Expert Details

Expert in Plastics Processes: Extrusion, Injection Molding, Blow Molding, Structural Foam Molding, and Training

Expert ID: 731676 Ohio, USA

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Expert F Expert has over 55 years of plastics processing experience. His main focus has been extrusion processes using extruders -- twin or single screw -- for compounding, film, sheet, and profile. He has extensive experience with feed screw design and die designs. He has worked in the packaging industry, automotive, building products, firearms, medical, and appliance industries, either as a research process engineer, extrusion equipment salesman, executive management and owner of companies for extrusion, injection molding and other processes. He has worked directly with such screw design gurus as Bruce Maddock, Bob Barr, George Kruder, Devante, Kline and Tadmore (the first designers of computer simulation), Chan Chung, and Ed Stewart. All have done significant work on advancing screw performance in single screw extruders.
Expert has 6 years' experience with R&D process and product development via Union Carbide Corp., Glad Bags & Wrap, Ever Ready Batteries, Structural Foam Process, Blown film extrusion, cast film extrusion, wire coating, thermoset molding, compounding, LDPE film recycling and pelletizing.
Additionally, he has 11 years of experience in engineering, sales and sales management for plastics extrusion and molding equipment, plastic welding, and high-intensity mixing equipment via Waldron-Hartig, HPM Prodex, Werner & Pfleiderer Corp., Bernhard IDE, Andrea Crespi, Beilomatic Lueze & Co, TK Fielder.
He has 18 years' experience in corporate management, engineering, and sales for profile extrusion, compounding, recycling, injection molding, and fabrication in union and nonunion environments alike, including George Woloch Co. (Industrial plastic recycling and compounding automotive feedstock), Werner & Pfleiderer Corp, (Founded) Plastics Assembly Corp. (marketing process equipment and consulting), Johnson Rubber Corp. (automotive profile extrusion and injection molding),(Founded) Custom Pac Extrusions, Inc.(Custom profile extrusion and injection molding, patented process for plastic drum handling rings), Custom Materials, Inc.(job shop fabrication parts for electrical industrial products), and (Founded) LDL Consultants.
Expert’s consulting experience spans over 20 years with more than 85 company clients, most of these clients are involved in profile extrusion and the work encompasses new process and new product development, project management, management consultation, market and sales development, new business development -- he founded 3 companies and has helped start up others with management, administration, technical, and marketing services -- engineering and design, and expert witness, including contract liability and intellectual property patent defense. He is currently involved in Domestic and international travel to assist installation, startup and training for American Kuhne Corp., a Division of Graham Engineering. He is involved in developing seminars and classes in extrusion process engineering at University of Akron Polymer Training Center.


1. Worked for an arms and ammunition manufacturer and through proper material selection, change in vendors and testing, process improvement, major change in tooling for 12 gauge shotgun shell manufacturing, as well as some in the field market investigation, he was able to help the company increase their sales to the skeet and trap community by 100% over 3 years.2. Have travelled internationally for the last 10 years for a major manufacturer of extrusion equipment in a field service capacity as a process engineer, supervising installation, startup and training of 1, 2 and 3 extruder, co extrusion systems to produce drinking straws, profile extrusions and very high speed medical tubing systems. These were all turnkey extrusion lines with guaranteed performance.3. Have on a number of consulting assignments been engaged as a project manager to assist in startup company extrusion assignments to specify an extrusion system to accomplish manufacture of a specific profile, plastic lumber, automotive window gaskets, body side molding, dual duel durometer profiles, refrigerator gaskets, and medical profiles and tubing. He found vendors to supply turnkey extrusion systems, supervised installation, in some cases designed the dies and selected the screw design for the specific material, started up the lines and trained the engineers and operators to manufacture the product. In some situations there were post extrusions operations to complete manufacture of a product.4. Have accepted assignments to retrain engineers and operators to set up and run existing extrusion systems where the key people were lost through attrition and no one had experience to run the extrusion operations properly. One was a major supplier of medical products with 6 very specialized systems who were running complete automated systems manually because the key technical people had left the company. Another, in Canada had a unique extrusion system and the engineering and manufacturing managers were terminated for criminal activity and the whole tech staff was lost. It took several weeks to update and train the new manufacturing staff.5. One assignment in Canada was to inspect a complete compounding operation producing $125MM of thermoset material for molding of electrical fixtures with distribution to all of North America. The purpose was to get the plant design for 2 times the production to work as designed. Some major mistakes were made in construction of the total blending, compounding and pelletizing of the material. We found both processing miscalculations and bottle necks preventing full efficient processing, corrected the problems with new technology and were able to increase production over 80% while reducing scrap generation from 24% to 3% with a capital investment or input of $185,000. 6. Have assignments to perform due diligence in determining value of assets, viability of business and competence of employees to help an acquisitioned company grow7. Had a client who made roofing material and purchased a turnkey operation to their design from a German supplier. After 1,5 years of operation the system was generating scrap at approximately 25% extruding at 12000#/hr. With modification of the process under my recommendation the scrap generation was reduced to an acceptable 5% or less depending on which material suppliers material was being used. Scrap, during normal operation was being produced at 200#/minute on occasion.

