Expert Details

Expert in Polyolefin, Film Equipment (Microlayering), and Product Development

Expert ID: 735333 Texas, USA

Request Expert

Expert has over 30 years of resin and multilayer film innovation experience. He developed and patented a disruptive innovative "Inkless Printing" application in which plastic film is compounded with Ammonium Octamolybdate (AOM). When the film containing AOM is exposed to a certain wave lengthen of a CO2 laser, the AOM undergoes a white to black color change. It’s possible to image the film with bar codes, 3D matrices, or any graphics which can be programed into the laser. Thus, a laser imaginable film is available for “On Demand” printing applications. Expert started his career with E.I. DuPont as a research engineer responsible for developing Clysar’s first monolayer linear low polyethylene shrink film (LLDPE) competitive with Cryovac’s industry standard D955 shrink film. Upon patenting the Clysar’s first LLDPE shrink film, DuPont doubled their plant’s manufacturing capacity by purchasing 3 Prindi (now GAP) double bubble shrink film lines.

Later on, in his career as a Technical Manager, he developed and patented Nova Chemical’s dual reactor solution LLDPE Sclair technology. With the new Sclair technology, Expert partnered with Cryovac specifically to develop a new LLDPE for Cryovac’s annular micro-layered shrink film application. Sealed Air microlayered shrink film is half as thick but twice as strong as competitive shrink films around the world. Eventually, he was hired by Sealed Air (Cryovac) in the Medical Products Group as a Sr. Product Development Engineer. He was responsible for developing Sealed Air coextruded downward water quench Non-PVC IV Bag film and several other medical flexible packaging applications such as forming webs.

Consulting Examples:
Developed conventional barrier film for client after the purchasing over 50 W&H 9 layer blown film lines.
Developed coextruded bubble wrap film for a client with 5 plants customers included Staples, Home Depot, and Lowes.
Developed a annular microlayered shrink film for client in Mexico.
Currently consulting with the only 2 annular microlayering equipment suppliers in the world.

Education

Year Degree Subject Institution
Year: 2005 Degree: Masters Subject: MBA Institution: California State University, Sacramento
Year: 1993 Degree: Master of Science Subject: Polymer Science Institution: Akron University
Year: 1985 Degree: Bachelors Subject: Chemical Engineering Institution: University of Iowa

Work History

Years Employer Title Department Responsibilities
Years: 2013 to Present Employer: Undisclosed Title: Owner Department: Responsibilities: Services Offered: Emerging Technology/Innovation, New Business Development, Technical Services, New Product Development, Project Management, and Systematic Troubleshooting
• Global Technical SWOT Analysis for Medical Forming Web Market
• Direct Compression Molding Process Optimization of UHMWPW for hip and knee replacements
• Developed a business plan model for justifying the purchase of 3 microlayered blown film lines
• Consulting contracts for developing IV bag products in Russia and Korea
• Consulting with global film equipment supplier to develop microlayer/nanolayer blown film dies
• Awarded Society of Plastic Engineer’s “Best ANTEC Paper of 2015” in the Flexible Packaging Division; “Laser-Imageable Polymeric Film”
• US Patent 8871424; Laser-Imageable Polyolefin Film (Inkless Printing)
• Completed a single client Global IV Bag Marketing study
• Designed, formulated, optimized process conditions, and commercialized bubble wrap for 5 plants, thus acquiring Home Depot business

Years: 2013 to 2014 Employer: Hilex Poly, LLC. Title: Director of Technology Department: Responsibilities: Processing and development for all flexible packaging products produced in North American facilities with the following overall objectives:
• Maximizing the buying power of the Group
• Enhancing developmental relationships with selected resin suppliers
• Standardizing processes for cost reduction and quality consistency, Cost/Performance Modeling
• Plans and coordinates technical activities through subordinate supervisors

Essential Duties and Responsibilities:
• Reviews and advices on all capital equipment and major process change at all N.A. Flexibles facilities.
• Assists and sets up Quality systems where required. Advises on resin associated quality issues and assists where necessary on root cause analysis and investigation.
• Advises and assists Marketing and Sales in all Flexibles Groups on the development of new film formulations
• Participates with senior management in regards to strategic planning activities
• Coordinates activities of team members engaged in testing, collecting and laboratory analysis of films and blends for new products, quality control of current products and analysis of competitor products
• Identifies, in conjunction with marketing and Sales management, promising areas of research or technology that address unmet needs and have large potential markets
• Interfaces with Sales and customers in the development of new opportunities and problem resolution of existing products

