Engineer Process
Resume:
Gregory A. Westlake, PE
Tega Cay, SC 29708
abnryf@r.postjobfree.com
OBJECTIVE:
Experienced and motivated senior process engineering professional seeking a challenging leadership position in
the Pharmaceutical or Biotechnology industries. Ideal roles for my skill set would be: Senior Process Engineer,
Principle Engineer, Project Engineer or Process Department Manager.
CREDENTIALS:
BS in Chemical Engineering, Notre Dame University
MBA in International Finance, University of North Carolina
Professional Engineer, South Carolina
EXPERIENCE:
(3/1996 – 2/2009) CH2M HILL ENGINEEERS INC., SPARTANBURG, SC, USA
Project Engineer Client: PFIZER, Kalamazoo, MI, USA (1 yr.)
Led Pfizer focus teams through process engineering design of a $70 million retrofit sterile filling
pharmaceutical plant from conceptual through preliminary engineering phases.
Identified flow paths for all resources, such as: chemicals, utilities, materials, people, and products.
Developed process flow sheets, P&IDs, and equipment layouts.
Developed long lead equipment specifications for: formulation, stopper processing, vial rinsing, vial
sterilizing, sterile filling and stoppering, freeze drying, capping, parts washing, autoclaving, and CIP
system.
Acted as Pfizer Project Engineer working with equipment vendors to design sanitary equipment / piping.
Project Engineer Client: BAYER, Berkeley, CA, USA (4 yr.)
Relocated to the site to assist in coordinating all aspects of engineering design of a $75 million greenfield
sterile filling pharmaceutical plant from concept through construction, commissioning and validation
phases.
Identified flow paths for all resources such as: chemicals, utilities, materials, people, and products.
Developed material handling procedures and engineered carts for handling all resources.
Developed process flow sheets, P&IDs, equipment layouts, safety and risk analysis, and commissioning
/validation documents.
Developed all equipment specifications for: product thawing and bulking, vial rinsing, vial sterilization oven,
sterile filling and stoppering, freeze drying, capping, parts washing, autoclaving, VHP material pass
through, stopper drying, CIP system, and nitrogen system.
Acted as Bayer Project Engineer working with equipment vendors to design sanitary equipment / piping
and test it during FAT and SAT.
Coordinated the design of all process and facility HEPA filters and then supervised installation.
Process Group Leader Client: BAYER, Rosia, Italy (1 yr.)
Managed an 8 person process team during the preliminary process design of a $40 million greenfield
blood plasma pharmaceutical plant.
Identified flow paths for all resources, such as chemicals, utilities, materials, people, and products.
Developed process block flow diagrams, process flow sheets, PDS 2D P&IDs, utility sequencing analysis,
CIP system valve schematic, and equipment layouts.
Developed long lead equipment specifications for: bulk chemical storage, buffer staging, plasma
dissolution, chromatography, clean utilities, sterile filling, cold storage, vial packaging, and warehousing.
Process Group Leader Client: NORAMCO, Athens, GA, USA (6 mo.)
Managed the preliminary process engineering design of a $20 million expansion of a sterile suture
pharmaceutical plant.
Developed P&IDs, utility analysis, and equipment layouts.
Developed equipment specifications for: oxidizer, high-pressure gas storage, and NOx gas scrubber.
Process Group Leader Client: P & G, Greensboro, NC, USA (1 yr.)
Managed an 8 person process team during the design of a $20 million expansion of a food-grade antacid
making plant from concept through construction phases.
Developed process design basis, process flow sheets, PDS 2D P&IDs, material balance, batch
sequencing analysis, and equipment layouts.
Oversaw the implementation of the PDS 3D design for sanitary equipment and piping.
Developed equipment specifications for: dissolution reactor, batch mixing tanks, filter press, CIP bend
panels, sanitary PD pumps, NOx gas scrubber, and bulk chemical unloading station.
Provided on-site technical support during construction.
Senior Process Engineer Client: HUNT WESSON, Waterloo, IA, USA (6 mo.)
Assisted in the conceptual design of a $35 million aseptic pudding processing facility.
Developed process flow sheets, multiple flavor material balances, batch sequencing analysis, and
conceptual equipment layouts.
Developed long lead equipment specifications for: batch mixing tanks, powder handling equipment, aseptic
filler, and packaging equipment.
Senior Process Group Leader Client: DSM, Greenville, NC (9 mo.)
Managed an 8 person process team through the detail engineering phase of a $90 million expansion of a
high strength DAP fiber plant.
Implemented process improvements on the drying ovens to lower room emissions.
Developed equipment specifications for: silo, extruder, spinning equipment, drying ovens, fiber handling
equipment, hot oil system, decalin /water separators, thermal oxidizer, and sulfuric acid vent scrubber.
Project Engineer Client: PCMP, Podolsk, Russia (9 mo.)
Managed a 10+ person process team through the preliminary engineering phase of a $350 million green
field polysilicon plant.
Used Aspen process simulation of the mass balance to merge the design packages from 3 technology
suppliers into a single set of process flow sheets.
Optimized building layouts to reduce pipe runs and construction cost, which will save PCMP $15 million.
Developed preliminary equipment data sheets for: numerous reactor/process vessels, storage tanks,
cyclones, heat exchangers, distillation columns, material handling equipment, thermal oxidizers, vent
scrubbers, and filter presses.
Senior Process Group Leader Client: CYTEC, Greenville, SC, USA (6 mo.)
Managed a 10+ person process/utilities team through preliminary engineering phase of a $300 million
expansion of a carbon fiber plant.
