Intellex Acquires Expert by Big Village

We're thrilled to announce that Intellex has acquired Expert by Big Village, effective March 22, 2024. This strategic move enhances our capabilities and strengthens our commitment to delivering exceptional solutions to our customers.

Stay tuned for more updates on how this acquisition will benefit our clients and experts.

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Expert Details

Glass Bottles, Beverage Manufacturing and Packaging, Package Development, and Consumer Package Safety

ID: 728247 Massachusetts, USA

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Glass Bottle
As the Subject Matter Expert for glass bottles at a multinational beverage company -- a household name -- Expert was responsible for the performance of glass bottles used in 45 Billion consumer transactions annually across 180 countries. This included new launches, supplier authorization & management, technology assessment, troubleshooting, performance improvement, and training of colleagues in the field. He combined his knowledge of glass science and his experience of how bottles are used to introduce a global family of glass designs that were simultaneously stronger, lighter, and less expensive than those they replaced.

Glass Defect Identification
Expert regularly used his knowledge of glass defects and their causes to identify and correct quality issues before they became problems in the market. This skill was also used during glass package qualifications.

Glass Fracture Analysis
Expert's experience with glass fracture analysis began as a glass container plant worker and continued in Packaging Development at this household name in beverage manufacturing and sales. He used this skill during evaluation of new glass bottle designs, for troubleshooting, and as an expert witness for his employer.

In his supply chain optimization role, he was responsible for improving the flexibility and efficiency of the beverage production processes with filling being a major focus. Filling processes include sparkling, hotfill, and aseptic. He focused attention on the ”total cost of ownership” (TCO) showing that the packaging and production must be optimized jointly. He created the production transformation strategy and worked with suppliers to develop required equipment and packaging innovations. He has two patent applications pending for innovations in beverage filling.

Throughout his career, he worked in innovation and polished his skill at developing new packaging, technology, and processes. He builds teams that include the operational, marketing, business, and technical functions required for complete success and leveraged suppliers to reduce development time and cost. Expert is accomplished in all development phases including idea generation, building the business case, project management, commercialization, and post launch optimization. As a result of his development work, he introduced packaging innovation in the areas of glass, PET bottles, PEN bottles, closures, labeling, decoration, and paperboard and introduced patent pending technology to eliminate filling downtime between flavor changes.

Over 90% of the glass bottles sold globally by this multinational beverage manufacturing and sales corporation are refillable bottles that must be washed before filling which can damage the glass if done improperly. He applied design of experiment methods to optimize washing conditions to reduce water, energy, and chemical usage while assuring quality. He co-managed an industry team to modify the washing process when improved measurement methods revealed a contaminant in the washed bottles.

Throughout his career, he worked in innovation and polished his skill at developing new Consumer packaging, technology, and processes. He builds teams that include the operational, marketing, business, and technical
functions required for complete success and leveraged suppliers to reduce development time and cost. Expert is accomplished in all development phases including idea generation, building the business case, project
management, commercialization, and post launch optimization. As a result of his development work, he introduced packaging innovation in the areas of glass, PET bottles, PEN bottles, closures, labeling, decoration, and

He has repeatedly applied his deep understanding how packaging will be filled by the brand owner, distributed, sold, and eventually used by the consumer to create new robust packages that do not create problems in the
market. As part of this package development process, he knows the testing required to assure package safety before the package or product is introduced.

Expert has supported arbitration as an expert through auditing the client's operations against industry best practices and analyzing the documented processes of the opposing company to identify their poor practices. At the
hearing, he successfully explained his observations relative to industry practices. His statements were cited numerous times in the Arbitrator's written ruling in favor of his client.

Expert developed and introduced the first plastic closures for carbonated soft drinks as an alternative to the metal closures previously used. This provided experience with both the safety requirements and the capping
equipment required for a successful closure. He continued applying his knowledge throughout his career and has expanded his knowledge as a consultant to include flame arresters for bottles containing flammable liquids.

Throughout his career, the products and packages in Expert's projects were shipped, so he has extensive experience in industry practices required to prevent product damage and injuries to the people that handled full pallets.

Expert's development projects have always focused on creating a package or process that was safe for use even when misused for consumers. To do this, he studied consumer behavior when interacting with products or equipment. He learned to anticipate misuse, abuse, and failure to read instructions in order to prevent unintended actions from creating a failure or injury. Developers of new products, packaging, or processes have this responsibility to foresee and protect by establishing the requirements and practices to assure safe use.

