Rubber Manufacturing Manager and Principal Engineer

OBJECTIVE

Aspiring to be part of a dynamic and ambitious team in a Specialty Chemicals company, passionate to apply my 9 years of Materials Engineering, Applications development, Rubber Compounding, Formulation development, Process improvement, Projects management, Technical Sales, market insights and Analytical Chemistry experience to transform science into competitive novel products and work towards delivering cost effective solutions for customers. At the same time offering technical support to production/ process development on extruders, banbury mixers, calendaring process, application development, marketing, raw material and finished product analysis and addressing Quality issues, customer complaints by employing my experience as a Plant Manager.

PROFESSIONAL ACCOMPLISHMENTS

Honored with Lean certification for applying Six Sigma tools to improve the throughput upto 30% on a 90 C

N330 Black reinforced Welding Cable and also reducing the cost of Formulation.

Deployed feasible dynamic testing tools (Flex Fatigue resistance) to Improve the flex fatigue life of Nylon tire cord,

Spheron 6000 reinforced Polyisoprene with Low Hysteresis for Goodyear and Michelin

Led a team of Process and Product development Engineers to achieve $750,000 USD savings on the manufacturing

Cost of an Extruded -High temperature resistant- carbon black filled CPE and EPDM based UL 90C rated Flexible,

portable chord and Mining Cable

Instrumental in formulating SBR elastomer compound/ Tire with Carbon Black and RFL latex coated Nylon fabric

Exhibiting improved fatigue, wear and tear and abrasion resistance.

Devised a roadmap to successfully commercialize a high temperature resistant Cabosil (Fumed Silica) filled Silicone

rubber for Gasket and Sealant applications in Automotive.

Instrumental in identifying key business segments and market drivers in Automotive, flexible chord industry to

offer an annual savings of up to $4.0 Million USD by implementing Nanoparticles, low density foamed vinyl

Microspheres into specialty elastomers - SBR, EPDM, CPE, Nitrile rubber through excellent synchronization of

Polymer Chemistry, compounding, Analysis of Structure- property Relationship of Materials and Product Evaluation

Recognized with Best Paper award at an international conference for development and Commercialization efforts on

carbon black reinforced polystyrene and polyimide nano fibers using Electrospinning process

Adept in handling more than 20 customer accounts in 2 Quarters encompassing crucial high volume sales and potential

to generate $10 Million in revenue.

Conceptualized, developed and successfully commercialized a $1.7 Million copolyester resin product for flexible, tough

Hospital and industrial flooring Application containing Black Pearls 2000 Carbon Black (Anti static).

Developed conductive, high temperature and chemical resistant Polyimide & Polyaniline nanofibers- 90 to 300 nm

Utilized NBR, PP and other rubber crumbs to manufacture highly resilient, puncture resistant Pavers with improved

flexural properties and NVH performances (Noise, Vibration & Harshness)

Spearheaded a team of 7 comprising Procurement Director, Sr. Buyer/ Sourcing Analyst, Process Engineer, QC and Lab

Technicians in determining alternate vendors/ Material suppliers- viable and cost effective Thermoplastic Polymer

Resins and Additives- Impact modifier, Process Aids, plasticizer, Adhesives/ Reactive modifiers to offer USD $2.6

Million savings through synergistic properties, innovation and competitive price on consumer products at AZEK

Improved the processing ability and hydrolytic resistance of glass fiber reinforced Liquid Crystalline Polymer (LCP)

And Polyamides by developing formulation/ Compounding with cost effective reactive modifier- JONCRYL ADR,

Process aids on single screw extruder, calendaring process for laminates and industrial flexible packaging items

Envisioned the importance of having a non- halogen-flame retardant polymer cable in the market and Opened up

Avenues to propel an environment friendly -green Cable in an economical way, saving 40% on the cost

Troubleshoot customer complaints by Conceptualizing and developing a novel process and polymer resin along with a

2 Part cure system to integrate and bond functionalized Silicone- Fluorinated polymer with a non-woven fabric for

Medical applications

EXPERIENCE

Application Development Manager- Elastomers & Additives, Metabolix, Lowell, MA Nov 2014 - Present

Commercial and New Product Development initiatives and research projects were recognized on Plastics News Journal, conferences and online technical blogs.

Deployed roadmap to utilize biobased copolyester elastomers in a STERLING and VULCAN (CABOT) carbon black reinforced tire compound.

