Paul Giusto

** ******** ****

Southwick, MA *****

413-***-**** ad3ryl@r.postjobfree.com

PROFILE: Executive Manager, Senior Process Engineer, Senior Chemist, Project Manager, Technical Support/Service Manager with two decades of experience in the aerospace, coatings industry and graphic arts industry. Ink/Coatings and Printing industry consultant and expert witness. Extensive knowledge of SPC and DOE methods for product and process improvements, also material, coating and adhesive science, especially properties of organic and polymeric materials. Worldwide project responsibilities within corporate family. Co-inventor: US Patent # 7,014,895 and #7,910,203. Team Leader of ink manufacturing department while concurrently performing as a Senior Development Chemist.

Highlights that represent my leadership/management and technical ability in project management/technical service include:

• Technical Director, Functional Inks, Inc. Company created to service the custom ink, coating, and adhesive formulation market. Develop and coordinate the production of inks coatings and adhesives for the Screen Printed Heat Transfer Label market.

• As Senior Process Engineer, I developed processes that significantly improved yields of the main proprietary aerospace product. Costs were reduced so much so that new capital became available for equipment and facilities upgrades. I modified products to meet customer demands on schedule and under budget. Acted as technical consultant to the QA department for SPC methods, and chemical material analysis methods. Responsible for budget and capital equipment justification. Provide weekly updates to senior management. Maintain all process related documentation including BOMs, Routings and Work Instructions. Supervised two engineering technicians. Provided training to direct labor on proper methods of using new equipment and methods.

• As Ink/Coatings and Printing Industry Consultant and Expert Witness I provided formulation assistance to multiple clients developing organic inks and coatings. Developed a cleaning method for a critical part for a supplier to a major medical OEM. I was on retainer as an Expert Witness in a Patent infringement case involving specialty inks and coatings.

• As Project Manager, prepare technical requests and technical evaluations of materials submitted for new applications; Evaluate and develop specific production materials, including originating and/or improving qualitative and quantitative laboratory test methods to analyze raw materials and finished coating/ink products, identifying and purchasing new equipment. I managed my development projects from conception through commercialization, including troubleshooting in production and if necessary at customer locations. This often involves the development of qualitative and quantitative laboratory test methods to analyze raw materials, the processing of raw materials into components used to make the finished goods, as well as the finished goods themselves. For example, I use FTIR methods that I developed to determine the degree of cure of my UV formulations. I developed a color QC procedure for our ink department that uses an X-Rite 0/45 spectrophotometer. Using the same instrument I developed an on press color control program for the labels of a major US golf club manufacturer. I also developed analytical methods to evaluate new resin sources using a Shimadzu DSC 50. Using a viscometer made by Brookfield Engineering, I developed an SPC method for the resin solutions that make up more than 80% of all finished inks, in order to prevent defective inks from being printed and making it to the customer. I was involved in the identification, evaluation, and purchasing of these analytical instruments for my current employer.

• As a Team Leader, develop and maintain specifications for assigned materials; develop test procedures to predict the materials/coatings/inks performance in production and processing. I developed procedures regarding production record keeping, quality control procedures for viscosity of resin solutions using a Brookfield Viscometer and SPC techniques, color control using an X-Rite spectrophotometer. Lead the production team using Kaisan techniques to reduce the number of steps required to make a batch of ink. This resulted in a significant reduction in the lead- time for ink production. Introduced a Kanban inventory control method to the department. This resulted in a significant reduction of out of stock material.

• Serve as Senior Chemist and Technical Representative for correspondence and discussion with vendors/contractors concerning technical direction and issue to the purchasing officer technical directives with specific details and milestones. I would identify sources of materials, obtain samples of materials, test and report the results of the tests. These steps were completed when the materials were incorporated into finished products. Correspondence and meetings are conducted with the vendor/contractor until the materials are finally accepted for purchase, at which time, the purchasing agent (contracting officer) is given all information and responsibility for purchase of the material. The most recent and mission critical example occurred when Dow exited the Solution Vinyl Resin business a couple of years ago. It was my responsibility to obtain and qualify appropriate replacements. This resulted in the identification and replacement of four grades of vinyl resins. There was one grade for which there was no suitable replacement and that required reformulation using alternate resin types. I then gave the purchasing officer technical directives and specifications of the new materials. The purchasing officer (CO) started the purchasing process under my technical directions. Products affected are worth $4MM per year.

• As Senior Chemist, routinely prepare and write technical documents, oversee new product development, identify potential new production materials and/or suppliers and conduct practical laboratory and production trials of these new materials. Prepare technical reports/presentation of these trials and recommend the viability for use of these materials. Develop technical specifications of production materials. I led the development of UV-Curable and Solvent-Based inks, coatings and overprint varnishes for silkscreen and flexographic printing processes as well as UV-curable coatings for aluminum based offset printing plates. These coatings were applied by using slot coating, and roller coating methods. Development of these ink and coating systems requires production materials to be requested from suppliers for evaluation. These materials include but are not limited to: Resins, Polymers, Monomers, Oligomers, Photo-Initiators, Pigments, Dyes, Solvents and Additives. Substrate materials are also evaluated from qualified suppliers. These include coated and uncoated PET, or PP films and papers. Meeting with Manufacturer Representatives for these materials is commonplace and frequent.