Years: 2011 to 2013 Employer: Sealed Air Title: Sr Product Development Engineer Department: Medical Group Responsibilities: Specific Accountabilities:
• Innovation, clearly presenting new innovative suggestions and concepts in packaging that lead the business
unit in differentiating and commercializing new products
• Effective Communications, the ability to articulate customer requirements verbally and in writing
• Technical, clearly recognized as an expert within the department and facility related to chemistry, permeation, and functionality of raw materials and components used in manufacturing flexible packaging
• Business unit sales, marketing, product development, and manufacturing seek out this person for leadership and consultation and recommendations related to solving complex packaging problems.
Years: 2009 to 2011 Employer: Celanese EVA Title: Tech Ser. & Prod. Dev. Mgr Department: Technical Service Responsibilities: Responsible for:
• New business/market/pricing /product development of EVA and LDPE products for all market segments including: Photovoltaic Encapsulant, Medical Applications (Controlled Release, IV bags), Medical Packaging, Flexible Packaging, Compounding, Extrusion Coating (Thermal Lamination), Foam, Tubing, Blow Molding, Wire & Cable, Automotive, Adhesives, Cosmetics, and Cap liners
• Accountable for developing and implementing
o Technical service product/application development strategy
o Providing analytical technical support to high-pressure autoclave manufacturing plant,
o Product management, product development, regulatory (i.e. Heavy metals, FDA, USP Class VI, and ISO certifications), and customers;
o Developing competitive marketing information and sales tools by conducting head-to-head competitive product evaluations in order to support sales and marketing
o Resolving customer complaints, hiring, and conducting performance appraisals.
o As a Technical Account Manager, responsibilities include increasing sales volume, marketing analysis and recommendations, market intelligence, pricing, forecasting, and collecting AR’s.
Years: 2007 to 2009 Employer: Pliant Corp (Berry Plastics) Title: Profit Optimization Engineer Department: Plant Production Responsibilities: Development for both blown and cast film, process optimization, process troubleshooting, scrap reduction, cost reduction, and capacity planning for 3 plants: Kent, WA; McAlester, OK; and Macedon, NY;

• Developed trash can liner films for a start-up business with 55 million lbs/yr of potential volume
• Reduced raw material costs $1.4 million/yr by identifying a CaCO3 concentrate used for material substitution in healthcare, hygiene, and food packaging applications
• Reduced raw material costs by $350,000 in 2007 by purchasing prime resin from secondary sources
• Reduced PE coex blown film net waste 32% by optimizing temperature profile
• The increased output rate of blown PE product by 65% by optimizing die size and die gap
• The increased output rate of PE film by 28% by identifying and qualifying an HDPE resin which eliminated surging.
Years: 2000 to 2002 Employer: Nova Chemical Title: Technical Manager Department: New Product Development Responsibilities: Responsible for new business development, new technology development, market intelligence, polyolefin resin product development, application development, technical service, the establishment of product performance specifications, and up-grading extrusion equipment for polymer processing laboratory equipment
• Patented a solution LLDPE resin using dual reactor technology for oriented film applications with an estimated potential volume of 73 MM lbs/yr
• Developed business plans and a new series of HDPE barrier resins with a potential volume of 25 mm lbs/yr with a 300% increase in profit margin.
Years: 1995 to 2000 Employer: Equistar Chemical Title: Research Specialist Department: Product Development Responsibilities: Research Specialist, PE Product Development and Special Products Department
• Authored an HDPE solution process manual for the HDPE manufacturing plant
• Responsible for developing all HDPE products
Years: 1993 to 1995 Employer: James River Title: Project Leader Department: New Product Development Responsibilities: Resolved a $2 MM heat seal complaint by developing a new peelable heat seal for an HDPE cereal liner application.
Years: 1990 to 1992 Employer: Mobil Chemical Title: Process Engineer Department: Plant Production Responsibilities: Responsible for managing extrusion, coating, recycle, maintenance, and laboratory departments
• Assisted in the start-up of $100 million grassroots plant in La Grange GA
• Assisted in hiring and training 600 technicians and operators
• Developed a pay for performance program for technicians and operators