Based on his work experience packing hazardous concentrates requiring UN/DOT certified packaging, Expert has been retained in several cases concerning chemicals containers.

He assisted a glass supplier improve bottle quality while decreasing rejects.He assisted a private equity firms evaluate a packaging material recycler.He assisted a multinational consumer products goods company introduce a borosilicate glass baby bottle produced in China for the local market. Although the company had deep experience in plastic packaging, they had never sold a glass package and needed an expert to assure quality and protect their brand reputation.For a brewer, he determined the cause of glass breakage during production and then worked with their glass supplier to eliminate the defect. The glass supplier's field service engineers were unable to identify the cause.He analyzed a failed ceramic toilet and the property at which it was installed to determine the cause of the failure and resulting property damage.Redesigned a glass beverage bottle to improve strength after determining the root cause of filling line breakage.Identified the cause of leaking caps on jars of cheese dip filled with the Retort process and lead the project to eliminate the leakers.


Year Degree Subject Institution
Year: 1985 Degree: MBA Subject: Management Institution: Gerogia State University, Atlanta
Year: 1980 Degree: Bachelor Subject: Mechanical Engineering Institution: Georgia Tech, Atlanta

Work History

Years Employer Title Department
Years: 2010 to Present Employer: Undisclosed Title: President / Consultant Department:
He is sharing his packaging and beverage experience with clients to help them reduce cost and shorten-time to market. As an expert witness, he has a proven ability to explain the facts based on how packaging is designed, manufactured, filled, distributed, and used by the consumer.
Years Employer Title Department
Years: 2005 to 2010 Employer: THE COCA-COLA COMPANY Title: Sr. Manager Supply Chain Optimization Department: Supply Chain Planning, Strategy, & Commercialization
He improved the overall operational efficiency of the beverage supply chain. He created the vision of the 2020 supply chain required to meet changing demands and populated the development pipeline with the projects required for the transformation. He investigated new issues to define the opportunities and required next steps. He managed relationships with the equipment suppliers.
Years Employer Title Department
Years: 1989 to 2005 Employer: THE COCA-COLA COMPANY Title: Packaging Development Consultant Department: Global Packaging Development
He developed and introduced packaging innovations in glass containers, plastic bottles, labeling, and secondary packaging. He worked with operations and suppliers in developing markets to provide training and to upgrade package performance. He was the global subject matter expert for glass containers.
Years Employer Title Department
Years: 1984 to 1989 Employer: THE COCA-COLA COMPANY Title: Manager Package Testing Department: Engineering Development Center
He managed testing of all packaging used in the beverage industry. He created procedures for new packaging under development and improved the accuracy and efficiency of existing procedures.
Years Employer Title Department
Years: 1982 to 1984 Employer: THE COCA-COLA COMPANY Title: Staff Packaging Engineer Department: Corporate Packaging
He developed the first plastic closure for carbonated beverages.
Years Employer Title Department
Years: 1981 to 1982 Employer: THE TIMKEN COMPANY Title: Machine Designer Department: Research
He designed unique equipment for bearing manufacturing.
Years Employer Title Department
Years: 1980 to 1981 Employer: THE TIMKEN COMPANY Title: Industrial Engineer Department: Industrial Engineering
He performed time studies and set incentive rates for bearing manufacturing plant.

International Experience

Years Country / Region Summary
Years: 1989 to 2018 Country / Region: Globe Summary: Expert has supported operations for this household name in beverage manufacturing and sales globally for 28-years and has continued working globally as a consultant. This includes travel to 67-countries on five continents. The purpose of the visits could be in lieu of a local staff as he did in Russia and India during the start of operations in those countries, to train staff and suppliers in developing countries, or to work with local suppliers and bottlers to introduce innovations. As a consultant, he continues to work on international projects including two business trips around the world since 2010. He has traveled internationally on business at least once a year since 1989.