Expert may consult nationally and internationally, and is also local to the following cities: Cleveland, Ohio - Akron, Ohio - Youngstown, Ohio - Canton, Ohio - Lorain, Ohio - Lakewood, Ohio - Elyria, Ohio - Euclid, Ohio - Pittsburgh, Pennsylvania - Erie, Pennsylvania

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Education

Year Degree Subject Institution
Year: 1969 Degree: BS Subject: Marketing and Econ. Institution: Rutgers
Year: 1972 Degree: Attended MBA for 3 years Subject: Masters in Business Administration Institution: Seton Hall
Year: 1986 Degree: Attended MBA course Subject: Attended Management - Stratigic Planning Institution: Case University

Work History

Years Employer Title Department Responsibilities
Years: 1997 to 2019 Employer: Self Employed Title: Consultant Department: Plastics Industry Responsibilities: Expert has over 55 years of plastics processing experience. His main focus has been extrusion processes using extruders -- twin or single screw -- for compounding, film, sheet, and profile. He has extensive experience with feed screw design and die designs. He has worked in the packaging industry, automotive, building products, firearms, medical, and appliance industries, either as a research process engineer, extrusion equipment salesman, executive management and owner of companies for extrusion, injection molding and other processes. He has worked directly with such screw design gurus as Bruce Maddock, Bob Barr, George Kruder, Devante, Kline and Tadmore (the first designers of computer simulation), Chan Chung, and Ed Stewart. All have done significant work on advancing screw performance in single screw extruders.
Expert has 6 years' experience with R&D process and product development via Union Carbide Corp., Glad Bags & Wrap, Ever Ready Batteries, Structural Foam Process, Blown film extrusion, cast film extrusion, wire coating, thermoset molding, compounding, LDPE film recycling and pelletizing.
Additionally, he has 11 years of experience in engineering, sales and sales management for plastics extrusion and molding equipment, plastic welding, and high-intensity mixing equipment via Waldron-Hartig, HPM Prodex, Werner & Pfleiderer Corp., Bernhard IDE, Andrea Crespi, Beilomatic Lueze & Co, TK Fielder.
He has 18 years' experience in corporate management, engineering, and sales for profile extrusion, compounding, recycling, injection molding, and fabrication in union and nonunion environments alike, including George Woloch Co. (Industrial plastic recycling and compounding automotive feedstock), Werner & Pfleiderer Corp, (Founded) Plastics Assembly Corp. (marketing process equipment and consulting), Johnson Rubber Corp. (automotive profile extrusion and injection molding),(Founded) Custom Pac Extrusions, Inc.(Custom profile extrusion and injection molding, patented process for plastic drum handling rings), Custom Materials, Inc.(job shop fabrication parts for electrical industrial products), and (Founded) LDL Consultants.
Expert's consulting experience spans over 20 years with more than 85 company clients, most of these clients are involved in profile extrusion and the work encompasses new process and new product development, project management, management consultation, market and sales development, new business development -- he founded 3 companies and has helped start up others with management, administration, technical, and marketing services -- engineering and design, and expert witness, including contract liability and intellectual property patent defense. He is currently involved in Domestic and international travel to assist installation, startup and training. He is involved in developing seminars and classes in extrusion process engineering at University of Akron Polymer Training Center.
Years: 1981 to 1997 Employer: Custom Pac Extrusions Inc Title: President, Owner, Founder Department: Management Responsibilities: to produce plastic drum handling rings under patents he developed 1980 to 1983. The joint venture partner is Custom Materials Inc. Sales $2.9MM profitable. Handled all the General management, sales and marketing for the company. While managing Custom-Pac, also managed sales for Custom Materials Inc. his joint venture partner. Sold company to US Plastic Lumber, Inc.
Years: 1981 to 1997 Employer: Custom Materials, Inc. Title: Director of Sales and Marketing. Department: Sales Responsibilities: Fabricator of metallic and non-metallic parts primarily for the electrical generation, distribution and motor markets. Reorganized the sales and marketing of the company. Sales grew from $2.3MM to $9.2MM as Custom-Pac grew to $2.9MM sales. CMI was a joint venture partner in Custom-Pac Extrusions Inc.
Years: 1979 to 1981 Employer: Johnson Rubber Corp Title: Executive Vice President Department: Plastics Division Responsibilities: . Complete P&L responsibility for division with 245 union employees, a $15MM profile extrusion and injection molding company, Johnson Plastic Corp. and technical responsibility for OEM Corp. and their Norbolt Division, a fabrication and plating operation.
Years: 1976 to 1979 Employer: Werner & Pfleiderer Corp Title: Business Manager Department: Engineering and Sales Responsibilities: His group marketed and engineered for US operation, precision profile equipment (Bernhard Ide), plastic welding equipment (Beilomatic Lueze & Co.), and high intensity mixing equipment (T.K. Fielder, Ltd.).
Years: 1975 to 1976 Employer: George Woloch Company Title: Production Manager Department: Extrusion, compounding recycling Responsibilities: Production Manager to manage a 170,000 sq. ft. plant with 55 union employees producing 3MM#/mo. in thermoplastic compounding and industrial recycling.
Years: 1972 to 1975 Employer: HPM Corp Title: Area Sales Manager Department: Prodex Extruders Responsibilities: Covered the eastern seaboard selling plastics extrusion equipment. Personal sales ranged from $1.1MM to $1.8MM. He managed the $6.3MM Eastern sales office last year of employment.
Years: 1969 to 1972 Employer: Waldron Hartig Div. Midland Ross Title: Field Sales Engineer Department: Hartig Extrusion Responsibilities: NJ Sold plastics extrusion equipment in northern NJ and SE states. After sales training in Northern NJ for a year, He developed $1MM sales in new SE territory in one year and had $1.4MM sales in the last six months of employment.
Before that:
Left 6 years of research, Union Carbide, Consumer Products Division.R&D technician in. process and product development group while going to college at night. I worked with a wide variety of thermoplastic and thermoset plastic processes.