Years: 1987 to 1990 Employer: Dow Chemical Title: Development Engineer Department: Technical Service/Dev Responsibilities: • Developed and commercialize a new HMW-HDPE resin
• Increased sales volume from 50 MM lbs/yr to 147 MM lbs/yr by resolving quality issues
Years: 1985 to 1987 Employer: E.I. DuPont Title: Research Engineer Department: Product Development Responsibilities: • Developed and patented an LLDPE monolayer shrink film to compete against Cryovac’s D955 shrink film resulting in the purchase of new Prandi Double Bubble blown film lines installed in the remodeled power plant
• Established and implemented a quality control program using dosimeter chips to measure the degree of ebeam cross-linking on PE shrink film
• Developed and commercialized an antistat LLDPE shrink film
• Developed and commercialized a window shrink film for 3M

Government Experience

Years Agency Role Description
Years: 2005 to 2007 Agency: USA/Dept of Toxic Substances California Role: Hazardous waste permitting Description: hazardous waste permitting responsibilities

International Experience

Years Country / Region Summary
Years: 1987 to 1990 Country / Region: Germany Summary: Evaluate International blown film equipment suppliers
Years: 1987 to 1990 Country / Region: Italy, Canada Summary: Purchased equipment line time to develop resin for film applications
Years: 1987 to 1990 Country / Region: Mexico Summary: Mexico was my sales territory of EVA resins
Years: 1987 to 1990 Country / Region: Mexico Summary: Shrink film Project: purchase install and develop micro-layered barrier film

Career Accomplishments

Associations / Societies
Society of Plastics Engineers, SPE: 1987 to 2019
Licenses / Certifications
Black Belt Six Sigma 2009
Green Belt Design for Six Sigma: 2012
Professional Appointments
Expert has over 30 years of experience in developing resins and film applications for such companies as:
• Resin Companies
o Dow Chemical
o ExxonMobil
o LyondellBasell
o Nova Chemical
o Celanese
• Film Companies
o DuPont, Clysar
o James River (Printpack)
o Pliant (Barry Plastics)
o Novolex
o Sealed Air
 Expert has worked in the Lenior NC plant where Sealed Air manufactured bubble
Awards / Recognition
Silver Key Award; James River; successfully developed peelable heat seal for General Mills, Kellogg's cereal liner film
Innovision Runner Up Award for Innovation; successfully developed Laser Imageable Film (Inkless Printing)
Best Technical Paper; Flexible Packaging Divison; SPE ANTEC Conference
Medical / Professional
Direct Compression Molding Process Ultra-high molecular weight polyethylene (UHMWPE) Process Optimization using Surface Response Design of Experiments for Medical Device Hip and Knee replacements
Publications and Patents Summary
Patents:
• US Patent Shrink Film
• US Patent Laser Imageable Polyolefin Film

Patent Applications:
• Laser Imageable Non-Polyolefin Film
• Packaging Receptacle for Making
Packaging Article Exhibiting Combination
of Linear Tear and Directional Curl

SPE-ANTEC Technical Papers
• Laser Imageable Polymeric Film, SPE-ANTEC Paper
• Split Peel Seal System for Flexible Medical Device Packaging Prototypes, SPE-ANTEC Paper
• Peel Seal System for Flexible Medical Device Packaging Applications

International Polyolefins Conference, Houston
• Polyolefins in Blown Film Applications Tutorial
• Annular Nanolayering Film Extrusion Overview Presentation
• Dual Reactor Solution LLDPE Development and Use in Biaxially Oriented Shrink Film

Additional Experience

Marketing Experience
Developed single client Global Technical SWOT Analysis for Medical Forming Webs
Developed single client Global Marketing Report for Non-PVC IV Bags
Other Relevant Experience
Completed a Process Capability Analysis for Johnson and Johnson Medical Device application: UHMWPE Hip and Knee Replacements
Presented "Annular Nanolayering Film Extrusion Overview" paper/presentation at the International Polyolefin Conference 2018
Presented "Split Peel Seal System for Flexible Medical Device Packaging" technical paper at SPE ANTEC Conference 2015
Presented "Peel Seal System for Flexible Medical Device Packaging Applications" technical paper at SPE ANTEC Conference 2015

Language Skills

Language Proficiency
English Native Speaker

Fields of Expertise

Request Expert

Dev Tool:

Request: expert/polyolefin-film-equipment-microlayering-and-product-development
Matched Rewrite Rule: expert/([^/]+)(?:/([0-9]+))?/?$
Matched Rewrite Query: experts=polyolefin-film-equipment-microlayering-and-product-development&page=
Loaded Template: single-experts.php