, 2000 - Present

  • Safety programs marketing.
  • Safety surveys and training; visiting companies to improve their safety performance.
  • Safety improvement and process hazard survey consultation.
  • Presentations given for the most common safety issues in factories, accident prevention, identifying hazards, reducing medical treatment costs and downtime.
  • Conducting safety consultation in Russia and the United States.

E. I. Du Pont de Nemours and Company, Wilmington, DE, 1967 - 1999

Senior Technology Associate, Packaging and Industrial Polymers, 1993 - 1999

  • Oversaw the site selection and relocation of the Elvanol® polyvinyl alcohol (PVA) storage facility from Greenville to Laurens, SC.
  • Led the front-end loading of Elvanol® powder handling and packaging at Greenville, SC, and LaPorte, TX.
  • Headed the team defining the projects needed to optimize the packaging and bulk handling system at Sabine River, Works, Orange, TX; led the front-end loading for new packaging line.
  • Consulted on a team that reduced the bottleneck at the Keldax® facility at M.A. Hanna in Dyersburg, TN, and increased its capacity from 250 million to 320 million pounds a year.
  • Worked as EVA project team leader with a full-service design contractor to design and estimate the cost ($6 million) of a system for adding Bynel® compounding capacity at the plant in Dordrecht, Netherlands.

Senior Technology Associate, Fabricated Products Department, 1983 - 1993

  • Headed the team that estimated the investment needed to construct a nylon recycling plant in Bayswater, Australia; designed the plant.
  • Oversaw the manufacturing of Alcryn® rubber for a contract compounder at a plant in Carpentersville, IL.
  • Led the front-end loading for the expansion of a film warehouse in LeTrait, France.
  • Directed the team that selected the site and designed the NDDB/DuPont plant in Ahmedabad, India, for producing extrusion blown film for low-density polyethylene.

Senior Engineer, Fabricated Products Department, 1979 - 1981

  • Supervised the team that designed and constructed the Howell Recycle Center in Howell, MI, for recycling PET beverage bottles.
  • Led the team that developed a process for recycling PET beverage bottles; designed and constructed the Grifton Recycle Ctr. in Grifton, NC, using this process.

Senior Engineer, Engineering Polymers, Washington Works, Parkersburg, WVA, 1975 - 1979

  • Directed a $5 million project optimizing the acrylics process.
  • Led the team that optimized the Lucite® and Elvacite® manufacturing processes for cost, capacity, and quality, included several successful projects for bulk handling and compounding.

Division Engineer, Engineering Polymers, 1967 - 1970

  • Headed the start-up and expansions of DuPont's first plastics compounding division in Parkersburg, WVA.
  • Directed the team that developed and commercialized the manufacturing process for the original family of glass-reinforced Zytel® nylon products at the plant at Wapakoneta, OH.

Honors & Publications

Academic and Professional Affiliations

  • American Society of Plastics Engineers
  • American Institute of Chemical Engineers

Honors

  • DuPont Executive Committee Award

Credentials

  • EIT Certificate in West Virginia

Education

  • B. S. Chemical Engineering, University of New Hampshire, Durham, NH
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