compounding consultant

Dan Davidson
​Senior Compounding Consultant

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Dan Davidson
Dr. Davidson is an experienced consulting advisor, market and technical researcher in the field of engineering plastics and composites for the past 20+ years, focused on experience with resin producers, processors, additive suppliers and plastic compounders. He has lived and traveled extensively in Asia: working with the composites compounding and plastics additives industries in China, Taiwan, Thailand, Singapore, India, Malaysia, Indonesia, Philippines, Japan and Korea. He also owned and managed an independent testing and consulting laboratory, PlastiScience, LLC, focused on validation of consulting recommendations to clients. PlastiScience had the capability to conduct complete product development of engineering plastics formulations and additive performance, using twin screw processing equipment, injection molding and comprehensive physical property examination and UL testing. Dr. Davidson has consulted independently since 1993, previously owning DerriTech Consultants International, Inc. and now active with his own company.​
PROFESSIONAL EXPERIENCE

2007 - Present
Private Practice – Consulting Director and Founder
Cochranville, PA
  • Management and technical consulting firm specializing in thermoplastics and composites. We deliver value to clients by increasing revenue and profitability by developing exceptional breakaway polymer products and processes. We oversee global customer projects, meeting with multinational customers, and creating/delivering solutions based on commercial, operations, quality and technical needs.
  • Assist clients to understand the plastics industry as an educator with major consulting online platforms.
  • Secures outside sources for testing and development, and follow-up, saving clients time and money.
  • Develops plastics formulations, processing (fabrication and reactive), and commercial applications.
  •  Provide litigation support and expert witness services in polymers.

1999 - 2008
PlastiScience LLC – Managing Director and Founder
Smyrna, DE
  • Founded PlastiScience as a plastics testing and validation company assisting clients with product development, including twin screw compounding and injection molding of customer parts and test samples. Ensured ISO 17025-2005 laboratory compliance, becoming an expert. Secured additional capital/credit to facilitate company growth. Processing lab with twin screw extruder for compounding, injection molding for samples, and full mechanical, aging and electrical testing lab for plastics.
  • Increased revenues 300% in three years through leveraging testing and consulting services, which enabled project pricing to range from $50K- $100K.
  • Established PlastiScience as a UL plastics testing site for flammability and RTI testing under the CWTDP.
  • Secured a multiyear exclusive contract with ASTM for molding test samples under the flammability proficiency test program.
  • Delivered compounding expertise for multinational clients, resulting in repetitive projects with individual clients.

1993 - 2006
DerriTech Consultants Intl. – Consulting Director and Founder
Hong Kong, Taipei, Smyrna, DE
  • Created and founded this consulting company originating in Asia. Oversaw global customer projects, met with multinational vendors and customers as needed, and created/delivered solutions based on sales/technical needs; developed research and prepared reports.
  • Consulted a client on a $27M Kuwait plastics compounding investment by researching and supporting the development of a global sales and operations, technical, and marketing business report.
  • Successfully drove sales for North American multinational clients, providing effective technical service and sales consulting (many in Asia) for Fortune 50 chemical companies in engineering plastics, elastomers and composites formulations, and additives for plastics formulations.

1994 - 1996
Bay Resins, Inc. (now Clariant Corporation) – Vice President Technology
Millington, MD
  • Directed research and new product development for this compounding company of nylon 6 and 6,6 and also blends. Managed 15 employees of the quality assurance and color.laboratory, and new product research and development. Product market emphasis on automotive sector; significant interaction with engineering staff at Ford, GM and Chrysler and tier one suppliers to improve products and develop technologies. Interacted with manufacturing consistently to maintain quality standards.
  • Brought expertise on PBT compounding technology to develop new product line.
  • Implemented new computer system for product formulations, tied to ISO standards, quality statistics, and color formulations.
  • Introduced new sources of raw materials reducing formulation costs by 30%.

1990 - 1994
Shinkong Synthetic Fibers Corporation – Manager, Market Development / Director, Technology & Manufacturing
Taipei, Taiwan, ROC
  • I was a long term plastics consultant under contract. Collaborated with product development, manufacturing, and sales teams to identify profitable products. Conducted/analyzed customer surveys and devised strategies to expand product markets. Coordinated the UL approval/expansion program. Spearheaded product development, quality assurance, and manufacturing teams for engineering plastics compounding. Managed product quality/manufacturing process improvements, including implementing SQC programs and process parameter tracking efforts. Directed new product development in the plastics compounding division, and collaborated with product development, manufacturing, and sales teams to develop profitable products. Coordinated the UL approval/expansion program and supervised a staff of 40 and controlled P&L. Traveled extensively within Taiwan/Asia/Europe to meet with customers and manage product development. Created and implemented a management technical and manufacturing reporting system.
  • Improved product value/company image by expanding product line within three months and gaining UL approval for four new FR PP products, driving sales growth by 20% in one year.
  • Increased sales by 50% through initiating UL approvals for nylon products.