Used Aspen simulation to optimize solvent recovery in distillation columns.
Developed long lead equipment specifications for: numerous reactor/process vessels, storage tanks, heat
exchangers, distillation columns, oxidation and carbonization furnaces, dryers, fiber handling equipment,
thermal oxidizers, and gas-fired boiler.
Process Group Leader Client: BASF, Geismar, LA, USA (1 yr.)
Managed a 10+ person process team during the design of a $65 million surfactants plant from concept
through detail engineering phases.
Managed the development of: project design basis, process flow sheets, PDS 2D P&IDs, and equipment
specifications.
Oversaw the implementation of the PDS 3D design for design of equipment and piping.
Process included: multiple reactor designs, hose stations, vacuum jets, gas scrubbing, truck and rail car
loading and unloading, and multiple storage tank farms.
Senior Process Engineer Client: PEQUIVEN, Caracas, Venezuela (6 mo.)
Managed the preliminary process engineering design of a petrochemical marine terminal.
Developed a pipe sizing study based on shipping berth utilization during the expansion of the Jose Chemical
Complex.
Developed process flow sheets, P&IDs, specifications for dock loading equipment, and piping layouts for
cryogenic service.
Process Consultant Client: HCC, Spartanburg, SC, USA (3mo.)
Analyzed the machine capacities of all polyester staple fiber-making lines.
Authored a detailed study entitled, “Installed Cost of Opportunities for Capacity Expansion” in spinning,
canning, stretching, and baling production areas.
Senior Process Engineer Client: HCC, Mount Holly, NC, USA (3 mo.)
Performed numerous relief device calculations on the sequenced operations of oil-heated batch reactors in
the production of specialty chemicals and surfactants.
(12/1994 – 3/1996) PERFORMANCE ENGINEERING, CHARLOTTE, NC, USA
Project Manager Client: HCC, Salisbury, NC, USA
Supervised the engineering designs of numerous polyester fiber projects, which were executed by Perigon
Engineering.
Managed fund appropriations requests, budgets, equipment purchases, coordinated customer meetings,
and coordinated installation by plant Maintenance.
Supervised the engineering design of an automatic bale weighing, labeling, and stacking operation.
Other projects included: several inverter drive and PLC upgrades in support of staple fiber manufacturing,
baling, and warehousing.
(4/1993 – 12/1994) DAY & ZIMMERMAN, S. E., CHARLOTTE, NC, USA
Lead Process Engineer Client: WELLMAN, Florence, SC, USA
Managed the detail engineering design of a $35 million polyester (PET) solid-state polymerization plant and
managed the engineering design of a $4 million PET chip storage facility.
Developed process design basis, PLC / Operator interface design basis, process flow sheets, P&IDs, and
equipment layouts.
Developed equipment specifications for: dense and dilute phase pneumatic transfer systems, storage silos,
dust collectors, rail car loading with a scale, and a vacuum collection system.
Provided on-site technical support during the construction phase.
(6/1988 – 4/1993) HOECHST CELANESE CORP. (HCC), CHARLOTTE, NC, USA
Corporate R&D Engineer Site: HCC, Charlotte, NC, USA (3 yr.)
Proposed and implemented process improvements in the acid recovery areas of cellulose acetate plants
and held two international technology conferences.
Conducted groundbreaking research in the field of electro-pulse extraction, which was noted in Chemical
Engineering magazine.
Studied the feasibility of replacing a benzene-based technology for manufacturing acetic anhydride with the
Ketene process which resulted in a $120 million project at two HCC plants.
Discovered a method of improving anhydride clarity in the laboratory that was successfully implemented in
the plants’ design.
Process Development Engineer Site: CAPE INDUSTRIES, Wilmington, NC, USA (2 yr.)
Developed engineering designs which supported the production of a polyester precursor, DMT.
Used ChemCad process simulation to redesign distillation columns and install structured packing to
enhance the removal of unwanted byproducts from the process.
Implemented a trial on production oxidation reactors to determine the time and temperature affects on
multiple reaction kinetics that resulted in the successful implementation of an $8 million process
improvement.
Designed several column gas spargers that operated successfully and met their design objective.
(5/1986 – 12/1987) GAST MANUFACTURING, BENTON HARBOR, MI, USA
Product Design Engineer
Conducted analytical and micrographic testing on carbon/graphite and thermoset plastic/ graphite composite
vanes for use in rotary vacuum/compressors.
Responsible for specifying internal finishes on aluminum and cast iron castings. Familiar with SPC quality
analysis and JIT manufacturing.
(6/1984 – 5/1986) REYNOLDS METALS, Benton Harbor, MI, USA
Project Engineer
Implemented mechanical projects on aluminum smelting furnaces and rotary chip dryers.
Ordered materials and supervised 3 furnace refractory rebuilds.
Designed a baghouse for the rotary chip dryer to comply with environmental regulations.
Wrote a computer program for preventative maintenance (PM) scheduling.
(5/1983 – 6/1984) LECO CORP., ST.JOSEPH, MI, USA
Product Design Engineer
Developed an innovative design for an automated wet lab instrument used for measuring the quantity of
aluminum in steel. The design surpassed the “repeatability” of the patented research version of the
equipment.
Conducted metals analysis in the destructive and micrographic metals testing laboratories.
(5/1982 – 9/1982) GENERAL ELECTRIC, NUCLEAR FUELS DIV., WILMINGTON, NC, USA
Production Supervisor (Intern)
Supervised other summer interns on the operation, testing, and maintenance of a nuclear fuels ball mill.
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