Request Expert

Expert has shown the ability to identify and implement packaging cost savings throughout his career. He reduced the material usage of a cupped pudding product by reducing the plastic cup material thickness while maintaining production line speeds and the stacking strength of the cups. In another example, he saved over $2MM by moving a foodservice client to a family of lower cost packaging types that not only where less expensive but also scored higher in customers' perception of quality. Expert has been able to achieve success in this area by utilizing a big picture approach. This often leads to cost savings ideas that are less obvious. Such as increasing the corrugated board grade on a food production shipping container that allowed the product to be double-stacked in the warehouse and during truck shipping. This increase in packaging material cost actually reduced the overall cost to the client company in warehousing and freight cost savings that more than offset the increase. He is knowledgable of a wide array of packaging materials and their characteristics and will use this knowledge to drive cost out of most packaging systems.

Expert has successfully developed a wide range of packaging in his 20+ years as a packaging engineer. In doing so, he has often worked in cross-functional teams that included marketing, engineering, procurement and operations. He has the ability to read and adapt to situations so is effective at moving his projects forward to completion in different environments and cultures. Most of his 20+ years was spent in the food industry working for companies such as ConAgra Grocery Products and Yum! Brands. He has been offering his services as a consultant for the past 9+ years. During that time he has completed projects for General Mills Yoplait, H.J. Heinz, 7-Eleven, Black & Decker/Kwikset, Pharmanex, and POM Wonderful to mention just a few of his clients. While at ConAgra he developed a new plastic material blend that allowed the production of clear cups on an aseptic thermoform/fill/seal machine for the first time. This breakthrough resulted in a major marketing advantage versus competitors. He worked on the commercialization of yogurt stick pack pouches during their inception for Yoplait. This product was the first of its kind and spawned various new products to be put on the markeet in similar packaging. Expert has many more examples of successful packaging he has developed. He has gathered much knowledge in this area over the years and also has a passion for what he does.

Expert has developed successful packaging from many different material types, in many different package forms. He has worked with glass, metal, rigid plastic, flexible plastic films, paper, paperboard and corrugated board. Most of his project work has required the developement of packaging systems that incorporate these various materials. He typically will develop not only the primary package, but the secondary and tertiary packaging as well. He has build a solid base of knowledge while working with these materials over the years. While this is the case, he has focused most of his efforts on plastic materials. These materials are both complex and versatile, and are growing in use. He has recently completed graduate level course work in polymer science to keep up on the advances in this area.

Array

Challenge:
Complete development of new yogurt package, integrated with new FFS equipment and support start-up on an accelerated production ramp-up schedule.

Work Performed:
Finished the development and implemented unique "stick pack" packaging for a new yogurt product called "Go-Gurt”. Was a member of a team that worked in partnership with the equipment supplier to design, build and troubleshoot new concept form/fill/seal machines to efficiently package the product. Gathered equipment performance and package quality data. Analyzed data and made recommendations for improvements that were incorporated into packaging and equipment.

Results:
Successful product launch. Production equipment was able to meet very aggressive ramp-up schedule. High quality product was shipped on time with no shortages or deletions occurring.



Challenge:
A QSR's packaging department did not have adequate resources to complete demanding marketing calendar projects and various cost savings projects.

Work Performed:
Developed and implemented numerous food packages that included: box and carryout bag, wraps, rigid food containers, promotional packaging, plastic "cruiser" drink cups, pouch material cost reduction and conversion from #10 can to pouch.

Results:
One of these package types, a family of rigid food containers, provided a cost savings of $2,000,000 while at the same time greatly increased package function, aesthetics and consumer appeal.

Challenge:
A health and personal care company lacked resources to develop packaging for an upcoming launch of a new line of products.

Work Performed:
Developed packaging for a new line of personal care products that included shampoo, conditioner, styling gel, styling foam and body wash. This included the retail packaging and sampler packaging for each product.

Results:
Successful on-time product launch. Packaging could be run at high efficiencies by co-packer. New product line was well received by distributors.

Challenge:
A large consumer products company needed packaging developed, sourced and implemented for a complete new line of upscale residential door fixtures. The packaging needed to communicate the image of high quality while still being cost effective and acceptable for store handling at Home Depot.

Work Performed:
Developed packaging for 14 different products. Primary, secondary and tertiary packaging was designed for each. Designs were verified through drop and vibration testing.

Results:
The new packaging was used in the on-time launch of the new product line. The products were well received by Home Depot.

Challenge:
A nutritional supplement company had quality problems with their highest volume product. Pills of the supplement, sourced in Asia, were degrading during shipment.

Work Performed:
Performed an analysis of the supplement’s distribution environment. Researched various pouch film barrier materials, film structures, their costs, and potential suppliers.

Results:
Recommended new pouch film specification for the product and potential sources. Tests with the new film proved the elimination of supplement degradation. The company shifted all of these supplements to this type of film.