1986 - 1990
Ferro Corporation, Filled & Reinf. Plastics Div. (now A. Schulman)  –  Technical Director
Evansville, IN
  • Directed a staff of 23 scientists and technicians, involved with research and development of new formulations for engineering plastics, mainly polypropylene. Strong interface with marketing and sales staff to develop new compounds for customer applications. Improved Interface with marketing, sales, and customers, with product emphasis in automotive molded plastic products. Interfaced with big three automotive companies and Tier one suppliers.

1984 - 1985
Ciba Geigy Corporation – Technology Manager, Polyolefin Additives
Ardsley, NY
  • Responsibilities included administrative staff management of 15 employees, directing technical programs for R&D of new polyolefin additives, continuous contact with customers, conference presentations. Technical emphasis on heat, light, and process stabilizers for polyolefins, mainly LDPE, LLDPE, PP and HDPE.

1979 – 1984
Arco Chemical –  Research Scientist
Newtown Square, PA
  • Developed new formulations for wire and cable applications, particularly for foamed HDPE high speed extrusion applications for telephone singles. Interfaced daily with plant in Texas for lot approval, and significant on site experience in HDPE compounding plant. Later was responsible for developing new thermoplastic products using Z polymer PP, with emphasis on medical applications. Significant plant experience here also with production of Z polymer process.

1975 – 1979
Union Carbide Corp. (now Dow Chemical) – Project Scientist 
Bound Brook, NJ
  • Project Scientist responsible for wire and cable applications, particularly cross-linked polyethylene formulations, for medium and high voltage power cable. Interfaced with many wire and cable companies as customers.

KEY QUALIFICATIONS 
  • Ability to communicate and interact with people with various levels of responsibility, while presenting information clearly and logically.
  • Knowledge of data collection operations.
  • Skill in analyzing cost and progress data, and in preparing status reports and inquiry responses as necessary.
  • Work with internal and external team resources to:
    • Challenge assumptions to produce novel concepts
    • Identify project requirements
    • Develop, execute, and document project deliverables in compliance with committed timelines and project goals 
    • Develop and maintain design records associated with assigned projects
  • Design components and develop specifications to produce prototypes and test hypotheses
  • Define material properties and processes to achieve necessary compatibility with therapeutic agents
  • Leverage deep understanding of manufacturing processes and requisite barrier properties to develop prototype manufacturing processes that can translate to high volume production
  • Develop proof of concept test beds and methods to evaluate key performance criteria
  • Interface with customers and users through well-constructed information gathering methodologies to qualify market preference and optimize user experience
  • Analyze evaluation results and make well-informed and well-reasoned strategic recommendations
  • Maintain an awareness of “state of the art” technology as it applies to industry.
  • Comfortable with ambiguity and complexity in effort to solve problems
  • Demonstrated ability to:
  • Lead, prioritize, and complete multiple technical projects
  • Learn and apply new skills
  • Understand and communicate technical ideas and concepts with technical and non-technical audiences (written and verbal).
  • Translate ambiguous user needs to defined requirements
  • Demonstrated track record of generating intellectual property
  • Experience working with the processing and application of fluoropolymer films
  • Knowledgeable of Design for manufacturability encompassing plastic injection molding, compression molding, film lamination, and machining operations
  • Experience designing design verification and validation activities
  • Product and Market Development for All Engineering Plastics & Elastomers
  • Design validation for Product Applications
  • Raw Material Selection (polymers and additives) and Procurement for Best Cost/Performance
  • Custom Compound Formulations, Marketing Research and Applications Development (including processing) for Specific Applications
  • Polymer Compounding Recommendations, including Deformulation, Additives, Alloys, Blends and Specialty Formulations
  • Processing Expertise
  • Plastics Testing