• As an R&D/production liaison, provide technical support for production problems or issues related to materials in question. Plan, lead and participate in specially controlled studies and investigations to resolve production problems. I am responsible for trouble shooting internal problems and external problems due to customer complaints. For example, the UV inks I developed were not curing completely. This could be verified by FTIR analysis using the techniques I developed for this purpose. Analysis of the UV lamp output was measured using a radiometer that I purchased for this purpose. It was determined that the crystals used to absorb IR from the lamps had become dirty and needed periodic cleaning. Also I determined that city water was not suitable as a chiller roll fluid due to variation of incoming water temperature throughout the year. I identified and justified for purchase a chiller for this purpose. This resulted in a much more consistent process.

WORK

HISTORY: Functional Inks, Inc.- Technical Director (May 2014-Present) Advanced Defense Solutions Technologies (Division of Swift Textile Metalizing) July 2011- July 2015

23 Britton Drive

Bloomfield, CT 06002

Senior Process Engineer

As Senior Process Engineer, my primary function is the development and support of production processes to support the production of highly proprietary aerospace products. I provide process engineering expertise, including skills related to statistical QC and DOE. I developed processes that significantly improve yield and consistency as measured using process capability techniques. I provide technical expertise to solve production problems, interface with vendors of raw materials and material testing labs when analytical testing is required beyond our in-house capabilities. Additionally, I maintain BOM and production routings in an ERP system.

Selected Accomplishments:

• Significantly reduced set-up time and direct labor for a major process while also improving quality and yield.

• Reduced defects by introducing new coating processing techniques.

• Trained Engineering staff on Statistical Design of Experiments techniques. Also provided training using self-programmed spread-sheets and MINITAB.

• Provide technical input to assist the management team with capital purchases and facility upgrades.

ITW-GRAPHICS (FORMERLY PRO/MARK CORP.) Sept. 1994 – March 2011 375 New state Road

Manchester, CT 06042

Senior Development Chemist

As Senior Chemist, my primary function is the Development of Heat Transfer Label Products from conception to commercialization and beyond, produced primarily by using industrial screen-printing methods. This includes the complete formulation of ink, where all ink components are received in their basic state and all value added processes are part of the developmental process; for example, how to disperse a pigment in a UV-curable vehicle. Also included in the development process is the specification of the carrier web, whether paper or polymer film, coated or uncoated. Commercialization requires in-house technical service in our production department, qualification of the finished product in our tech services lab, and acceptance of the product at the customer’s production facility. I also acted as Production Team Leader for the ink-manufacturing department. Selected Accomplishments:

• Qualitative/Quantitative Lab Test Methods: SPC of resin solution viscosity, FTIR methods of determining UV Curing, DSC methods to determine degree of thermal curing, Spectrophotometer methods of color control in the ink department and on press, density procedures for 4-color process printing. Justified and purchased the equipment for the tests mentioned above.

• Production Materials related to my area of expertise include specifically UV- Curable and solvent-based inks and coatings. Adhesive development for polymeric and composite materials, printing on polymeric and coating materials. Also adhesive development for inorganic materials; such as Aluminum, Stainless Steel, and Glass.

• Developed Specifications for color control, viscosity control, curing control, and release properties of coated films. Computer based color control significantly reduced complaints received for color consistency traced back to the ink manufacturing process. Viscosity control, via SPC charting methods, reduced the variation seen on press between batches of ink. Curing control methods were developed to insure complete curing of the UV formulations I developed.

• I provided on-going Technical Support of production problems related to the commercialization of a selectively metalized heat transfer label product at our location and at the supplier’s location, which was an ITW sister company. This is the basis of Patent #7,910,203. This is one example of many projects worked on over the years.

• Technical Support for major customers is ongoing but specifically, I am working with the supplier of a major component of a surgical robot. I am technical liaison between this customer and their customer with regard to decorating the part with a functional label. Current challenge: cleaning the part before decoration.

• Products Developed: UV-curable screen printing inks for Polypropylene that are exceptionally flexible, UV-curable inks for appliance parts that pass General Electric’s performance specifications. Selectively metalized label. Post UV- curable inks that provide exceptional chemical and abrasion resistance. UV-Curable flexographic inks for heat transfer labels. Solvent based labels for coated graphite arrows (archery), cosmetic jars, painted/bare metal and glass. EDUCATION: Master of Science Degree: Engineering Management, Western New England College, Springfield, MA 01119. GPA: 3.83

Bachelor of Science Degree: General Science, Chemistry Concentration. Honors: Cum Laude, Westfield State College, Westfield, MA 01085

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