Senior Formulations Consultant

Senior Formulations Consultant

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Our senior associate has extensive experience in rigid PVC formulations
Our Senior Associate has extensive experience in rigid PVC formulation for specialty applications along with the processing technology needed for novel extrusion applications.  He is also a plastic profile consultant that is a customer-focused, profit-driven, plastics engineer with extensive experience in turning ideas into plastic profile extrusion die designs.  He is a hardworking, innovative, and dependable leader with an enthusiasm for solving the problems involved in growing a plastic-related business. 
Experience
August 2018 - Present
Plastics Engineer Consultant (Various Companies)                                     
  • Presented "Formulating Rigid Vinyl for Processability" at AMI Formulations conference
  • Helped develop and commercialize a novel composite siding panel.
  • Developed a patented technology for increasing output rate on complex rigid profiles through an Innovative Cooling Technology.
  • Developed an instrument to measure the melt temperature of the plastic melt inside an extruder.
  • ​Plastic Profile Extrusion Die Design
 
2012 – August 2018
SEKISUI SPI, Research Leader
 Bloomsburg, Pennsylvania                                                     
  • Led the development of an innovative high-impact aviation compliant rigid formulation.
  • Coordinated the development of a novel translucent aviation compliant rigid formulation.
  • Found and approved alternate ingredients when two critical raw materials became unavailable.
  • Continuous improvement of existing products while delivering an average of three new products per year.
  • Implemented a Stage Gate process for new product development.
  • Developed a novel sheet die design to improve yield and reduce edge burning.
 
2007 - 2012
Barrette Outdoor Living, New Product Development Manager
Bulls Gap, Tennessee                                                         
  • Pushed through the development of a new fence product in 2009, as sales were dropping off, that led to an increase in sales of about $8 MM in that year.
  • Formulation development that saved ½ cent per pound on white compound and improved performance on colored compounds.
  • Implemented continuous improvement to existing products while pushing for innovation and development of new technologies.
  • Led the development of an innovative guard rail system that was introduced in 2012.
  • Created and led the development of a novel, patented fence panel.
 
2004 - 2007
Milgard Manufacturing, Director of Materials Development
Tacoma, Washington                                                
  • Formulated a new window compound that resulted in about $1.8 MM / yr in savings.
  • Developed novel polyurethane material and pultrusion technology that resulted in material cost savings of 10 – 15% on fiberglass lineals with improved performance.
 
2003 - 2004
Plastics Engineer Consultant (Various Companies)                                     
  • Managed tooling development of an average of two new dies per week while acting as Engineering Manager.
  • Completed initial design for the installation of a new compounding line.
  • Developed training program for new extrusion operators.
  • Led the changes needed to take a foam extrusion line from 50% scrap and behind schedule to on time, doubling the output rate, and turning profitable.
  • Led the process of approving alternate material sources that resulted in 10% reduction in total raw material costs.
 
Crane Plastics Manufacturing, Technical Director
Columbus, Ohio
  • Built the capability to pelletize in-house PVC compounds, resulting in cost savings of over $500 M / yr compared to purchasing pellets.
  • Managed the blending operation and helped reduce costs by about $300 M / year while improving delivery and service to in-house customers.
  • Reduced scrap levels on wood fiber composite profiles from over 50% to 10% while increasing output and improving profitability.
  • Formulated several new compounds that resulted in about $600 M / year in savings.
 
Innovative Plastic Products, President and Founder
Toledo, Ohio
  • Created a custom plastic profile extrusion company and built it up to $ 500 M per year in sales with complete P/L and management responsibility and five employees.
  • Engineered technology oriented extruded products from fiberglass reinforced materials, thermoplastic pultrusion, metal embedded profiles, structural foam extrusions, and traditional plastic profiles.
 
Aeroquip, Plastics Division, R & D Manager
Maumee, Ohio; Jackson, Michigan; and Elkhart, Indiana
  • Started an "intrepreneurial" business around a novel foam garage door seal that increased to $ 1 MM / yr. in sales within one year under my leadership.
  • Demonstrated excellent communication when working with customers in the development of new products and the solution of their problems with our products.
  • Implemented a Quality program across the plastics division that was based on Targets for Excellence.
 
BFGoodrich, Senior R & D Engineer
Avon Lake, Ohio
  • Developed several new rigid PVC compounds for new sheet and profile extrusion applications.
  • Provided technical service to customers to help them solve their technical problems using our materials.

Education
  • University of Akron, Akron, Ohio, M.S. Polymer Science
    • Thesis: "The Relative Contribution of Radial Position on Extrudate Swell"
  • University of Akron, Akron, Ohio, B.S.  Chemical Engineering
 
Memberships
  • Society of Plastics Engineers, Senior Member
  • Vinyl Division, past Chairman, current Treasurer
Patents
  • 13 patents
 Publications
  • 14 Technical Publications​