Employed Application Development efforts to successfully incorporate a Specialty additive within industrial rubber segment- Rubber mats, flexible toughened runners, Molded Utensils & EPDM Automotive Weather stripping.

Conducted techno-commercial feasibility study within specialty additives and commodity polymers segment to forecast and project sales based on volume and viability for business – Urethane Belts & Hoses at CONTITECH.

Instrumental in understanding customer needs, business development tasks, constant follow-up through call, emails and frequent visits resulting-in $2 Million in revenue per year.

Presented Research work on Specialty Polymer Additives at 2 international Conferences.

Inventor on 3 patents. One has been issued across the globe and widely accepted on an international platform.

Demonstrated improvement in physical properties within mineral filled elastomers, CPE and Nitrile/PVC rubber for Vartek’s Industrial Hoses product lines

Developed a series of novel silane treated clay reinforced biobased crosslinked thermosetting Co-Polyester elastomer with increased toughness, low temperature brittleness with enhanced mechanical and thermal properties targeting tire, medical, construction, textiles and consumer goods.

Senior Polymer Process Development Engineer, Belden, Richmond, IN, USA April 2014 – November 2014

Identified critical polymer properties to implement cost effective PU elastomer, Fluoro-ethylene copolymers, ETFE, PVDF and high temperature resistant polymers for industrial, communication and coaxial cable application.

Offered technical support on Fluorinated polymer resin selection based upon melt flow index, shear rate, viscosity, draw

down ratio, melt fracture properties and melt density.

Demonstrated Persistent efforts and initiatives on troubleshooting degradation of PVC, FEP, Teflon, PVDF (Solef),

ETFE (TEFZEL) compounds on single screw extruders through formulation optimization, processing parameters,

thereby offering annual savings upto $300,000.

Implementation of Lean Daily Management Tools, stage gate processes in addressing new products, compounds and polymer processing concerns.

Senior Polymer Science Engineer, Azek Building Products (CPG International), Scranton, PA, USA August 2013 – April 2014

Developed low shrinkage, durable outdoor Polyolefin sheets using 2% loading on PLASBLACK PE2272 Carbon Black.

Envisioned and developed result oriented, non- standard test methods to evaluate thermal properties – conductivity,

Thermal expansion- TMA and mechanical properties of a Glass fiber reinforced Polyurethane for outdoor application

Developed a novel thermoplastic (PVC) formulation as per Building Codes and optimized processing conditions at 164 mm diameter size twin screw extruder thereby accomplishing $ 1.2 Million annual savings.

Led a team of Process Engineers, Chemists, QC technicians and Polymer Lab technicians to deploy strategic plan on

QC techniques, validation and Approval of cost effective raw materials for Natural Rubber, Crumbs and Polyolefin

Elastomer.

Conceptualized and offered substantial cost reduction on existing products ( PVC, HDPE, Polyolefin Elastomer) through

reformulation and reduction in cycle time on compounding phase- Dry Blend and Extruders.

Identified bi and Tri functional, unsaturated monomers/ raw materials and developed formulation to improve the

Compatibility and adhesion between elastomeric and Olefinic- PE, vinyl thermoplastics in reactive extrusion process.

Senior Polymer Chemist (Product Development Engineer), General Cable, Rhode Island, USA April 2012 – August 2013

Identified key product lines and drivers in Wire and Cable Market to render an annual savings of upto USD 4 Million.

Interaction with screw, die designing vendors, additives, fiber and polymer resin suppliers on a daily basis to identify cost effective, high performance materials for existing and new cable products – Non Halogenated Jacket layer

Conducted Analysis/ Lab Evaluation on additives, incoming raw materials – TEFLON, Polyolefin's, Polyamides, formulations and finished products using Rheometer, FTIR, TGA, DSC, TMA, SEM, Mechanical - fatigue test, Thermo Gravimetric Analysis and Dynamic Scanning Calorimeter.

Formulated and scaled-up a cost effective, low temperature and flame retardant- N330 Carbon Black reinforced chlorinated –PE elastomer ( CPE) Compound for Industrial and Automotive applications as per UL, CSA and ICEA

Supervised a team of 2 chemists, 2 QC technicians and lab technicians

Improved Single screw extrusion processing parameters on an SBR elastomer for development of high abrasion and oil resistant military jacket/ external sheath products

Propelled Compounding- Banbury equipment and extrusion process through cross functional interaction with a group of product design engineers and chemists in the development of economical- light weight Kevlar incorporated EPDM outdoor product

Offered a seamless transition on EPDM, Polyolefin elastomers and acrylo nitrile elastomer based compounding technology from a manufacturing facility, aimed at utilizing the resources in an efficient manner.

