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Process-Project
Engineer
04632
Industry:
Plastic Films, Extrusion
Resides:
Virginia
Salary:
Open
Relocate:
Yes
On
the Market:
Education: B.S. Chemical Engineering, Lafayette College (Easton, PA)
Engineer
- Film Manufacturing
Experience in film manufacturing as a technical leader, supervisor, plant
manager and process/project engineer.
Product/Process Experience
- Film and sheet processes Calendering, Extrusion, and Coextrusion
- Shrink film
- Compounding processes; PE, PET, PETG, PP, PVC and BOPP
- Fluoropolymers, PEI, PMP
- Formulating of rigid PVC
- Commodity films for laminating, packaging and thermoforming applications
- Engineering film and sheet
- PVC Compounds
Equipment Experience:
- Calendering lines; Compounding lines; MDO lines (shrink films)
- Cast and blown film coextrusion lines; Winders, Treaters, Dryers, Slitters;
Thickness control systems beta, GBS, IR, air shower
- Multiple CCD camera web inspection; Conveying, recycling, and gravimetric
blending systems; Roll handling equipment... Robot arms, gantry cranes
- Automatic Doffing system; Fluxing systems; Film dies (auto and manual)
Calendering
- Designed and installed new chill rolls that improved film shrinkage
control of thermoforming films and increased calender line capacity utilization
to the maximum output of the fluxing units (5500 pph).
- Developed a process for the elimination of the "oxbow" TD profile on
calender lines and allowed for fine adjustments to eliminate gauge bands
and hardspots in mill rolls at windup.
- Formulated rigid PVC blends for the production of films for FDA and
Industrial applications.
- Developed "positive pickoff" technology to enable operation of a PVC
calender at sufficiently high processing temperatures to eliminate defects
such as bank marks, processing gels, haze, knit lines.
- Wrote training manuals for calendering line job functions in brainstorming
sessions with associates.
Converting
- Modified slitters to eliminate "angel hair" formation on the edges of
slit rolls.
- Modified slitters for both narrow width thin delicate webs (½" slit
width, ½ mil) and stiff webs up to 1/8" thick.
- Made winder modifications that enabled efficient inline locked-core
slitting of narrow width rolls.
- Engineered a roll handling system for direct packout of inline slit
rolls from the winder of a high speed casting line.
- Added roll handling systems at slitters for safety and increased productivity.
- Added both pedestal and gantry manipulator arms (Positech)
- Automatic slitter doffing and reloading system for 102" slitter that
increased throughput by 50 percent on narrow width, small diameter slit
rolls for pharmaceutical converters.
Extrusion
- Introduced a densifying system that enabled the direct recycling of
edge trim and slitter trim during extrusion of thin films (0.5 to 2.0
mils). This increased yields from the low 60's to almost 100 percent.
- Facilitated the design of a barrier screw by SPR that enabled the gel-free
addition of recycle and more than a 50 percent increase in extrusion rate.
- Made operational a multiple CCD camera web inspection system that provided
100 percent inspection of film for pinholes.
- Technical Leader of a cast film coextrusion line that commercialized
R&D films developed for fiber-optic cable wrap, automotive overlay,
and OTR specific applications.
- Formulated rigid PVC compounds for the extrusion of films for FDA and
Industrial applications.
- Leader of cross-functional teams and Kaizens in film/slitter departments
that implemented capital and process improvements... new film dies and
screws, embossing system, modification of casting line for shrinkage control,
50% reduction in setup time, design of vacuum boxes, etc.
- Technical support for blown BOPP film coextrusion lines including commercializing
new products.
Management
- Directed operations of six film/sheet (4.0 - 60.0 mil) extrusion lines
and two scrap film repelletizing lines. Manufactured rigid PVC, PETG,
barex, propionate and butyrate films for thermoforming applications. Also
a substantial recycling operation from a customer scrap buy-back program.
- Set up and managed a facility in Canada calendering rigid PVC film,
primarily for FDA applications.
- Member of management team that upgraded a facility from ISO-9000 to
QS-9000 certification.
- Trained in DOE, FMEA, PPAP and SPC.
- Introduced and administrated the STOP Behavioral Safety Program. Facility
received the company's Platinum Safety Award the year after introduction
of BST.
- Negotiated new contract with the Teamsters union for approximately 130
employees..
Project Engineering
- Developed an MD shrink film business from a marketing request to full
commercial operation. This included equipment selection, field trials,
equipment modifications, purchase negotiations, facilitating the installation,
startup and the technical support to develop new products working with
customers.
- Received President's Award for managing the scale-up of a controlled-atmosphere
corona treatment process for fluoropolymer lamination films from an R&D
bench process to a full scale production line.
- Designed and built a 40mm ppy PVC compounding plant. Henschel blending,
a 2-stage Battenfeld planetary extruder, and hot-face pelletizing.
Work History:
10/01 - 9/02 (Company name) Films
VA
Process Engineer
11/96 - 4/01 Saint-Gobain PPL
Wayne, NJ
(formerly Norton PPL)
Senior Process Engineer
5/95 - 9/96 James River Corporation
New Castle, DE
(bought by Printpack 8/22/96)
Technical Unit Leader
2/86 - 2/95 American Mirrex Corporation
Delaware City, DE
(bought from Hoechst-Celanese
in 9/89)
Senior Process Engineer
2/84 - 2/86 Technical Plastic Extruders, Inc.
Newark, N.J.
Plant Manager
4/78 - 2/84 Hoechst Canada Inc.
Cambridge, Ontario Canada
Plant Manager
7/72 - 4/78 American Hoechst Corporation
Delaware City, DE
Process Engineer
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