US Marine Corps - 1958 to 1962
Honorably Discharged – Top Secret Clearance, Infantry NCO, MP, Small arms expert, radio communication.
Years: 1962 to 1968 Employer: Union Carbide Corporation Title: Extrusion Tech Department: R&D bound Brook Responsibilities: Worked with Consumer Products Group in development of Extrusion, Injection Molding and other process engineering projects to make Glad Bag products, Eveready Batteries and other consumer products. Wile going to college at night for 6 years BS Degree
Years: 1958 to 1962 Employer: USMC Title: 0311-Firearms training- MP Department: World Responsibilities: Camp Leguene Med, Japan, Viet Nam Home

Government Experience

Years Agency Role Description
Years: 1958 to 1962 Agency: US Marine Corps Role: Infantry NCO, MP, Expert Marksman, radio comm, Description: Military Police, expert marksman

International Experience

Years Country / Region Summary
Years: 1962 to 2016 Country / Region: Russia Summary: He supervised unpacking, installation and start up of extrusion lines to produce PP drinking straws
Years: 1962 to 2016 Country / Region: Saudi Arabia 3 times Summary: He supervised unpacking, installation and start up of extrusion lines to produce PP drinking straws
Years: 1962 to 2016 Country / Region: Brazil Summary: He supervised unpacking, installation and start up of extrusion lines to produce PP drinking straws
Years: 1962 to 2016 Country / Region: India 3 times Summary: He supervised unpacking, installation and start up of extrusion lines to produce PP drinking straws
Years: 1962 to 2016 Country / Region: Mexico Summary: He has travelled 13 times to Mexico to supervise installation, startup and training of medical tubing lines designed to run at very high speeds and with computer controls.
Years: 1962 to 2019 Country / Region: Costa Rico Summary: Process engineering extrusion medical cable
Years: 1962 to 2019 Country / Region: Canada Summary: traveled to Canada several times a year for 25 years. Start up recycling.Process engineering sheet extrusion

Career Accomplishments

Associations / Societies
Society of Plastics engineers, Society Of Plastics Industry plastic drum institute, Profile Extrusion Division
Boy Scouts of America - Eagle Scout - Scout Master 16 years member 1948 - 2019
Free masons Golden Gate Lodge 245 Chagrin Falls OH
Shriner - Cleveland Valley 32d Degree Masons, El Koran Lodge
American Legion Post 383 Chagrin Falls, OH
Licenses / Certifications
2 patents related to production of plastic drums
Designed and built plastic welding equipment to join extruded and injection molded parts into an assembled product like drum rings, auto tail lights, Vacuum chambers etc.
Professional Appointments
Executive VP - Johnson Rubber - all plastics operations
President - Custom Pac Extrusions Inc
Publications and Patents Summary
Expert has 2 patents that were developed to produce plastic drum handling rings using profile extrusion and plastic welding processes.

