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Plastic and Thermoplastic Elastomer Processing and Operations Consultant

Technical Consultant #1043


  • Plastics manufacturing; plastic processing and business.
  • Plastics processing machinery.
  • Polymer materials development and polymer compounding.
  • Thermoplastic elastomer processing and elastomer product development.
  • Problem solving related to plastic processing and machinery.
  • Extrusion and forming of plastic materials: Injection molding, blow molding, compression molding and rotational molding.
  • Plastic materials testing and analysis.
  • Plastic and polymer research and development management.
  • Business development, product development and business commercialization.
  • Project management.
  • Organizational development and training.


Independent Consultant, Present

Undisclosed College, 1997 - Present

  • Director, Plastics Manufacturing Center

Undisclosed Company, 1995 - Present

  • Plastics Engineering Consultant

Kerr Group, Lancaster, PA, 1993 - 1995

  • Director of Product and Materials Development

The West Company, Phoenixville, PA, 1971 - 1993

  • Business Development Manager, Health Care Marketing Group, 1990 - 1993
  • Director of Research and Development, Thermoplastics Group, 1986 - 1990
  • Division Director, Research, Development and Testing, 1984 - 1986
  • Manager of Plastics Technology, 1978 - 1981
  • Supervising Chemist, Analytical and Physical Testing, 1971 -1978

Borg Warner Corporation, Washington WV, 1967 - 1971

  • Chemist/Laboratory Supervisor, Plastics Research and Development


Research and Development

  • Provided competitive advantage of a rubber products company, established corporate task force to determine strategic direction and planned, equipped, and staffed completely new research and development unit.
  • Effort resulted in the development of five new thermoplastic products, enabled company to realize a saving of a $6 million product line from erosion to competition, and was promoted to Division Director.

Product Development and Commercialization

  • Developed revolutionary new material for producing infant feeding nipples from proprietary materials.
  • Replaced non-profitable and antiquated rubber nipple product line.
  • Enabled the manufacture of the product in a more precise and efficient plastics molding process.
  • Commercialized this new material and process, brought about an annual shared-savings of $1l8 million to company and a higher quality product to consumer.
  • Received national award for this design innovation.


  • For a highly automated mail order pharmaceutical company, developed a clear plastic container from nucleated polypropylene random copolymers utilizing biaxially oriented stretch blow molding processes.
  • With this clear container, enabled inspection without opening and significantly reduced cost and efficiency.

Strategic Planning

  • Conceived and implemented a five-year plan for building and staffing a research and development facility, developing new technology materials and constructing a pilot production plant.
  • Produced, through this research and development program, five patented thermoplastic elastomer materials.
  • Planned, budgeted, constructed, and operated a continuous production line, with a capacity of one million pounds per year, for compounding plastics and elastomers.

Business Development

  • Conducted market research and identified medical tubing products made from high performance thermoplastics that could be successfully marketed against high-priced silicone tubing.
  • Developed three product lines for market segment launch.
  • Outsourced production to a manufacturing site with sufficient capacity to produce projected product volume.
  • Commercialized and coordinated market introduction of medical tubing line with sales potential for $5-10 million.

Project Management

  • For highly competitive non-carbonated beverage market requires low-cost closures, identified and selected European companies to develop and test new high performance materials for newly patented high-speed compression molding processes with output rates of 400-600 per minute.
  • Enabled projected sales for company of these low cost closures of $5 million per year.

Honors & Publications


  • Instructor: Dale Carnegie Leadership Institute

Academic and Professional Affiliations

  • Modern Plastics Management Advisory Panel
  • Society of Plastics Engineers
  • Parental Drug Association
  • American Marketing Association


  • Design Innovation: National Award


  • Various publications:
  • Parental Packaging
  • Properties of ABS Materials


  • MBA University of Southern California, CA
  • B.S. Chemistry, Fairmount State College
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