Career Accomplishments

Associations / Societies
He is a member of the Institute of Packaging Professionals (IoPP), the Product Development & Management Association (PDMA), the International Society of Beverage Technologists (ISBT), the Master Brewers Associations of the Americas (MBAA), and the American Ceramic Society (ACerS), American Chemical Society (ACS)
National Fire Protection Association (NFPA)
Licenses / Certifications
CPP - Certified Packaging Professional by IoPP
Six-Sigma Green Belt Business Process Excellence Group
Publications and Patents Summary
He has 2 US Patent and 2 Australian patents issued plus 1 US patents pending and 3 PCT application pending.

Additional Experience

Expert Witness Experience
He has been an expert witness testifying at trial 3 times and in 15 depositions for civil suits involving glass bottles or consumer packaging representing both plaintiffs and defendants in both state and Federal courts. He has written reports and provided testimony in a ICC arbitration case. He performs glass container fracture analysis to determine cause. He advises Counsel on the technical aspects of consumer product packaging, glass containers, packaging safety including packaging for flammable products, and other packaging. He analyzed samples and provided reports on packaging involved in extortion and counterfeiting cases. Applying his experience with the proper packing and loading practices in shipping products, he has served in an expert in cases involving damaged goods and injuries during the shipment of goods. He also serves as an expert in commercial arbitration, property damage, and criminal cases. In a property damage case, he has applied his fracture analysis training to identify the root cause of a bathroom fixture failure. Based on his extensive with international shipments of packaging in shipping containers, he wrote a Rule 26 report resulting in a Summary Judgement for his client concerning the poor practices used in loading electric carts that rusted when shipped from France.
Training / Seminars
Co-delivered Webex concerning Digital Printing of Packaging to 350+ global participants. Speaker at Digitally Printed Packaging Conference.
Speaker at the 2015 NASP conference in Reno Nevada on "Spotting Subrogation Opportunities in the Failure of Glass, Ceramics, and the Packaging of Glass Containers".
Vendor Selection
He served as the packaging manager for the reentry of this U.S. multinational beverage manufacturing and sales corporation into India after a 15-year absence where he surveyed the packaging industry before selecting and qualifying local suppliers which is a skill that he has continued to apply. He regularly worked with existing suppliers in developed and developing markets to upgrade their capability.
Marketing Experience
He was responsible for translating anticipated beverage marketplace changes into future packaging and process technology requirements. He created the beverage supply chain transformation roadmap based on feedback from his large global network which guides new development and investment. Expert applied his knowledge of cost drivers to bring about meaningful change. He has worked with all of the global equipment suppliers to the beverage industry.
Other Relevant Experience
Supplier/customer relationship management. Package quality specifications and test methods.

Fields of Expertise

glass bottle, glass defect identification, glass failure analysis, bottle glass, container glass, glass, glass container, glass packaging material, fractography, soft drink filling, carbonated beverage filling, beverage packaging process, beverage, beverage industry, bottling, carbonated beverage, package cost reduction, bottle washing, foreseeability, package testing requirement, primary packaging, packaging development, development process, packaging innovation, consumer packaged goods, consumer product safety, packaging evaluation, arbitration testimony, flame arrester, package closure, shipping accident, distribution packaging material, pallet handling, truck loading, international shipping, consumer behavior, environmentally safe packaging, human factors, consumer insight, child-resistant packaging, package regulation, consumer packaged goods industry, consumer safety, hazardous material packing requirement, winery, due diligence, package manufacturing, beverage technology, expert witness, package impact testing, commercialization, single-stage injection-stretch blow molding, lean manufacturing, bottle inspection machinery, glass fracturing, glass stress, glass thermal stress, plastic can, bottle design, beverage quality assurance, packaged product, beverage ingredient, safety packaging, consumer product packaging, automated filling, fracture analysis, case-hardened glass, plastic package testing, glass blister, package handling, voice of the customer, parison, glass cullet, polyethylene terephthalate bottle, baby bottle, technology development, glass strength, manufacturing troubleshooting, glass property, filling process, hazardous material package, glass manufacturing process improvement, brewing, glass recycling, inventions, glass color measurement, aluminum can, packaging machine, process development, beverage canning, troubleshooting, rotating machinery development, packaging technology, management, defect, packaging machinery design, bottled water, aseptic filling, glass failure, glass inspection, new product development management, blow-molded container, package consumer testing, fracture stress, legal patenting, sterile packaging process, soft drink, packaging engineering, ceramic failure analysis, carbon dioxide, alcoholic beverage

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