 PROFESSIONAL TECHNICAL SOCIETY MEMBERSHIPS
  • American Chemical Society, ACS, 1970 – 2016 (46 years)
  • Society of Plastics Engineers, SPE, 1999 – 2008; 2011 – 2014
  • American Society of Testing Materials, ASTM, 2005 – 2008; 2011 – present
    • D20 Committee, Plastics
    • C16 on Thermal Insulation
    • F42 Additive Manufacturing
    • US TAG to ISO/TC61 Plastics

PUBLICATIONS
  1. Chapter in Recent Advances in Polymer Blends, Grafts, and Blocks; Synthesis and Characterization of Butyl Rubber – g – Polystyrene and PVC - g – Polyisobutylene, with J. P.Kennedy, J. J. Charles, ACS Polymer Division Symposia, August 1973, 157-63.
  2. Polymer Preprints, 1974, 14, No. 2, 974, PVC –g-PIB, with J. P. Kennedy.
  3. Polymer Preprints, 1974, 15, No. 2, 209, PVC – g-PIB Characterization, with J. P.Kennedy.
  4. Rubber Age, September 1974, 60-63, Graft Copolymerization, with J. P. Kennedy and J. J. Charles.
  5. Synthesis, Characterization and Physical Properties of Poly (vinyl chloride – g-isobutylene), Dissertation, University Microfilms, No. 75-23, 958, 1975.
  6. J. Polymer Science; Polymer Chemistry 14, No. 1, January 1976, 153, Polyvinyl Chloride –g- Butyl Rubber, with J. P. Kennedy.
  7. Appl. Polym. Symposia 30, Wiley, 1977, 13-49, Synthesis and Characterization of Polyvinyl Chloride –g-Isobutylene, with J. P. Kennedy.
  8. Appl. Polym. Symposia 30, Wiley, 1977, 51-72, Physical Properties of Polyvinyl Chloride –g- Isobutylene, with J. P. Kennedy.
  9. Proc. Int. Wire & Cable Symposia, 25th, 1976, 265-71, Prediction of Polyethylene Aging by Isothermal DSC.
  10. SPE Retec, June 1979, 100-113, Thermal Stability of Wire and Cable Vulcanizable Polyethylenes.
  11. Kabelitems No. 154, Nov. 1979, Thermal Stability of Wire and Cable Compounds in the Dry Nitrogen Process, Union Carbide Corporation.
  12. SPE Antec 1984, May, 182-185, Novel Polypropylene Copolymers for Flexible Applications.
  13. SPE Antec 1985, May, 977-981, Stabilization of FilledPolypropylene.
  14. SPO 1996, September 25, 1996, Southeast Asian Trends in Metallocene Polyolefin Compounding, Schotland Business Research Conference.
  15. Metallocene Asia97, May 15, 1997, 291, Predicted Growth Markets for Metallocene Polyolefins in Southeast Asia.
  16. World Compounding Congress, March 11-13, 1997, Penetrating the Market for the Asian Independent Compounder, Applied Market Research Conference.
  17. Plastics News International, April 1997, 26, Penetrating the Market for the Asian Independent Compounder.
  18. Functional Fillers ‘99, Intertech Conference, Atlanta, June 14-16, 1999, Development of Compacted Ultra-fine Talc in PPCompounding.
  19. Asia Color, Intertech Conference, Hong Kong, September 27-29, 2000, New Developments in Approving Color Concentrates with UL.
  20. SPE Antec 2004, vol. 1, 1111-1116, Unique Antiblocks for High Clarity Polyethylene Film.
  21. Webinar on Audiosolutionz.com, October 31, 2017, “How to Improve Your UL94 Flammability Testing and Save Money”
  22. Webinar on Audiosolutionz.com, December 19, 2017, “Pitfalls and Challenges in Complying with ISO/IEC 17025-2005”
  23. Webinar on Audiosolutionz.com, April 24, 2018, “Formulating Flame Retardant Plastics”

PATENTS
  1. “Insulated Electrical Conductors,” Canadian Patent 1100752, May 12,1981.
  2. “Free Radical-modified carbon black-filled polypropylenes,”WO Patent 9116716, October 31, 1991.
  3. “Free Radical-modified carbon black-filled polypropylenes,” AU Patent 91063516, November 11, 1991.
  4. “Free Radical-modified carbon black-filled polypropylenes,” US Patent 5116540, May 26, 1992.
  5. “Flame Retardant Composition,” US Patent 10,851,228, December 1, 2020.


EDUCATION 

Ph.D : Polymer Science
University of Akron - Akron, OH
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Bachelor of Science: Chemistry,Organic emphasis 
Earlham College – Richmond, IN
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