Additional Experience

Expert Witness Experience
He hs been employed 3 times to perform Expert witness in a litigation.
1 for Patent infringement - My client sued a vendor who had been used to build components of a patented machine who after providing parts and assembly services proceeded to sell similar equipment to a direct competitor. My expertise was to identify that the patented parts of the equipment were unique to my clients design of a Bab making machine. The vendor was ordered by the court to cease using the design.
1 for employment infringement after termination with no compete. My client sued an individual who had been employed by them for several years and upon separation from their employment went into direct competition with my client in spite of a no compete agreement he had completed during employment. My assignment was to identify the various types of process equipment specific to my clients used equipment business and that which the ex employee was selling. The ex employee also copied my clients customer data base and used it to call my clients customers, many of whom were first contacted while employed by my client.
1 for ID of process and avoidance of royalty payment- My client was a manufacturer of plastics process equipment and sold the patented equipment with an agreement to pay a royalty on product produced for 10 years. My assignment was to ID the process equipment and indicate that the product produced on that equipment would be subject to royalty. I was the inventor and designer of the process.
Training / Seminars
He travels internationally to install equipment, conduct seminars on extrusion and other processes and train engineers and operators to run extrusion equipment. He is employed and trained by 3 companies, manufacturers of equipment to do this.
Vendor Selection
He, as President of Custom Pac and VP of Johnson Rubber was focused on purchase of plastic materials and capitol equipment for our operations. He is regularly called to consult as a project manager to select, purchase, install and startup extrusion lines for compounding, profile extrusion, and medical tube extrusion.
He has sold plastics process equipment for 6 machinery manufacturers in extruding sheet, pipe, profile, compounding, and injection molding and blow molding, thermoforming.
Marketing Experience
Generally in the plastics industry and specifically in process equipment medical industry, plastic lumber, some plastic materials. He can discuss industry trends, growth, players, customers, attitudes, technologies, cost drivers, etc.
Other Relevant Experience
Field service engineering, project management, recruitment, business planning, cost and profit projections.
He can trouble shoot and supervise process modification to gain efficiency, and reduce scrap generation.

Language Skills

Language Proficiency
English only Very proficient in any verbal communication speaking, teaching

Fields of Expertise

amorphous plastic, amorphous polymer, angle extrusion die, automotive plastic, chill roll, constant lead extrusion screw, constant taper extrusion screw, cored extrusion screw, cross-head extrusion die, decreasing lead extrusion screw, extrusion, extrusion-die spinneret, fluoropolymer processing, food packaging plastic, heat-sealable polymer, heat-shrinkable plastic, high-temperature plastic, homopolymer, hot extrusion, injection molded plastic, lineal extruded product, medical elastomer, medical polymer, medical polymer extrusion, medical polymer molding, medical polymer selection, medical tubing, medical tubing extrusion, metering extrusion screw, molten plastic, multiple-flighted extrusion screw, off-set extrusion die, particulate-filled plastic, plastic color concentrate, plastic die cutting, plastic drying, plastic film, plastic flow, plastic handling, plastic manufacturing, plastic material, plastic material pulverizing, plastic molding, plastic processing die, plastic profile extrusion, plastic resin, plastic welding, plastics industry, plastics melt cutter, polyamide, polyethylene extrusion, polyethylene terephthalate extrusion, polymer, polymer coextrusion, polymer devolatilization, polymer extruder, polymer extrusion, polymer extrusion screw, polymer film production, polymer flow, polymer foam process, polymer grinding, polymer joining, polymer machining, polymer pelletizing, polymer process tooling, polymer processing, polymer sheet dicing, polymer sheet forming, polypropylene extrusion, polystyrene extrusion, polytetrafluoroethylene ram extrusion, polyvinyl chloride extrusion, polyvinyl chloride profile, porous plastic, thermoplastic extrusion, thermoplastic foam extrusion, vacuum sizer, vertical extruder, vertical extrusion, polymer spheroidizing, elastomer sheet, plastic cleaning, barrier polymer, laminated plastic, polymer powder, elastic plastic, plastics printing, Society of the Plastics Industry, blood line tubing, plastic medical device, polymer thermal property, medical-grade polyurethane, plastics finishing, polymer sheet, polymer melt filtration, fluorocarbon plastic material, crystalline polymer, polymer mechanical property, construction plastic material, engineering plastic, fire-resistant plastic, electrically conductive polymer, high-performance polymer, meltblowing, energy-efficient plastic processing, crosslinking agent, agricultural plastic, copolymer, polymer property, plastic pressure bonding, cellular plastic, block polymer, biocompatible polymer

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