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Manager Engineer

Wake Forest, NC, 27587
March 27, 2018

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Alan Ebeling

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

Wake Forest, NC 27587

803-***-**** Cell

Packaging and Project Manager


Forty (40+) years of varying responsibility in packaging and project management in the Food and Pharmaceutical Industries. Major areas of concentration are management, engineering, training / mentoring, automation, instrumentation and controls, and material handling.

Two patents for the design of microwaveable packages.

Proficient in films, folding cartons, corrugate, blister packaging, solid dose capsule filling, liquid filling, plastic components, serialization, conceptual line design and installation.

Six Sigma Green Belt


April 2016 – Present

January 2017 – Present

Mallinckrodt, Hobart, New York

Project Manager for the installation of 5 case packers with serialization to meet FDA requirements.

April 2016-January 2017

Becton Dickinson, Franklin Lakes, New Jersey

Key resource for the implementation of Project Diomedes. Project is under development and I am restricted by a Confidentiality Agreement to discuss this further.


August 2011 – April 2016

BioMerieux, Durham, NC

Resolved open packaging CAPA issues to allow BioMerieux to meet FDA commitments.

Designed a new case packing area complete with new case erector, case labeler and checkweigher; this reduced ergonomic issues and insured 100% full cases are shipped form facility.

Designed a system that met a new marketing demand entitled “Fill to Line”. Project funded and l installed 1st Q 2014.

Designed a new automated packaging area that will enable bioMerieux to consolidate all packaging for Lines 1, 3 and 4 in one facility.

Instituted changes to robotic basket unloader that improved performance by 40%, reduced ergonomic issues and operator frustration. This savings could result in up to a $10M annual savings.

Hospira, Clayton, North Carolina

Designed an automatic reject system for Line 743A based on missing or elevated stoppers. Utilized Banner D10 sensors for detection.

Snyders-Lance, Charlotte, North Carolina

I provided a conceptual design that consolidated their two existing Variety Packaging Lines into one fully automated line. The concept included the use of 6 Delta robots for product forming, two Delta robots for carton loading and provided a central case loading area.

This design reduced their labor from 12 to 3 on the 8 count and from 21 to 3 on the 36 count. The estimated cost of this project was $2.8 million.

Kellogg’s, Cary, North Carolina

Client was experiencing 40 – 50% breakage on their Zoo animal Cracker Line.

Completed a failure mode analysis and determined that the breakage was coming from two specific areas.

I also determined that the packaging system contributed to the damage because of inefficient vibratory conveyors that were operating with damaged drives.

Unilever, Suffolk, Virginia

Packaging Project Discipline Leader for retooling current facility, project includes total redesign of packaging facility with 60 new baggers, 8 tri seal closing systems, 4 horizontal wrapping systems etc.

$15 million packaging portion of $125 million project

Kellogg’s, Charlotte, North Carolina

Installed a new conveyor packaging system that reduced manual packing by 9 people for a savings of $360,000

Covidien Healthcare, Raleigh, North Carolina

Designed additional packaging line for syringe packaging operation $1M project. Acted as client project engineer on a packaging project for Covidien Healthcare.

Responsible for designing two new parenteral lines for imaging solutions including conceptual layout, cost estimate, vendor selection and justification.

Estimated project cost of $7.8M


October 2009 – August 2011

Principal Packaging Engineer. Responsible for Cost Improvement Projects across North American GSK Sites and external contractors. Manager of the Corporate Packaging Lab for North America and European Union Pharma Sites.


January 2007 – September 2009

Project Manager and Senior Packaging Engineer.

Led packaging development projects for the Aiken facility and represented the site in all corporate functions relating to packaging.

Projects included thermoformers, cartoning, banding, bundling, case packing and palletizing.

Coordinated site responsibility with marketing on graphic changes, new product introductions, insured accuracy and ease of transferring from pilot status to full manufacturing.

Major accomplishments include:

Modification of ALLI package which reduced Cost of Goods Sold by $1.17 per sales unit. Modification of shrink and stretch banding material from 2.0 mil LDPE to 1.5 mil LLDPE to facilitate an increase in uptime and a reduction in costs.

Completed modification of Aylward Capsule filler to reduce downtime and accuracy.

Modification of Line 69 which packaged Beano Tablets to facilitate insertion of hand held dispenser into existing package. Added presence sensors to facilitate misaligned caps and added bucket elevator to eliminate redundant lifting.

Designed new $3.75 M line for miniature smoking lozenges in a handheld dispenser. (Mini Cooper Project)

Design included: sortation, filling, labeling, cartoning and case packing. Completed diligence comparing slat fillers vs. electronic counters and selected the slat filler for economic reasons and minimum need of changeovers.

Created all documents related to projects including: URS, FAT, IQ, OQ, PQ and material testing documents which include TCC, PTA and PQ.


January 2005 – January 2007

(Manufacturer of synthetic wine corks) Global Packaging Engineer.

Responsible for all packaging functions for the North Carolina and Belgium facilities.

Managed a 3.5 million dollar automation project of the packaging department in North Carolina and oversaw a similar project in Belgium for 2007.

Project includes robotic case packing and palletizing, conveying of product through a centralized distribution system and in line manufacturing data collection.

Modifications to existing 3 modes of distribution have resulted in increases to the bottom line of over $500,000 per year; FDA Compliant Facility.


September 1983 – January 2005

(Manufacturers of frozen pizza, eggrolls, ice cream, juice concentrates and breaded vegetables)

Positions Held:

Senior Packaging Research Scientist

Corporate Packaging Manager

Packaging Manager

Senior Packaging Engineer

Packaging Engineer


Bachelor of Science

Chicago State University


Senior Member Institute of Packaging Professionals

Member of Institute of Food Technologists

Member of Society of Plastics Engineer

Six Sigma Green Belt


Plochman Mustard-Production Manager

Solo Cup -Production Manager

Nabisco-Production Foreman

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