Expert Details

Expert in Resin, Polymer, Coating-Development/Synthesis/Processing/Production

Expert ID: 731060 Maryland, USA

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Expert has been involved in process development/process engineering in various industries including; paint processing, latex polymerization, styrene polymerization, polyester polymerization, acrylic polymerization, urethane polymerization, elastomer polymerization, fiberglass manufacture, acetate fiber manufacture, foam polystyrene manufacture, and SMA manufacture. Development and scale up of new of new and novel technology was the main outcome of this body of work.

Both continuous and batch processing were involved. Standard equipment was used in some cases and in others equipment was developed and built to suit the requirements of the process. Detailed engineering packages were created to document the process advantages and to provide the basic information for technology transfer to either a manufacturing site or a customer.

Types of equipment that Expert is familiar with includes; reactors, conventional mixers, high speed rotor.stator mixers, devolatization extruders, pelletizers, spray driers, fluid bed driers, filtration equipment, pumps, grinding and milling devices, distillation towers, solid and liquid metering equipment, and various other chemical processing units.

In most cases processes were developed in a lab, scaled to pilot plant, then commercialized in a plant or sold in a technology transfer. Drivers were both improved economics and/or improved properties based on specific application requirements.

In the area of paint processing new methods of producing automotive and industrial paints were developed that reduced cost and improved just in time delivery. Emphasis was focused on color matching thru development of novel pigment systems and intermix delivery systems.


Expert spent many years doing research and development on acrylic resins for the coatings industry. Solution polymers, emulsion polymers, dispersions, suspension polymers, and bulk polymers were all subjects of process development.

Batch and continuous processes were developed and commercially implemented. Patents were obtained for several significant breakthroughs. Designs for lab, pilot, and commercial scale were produced. Efforts on energy reduction, catalyst efficiency, and control of Mw resulted in significant cost savings. Minatureization of equipment due to high throughputs resulted in large capital cost reduction for plant scale equipment. Many process and control innovations were developed during these developments in acrylic technology.

Polymer devolitilization to low residual monomer/solvent levels has always been an industry challenge particularly with tighter standards for health continuously evolving. Expert has a wide aray of experience in mechanical and chemical devolitilization techniques and has applied them commercially.

Various types of mechanical devices such as devol extruders, freeze drying, flash drying, extraction, falling film, fluid bed, and skein units have been successfully developed and optimized for many different polymer types. Of particular interest was the development of highly efficient twin screw devolitilization techniques for several high molecular weight polymer systems.

Reaction catalysis to reduce residual monomers can be accomplished in many systems. Research on such systems was carried out and commercailly implemented on many polymers.

Familiarity with a wide variety of process equipment has been of special interest to Expert. Based on years of experience in several indiustries and many development projects, evaluation of all types of processing equipment have been conducted and used. Processing of many types of polymers have permitted Expert to gain working knowledge of the problems and solutions associated with polymer processing from reactor to recovery and finishing steps.

Expert was involved in several technology exchanges and sales to offshore companies. Scale ups were conducted in Asia on several projects along with detailed technical documentation prepared for the exchanges.

Polymer synthesis and polymerization techniques are a specialty of Expert. Many systems have been developed, optimized, and scaled up from lab to pilot and eventually to commercialization. Process development has been successful due to a knowledge of the chemistry as well as equipment required for optimum performance.

Expert conducted a world wide investigation of paint processing and pigment manufacture in order to sort out best practices for a paint company. This study included raw material quality, ingredient delivery, mixing, pigmentation, packaging, and quality control. In addition, development work was conducted on emerging technologies for processing. Just in time intermix systems were developed to reduce capital and inventory costs and improve delivery. Expertise in equipment cleaning technology was gained and also commercially implemented.

He is consulting with a specialty chemical company on a suspension polymerization process development that will be used in the cosmetic industry. Both formulation and synthesis parameters are being developed.He has completed a project with a manufacturer of shipping containers for the Dept of Defense that will contain small rockets. Design specs for foam padding as well as exterior painting were developed.He is working on an ultrasonic dispersion process for a particular pigment used in coating manufacture.

Expert may consult nationally and internationally, and is also local to the following cities: Pittsburgh, Pennsylvania - Frederick, Maryland

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Education

Year Degree Subject Institution
Year: 1969 Degree: BS Subject: Chemical Engineering Institution: University of Maryland

Work History

Years Employer Title Department Responsibilities
Years: 2008 to 2011 Employer: Alliant Tech Systems Title: Program manager Department: Tactical Propulsion Responsibilities: Expert was responsible for the development and commercialization of a solid rocket motor to be used in a ground to air defense missile. I had P&L responsibility. The program was eliminated by gov't after successful flights!
Years: 1979 to 2011 Employer: PPG Industries Title: Sr. Research Engineer/Mgr Process Eng. Department: Coatings and Resins Responsibilities: Expert was Manager of theR&D Engineering group responsible for long range process research and short range trouble shooting both in a pilot plant and commercial plants.
Years: 1969 to 1976 Employer: Arco Polymers (Arco Chemical) Title: Coordinator of Polystyrene Complex Department: Styrenics Responsibilities: Expert was responsible for the development of new foam polystyrene products and applications. He coordinated research with the develoment lab and commercial plant to grow the business.

International Experience

Years Country / Region Summary
Years: 1978 to 1979 Country / Region: Japan Summary: Technology exchange with Sekasui Plastics involving polystyrene and polystyrene foam. Responsible for scale up in Japan as well as the USA
Years: 1994 to 1995 Country / Region: Italy Summary: He was developing a paint additive process for the European market that was to be produced in Naples, Italy. The product and process was developed in the USA but the plant was built and started up in Italy.
Years: 1997 to 1999 Country / Region: England, Germany, Italy, France Summary: He conducted a world wide study of pigment and coatings processes to determine state of the art for the industry in several areas for the President of PPG. Many plants and R&D centers were visited and inspected during this period. Recommendations were made on what processes need to be improved, how and where.
Years: 2004 to 2004 Country / Region: Summary:

Career Accomplishments

Associations / Societies
AICHE
Professional Appointments
Sr. Engineering Associate - PPG R&D
Program Manager-Tactical Missile Propulsion-ATK
Publications and Patents Summary
1 - Patent Issued, 3 Pending

Additional Experience

Expert Witness Experience
Several depositions on patent cases
Training / Seminars
High School introduction to chemical engineering
Vendor Selection
Wide range of experience in working with vendors on equipment specs and developing specific equipmet for a process. Have done significant research on new applications for available process equipment with vendor support.
Marketing Experience
Good insight into various polymer industries as well as the paint industry. Limited knowledge of the defense industry.
Other Relevant Experience
Process Engineering knowledge and skill set.

Language Skills

Language Proficiency
none

Fields of Expertise

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