Introduced and compounded- chlorinated wax, novel functionalized Hisil (silica) filler reinforced –non halogenated acrylo-nitrile butadiene polymer, acrylic microsphere grafted polyolefin foams, Polyamides and Polyester reinforced composites

Addressed challenging tasks and customer complaints on outdoor weathering, chemical resistance, high temperature capabilities, low temperature flexibility and oil resistance for Mining, Communication, Plenum and Marine cable.

Application Development Engineer, Momentive, Indiana, USA May 2011 – April 2012

Imparted a cost effective process design to develop, manufacture and commercialize a Polyacrylate- Epoxy Resin

Analyzed catalyst and hardener chemistry in epoxy (amine – curing agent) and silicone 2 part cure adhesive to offer

Optimized curing conditions at a multi cavity injection molding process with an Automotive customer.

Developed, processed and analyzed Liquid Silicone Resins, Silicone Elastomer, RTV's for adhesion on engineering

Plastics substrates, (PTFE) Teflon Reinforced Silicone for Automotive Ignition- Cable applications, pressure sensitive

adhesives and troubleshoot extrusion, injection, compression molding process at Customer end.

Formulation of competitive Minusil reinforced- High temperature, Flame retardant Silicone polymer bonded with non-

woven Nylon Fabric for Consumer and Automotive application.

Collaborated with a group of Senior Process Technologist and manufacturing team to Synthesize a thermosetting silicone-epoxy modified acrylate copolymer by free radical polymerization and later to scale up at pilot and production stage. Conducted a techno-commercial study on the organic and physical chemistry aspects of a Hydrophilic Silicone polymer

As per VOC (Voice of customer), developed quality control techniques to evaluate epoxy-silicone resin and analyzed

Using DSC, NMR, FTIR, GPC, Gas Chromatography, viscometer, wet chemistry & Thermo Gravimetric Analysis (TGA)

Conducted a techno-commercial study on the organic and physical chemistry aspects of a Hydrophilic Silicone hydrogel

Polymer Research Engineer, Research & Development, Engineering Plastics, SRF Limited, India June 2009-April 2010

Accountable for design of experiments (DOE) and Polymer processing through single and twin screw Extruders

Devised a road map along with a Team of product developers at different geographic location (Thailand and Dubai/ Asia)

To envision and develop a super hydrophobic Poly (vinyl chloride) coated fabrics

Troubleshoot customer complaints on hysteresis and flex fatigue resistance of Natural Rubber based tires

Installed and built a compounding framework for the manufacture of PEEK and Polyamide 6.6 for film and profile

Extruded products

Worked with cross functional teams to propel a project on "Compounding of High heat resistant Poly Butylene

Terephthalate- filled with glass fibers and inorganic economical fillers" for Automotive applications

Analyzed Crystallinity, Heat of fusion on polymeric materials to determine suitable processing conditions

Developed in-house facility to conduct emulsion polymerization of specialty acrylic nanocoatings at lab scale

Supervised serving staff of 3 including an Area leader and practiced 5S, Kaizen and SPC- Statistical process control

Troubleshooting customer complaints on processability of liquid crystalline polymers and glass fiber reinforced

Engineering plastics using AUTOCAD and Mold-flow software

Developed carbon nanotube and graphene incorporated conductive epoxy and acrylic resins thermal Analysis- DSC,

TGA, Infra red spectrum, molecular weight- end group analysis and rheometer

Product Developer, Conducting Polymers Laboratory, Indian Institute of Technology-IIT, India May 2008-May 2009

Developed high temperature resistant, conductive Carbon Nanotube (SWCNT) reinforced Polyimide Nanofibers and analyzed using SEM, TEM, Raman Spectroscopy, IR, DSC for fuel cell electrodes and energy storage devices

Synthesized polyamide nanofibers and PEEK filtration membranes incorporated with functionalized –MWCNT's (Carbon nanotubes) and silver nanoparticles as a non-woven membrane using Electrospinning process

Manufactured flexible electrodes using carbon black reinforced Polystyrene Nanofibers through Electrospinning process

Designed and tested Thermally conductive Carbon fiber composite fabrics for Military applications

SKILLS

Software's: Microsoft office package, Cable Builder Package, Minitab- Full and Partial factorial DOE's, AutoCAD, Mold

