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Expert F Expert has over 55 years of plastics processing experience. His main focus has been extrusion processes using extruders -- twin or single screw -- for compounding, film, sheet, and profile. He has extensive experience with feed screw design and die designs. He has worked in the packaging industry, automotive, building products, firearms, medical, and appliance industries, either as a research process engineer, extrusion equipment salesman, executive management and owner of companies for extrusion, injection molding and other processes. He has worked directly with such screw design gurus as Bruce Maddock, Bob Barr, George Kruder, Devante, Kline and Tadmore (the first designers of computer simulation), Chan Chung, and Ed Stewart. All have done significant work on advancing screw performance in single screw extruders.
Expert has 6 years' experience with R&D process and product development via Union Carbide Corp., Glad Bags & Wrap, Ever Ready Batteries, Structural Foam Process, Blown film extrusion, cast film extrusion, wire coating, thermoset molding, compounding, LDPE film recycling and pelletizing.
Additionally, he has 11 years of experience in engineering, sales and sales management for plastics extrusion and molding equipment, plastic welding, and high-intensity mixing equipment via Waldron-Hartig, HPM Prodex, Werner & Pfleiderer Corp., Bernhard IDE, Andrea Crespi, Beilomatic Lueze & Co, TK Fielder.
He has 18 years' experience in corporate management, engineering, and sales for profile extrusion, compounding, recycling, injection molding, and fabrication in union and nonunion environments alike, including George Woloch Co. (Industrial plastic recycling and compounding automotive feedstock), Werner & Pfleiderer Corp, (Founded) Plastics Assembly Corp. (marketing process equipment and consulting), Johnson Rubber Corp. (automotive profile extrusion and injection molding),(Founded) Custom Pac Extrusions, Inc.(Custom profile extrusion and injection molding, patented process for plastic drum handling rings), Custom Materials, Inc.(job shop fabrication parts for electrical industrial products), and (Founded) LDL Consultants.
Expert’s consulting experience spans over 20 years with more than 85 company clients, most of these clients are involved in profile extrusion and the work encompasses new process and new product development, project management, management consultation, market and sales development, new business development -- he founded 3 companies and has helped start up others with management, administration, technical, and marketing services -- engineering and design, and expert witness, including contract liability and intellectual property patent defense. He is currently involved in Domestic and international travel to assist installation, startup and training for American Kuhne Corp., a Division of Graham Engineering. He is involved in developing seminars and classes in extrusion process engineering at University of Akron Polymer Training Center.


1. Worked for an arms and ammunition manufacturer and through proper material selection, change in vendors and testing, process improvement, major change in tooling for 12 gauge shotgun shell manufacturing, as well as some in the field market investigation, he was able to help the company increase their sales to the skeet and trap community by 100% over 3 years.2. Have travelled internationally for the last 10 years for a major manufacturer of extrusion equipment in a field service capacity as a process engineer, supervising installation, startup and training of 1, 2 and 3 extruder, co extrusion systems to produce drinking straws, profile extrusions and very high speed medical tubing systems. These were all turnkey extrusion lines with guaranteed performance.3. Have on a number of consulting assignments been engaged as a project manager to assist in startup company extrusion assignments to specify an extrusion system to accomplish manufacture of a specific profile, plastic lumber, automotive window gaskets, body side molding, dual duel durometer profiles, refrigerator gaskets, and medical profiles and tubing. He found vendors to supply turnkey extrusion systems, supervised installation, in some cases designed the dies and selected the screw design for the specific material, started up the lines and trained the engineers and operators to manufacture the product. In some situations there were post extrusions operations to complete manufacture of a product.4. Have accepted assignments to retrain engineers and operators to set up and run existing extrusion systems where the key people were lost through attrition and no one had experience to run the extrusion operations properly. One was a major supplier of medical products with 6 very specialized systems who were running complete automated systems manually because the key technical people had left the company. Another, in Canada had a unique extrusion system and the engineering and manufacturing managers were terminated for criminal activity and the whole tech staff was lost. It took several weeks to update and train the new manufacturing staff.5. One assignment in Canada was to inspect a complete compounding operation producing $125MM of thermoset material for molding of electrical fixtures with distribution to all of North America. The purpose was to get the plant design for 2 times the production to work as designed. Some major mistakes were made in construction of the total blending, compounding and pelletizing of the material. We found both processing miscalculations and bottle necks preventing full efficient processing, corrected the problems with new technology and were able to increase production over 80% while reducing scrap generation from 24% to 3% with a capital investment or input of $185,000. 6. Have assignments to perform due diligence in determining value of assets, viability of business and competence of employees to help an acquisitioned company grow7. Had a client who made roofing material and purchased a turnkey operation to their design from a German supplier. After 1,5 years of operation the system was generating scrap at approximately 25% extruding at 12000#/hr. With modification of the process under my recommendation the scrap generation was reduced to an acceptable 5% or less depending on which material suppliers material was being used. Scrap, during normal operation was being produced at 200#/minute on occasion.