Flow, MathCAD and Origin

Machines/Processes: Banbury Mixers, Two Roll Mill, Dry Blend Tower, Twin Screw Extruders, Six Sigma Tools,

Electrospinning, Gel spinning of UHMWPE, Polymer Rheology, Polymerization –Autoclave reactors, Solution, Emulsion, Pilot

Process, Process Flow Diagrams, Troubleshooting –Unit Operations,

Polymer Processing – Profile, Elastomer Compound, Footwear, V-Belts, Roofing, Cable extrusion, Elastomers, Sheet

Extrusion, Rotational molding, Melt spinning, Injection, Compression and Blow molding; compounding with Additives, Sputter

coating, Sol- gel chemistry, Composites- Spray, spin Coating, Wet-etch Process, Photo-chemical etching, Thin Film Coating,

Chemical Vapor Deposition (CVD) and Polymer Biaxial Orientation process

Material Analysis and Testing Tools: Arc resistance, Die Electric Breakdown strength, Parallel plate and Shear disc

Rheometer, Viscometer, Surface characterization –XPS, Auger Electron Spectroscopy, ESCA, AFM; Thermal analysis- DSC,

TGA, DMTA; Structure and Chemical bonding Analysis- Raman, IR and UV Spectrometer; Crystallinity, Morphology- TEM,

XRD and SEM; Wet Chemistry tests – PH, end group analysis, Gel Permeation Chromatography and molecular weight.

Business Development through Expos, International Conferences and Presentations.

Vinyltec 2015, AMI Profiles 2015 and NPE 2015.

EDUCATION

Master of Science in Materials Science and Engineering GPA: 3.91/4.00 December 2011

University of Florida, Gainesville, FL

Coursework: Polymer Physics, Materials Thermodynamics, Materials Characterization Techniques, Polymer

Characterization and Supply Chain Management

Research projects

Synthesis, characterization, testing and processing (extrusion) of carbon nanotube reinforced Polyamide composite fibers.

Bulk Insitu and Micro Emulsion Polymerization of Nylon- 6.10 coated Single Walled Carbon Nanotube composites for

Structural applications- seals and oilfield pipelines

Research Proposal

Study on the impact of electrosprayed PMMA-PVDF diblock copolymer micelles physical properties in the development of

Super Hydrophobic coating with micro-nano scale roughness

Bachelor of Technology in Polymer Science and Technology GPA: 4.00/4.00 April 2009

Anna University, India

Coursework: Rubber Engineering, Compounding of Polymers, Analysis and Characterization of Polymers, Polymer

Reaction Engineering, Principles of Chemical Engineering, Polymer Chemistry, Blends and Composites,

Processing Technology, Polymer Testing, Thermosets and Additives, Adhesives and Surface Coatings

PATENTS:

Inventor on following Patents at Metabolix, Inc

Highly Filled Polymer Systems, PCT/US2015/023186.

https://patentscope.wipo.int/search/en/detail.jsf?docId=WO2015149029 Oct 2015

Waxes Containing Polyhydroxyalkanoates

Filled for Provisional Application Aug 2015

Compounded PHA’s with Good Elastomeric Properties

Filled for Provisional Application May 2015

SEMINARS/CONFERENCES AND RESEARCH PUBLICATIONS

VINYLTEC 2015, Enabling Technologies for the Future of Vinyl Industry: Published and presented a path breaking

Research on “Biobased PHA Copolyesters as Multifunctional Additives in a Polymer compound”-

International Conference, Society of Plastic Engineers. Oct 2015

http://blog.metabolix.com/vinyltec-2015-pha-biopolymers-as-multifunctional-performance-additives-for-pvc-and-wood-

polymer-composites-2/

https://www.eiseverywhere.com/ehome/122014/303565/

PPS International Conference 2011, Published Research work on “Synthesis and characterization of Electrospun

Conducting polyimide SWCNT composite nanofibrous electrodes for energy storage devices”, Morocco. May 2011

B.Mansoor Akhthar, Dr.T.S.Natarajan, Dr.R.Vasanthakumari, “Development and Characterization of nanofibers as Flexible

Polymer Electrodes for Energy storage application”, Plastindia International conference, India

(Best Paper Award) Feb 2009

B.Mansoor Akhthar, Dr.T.S.Natarajan, Dr.R.Vasanthakumari, “Carbon nanotube reinforced Non-woven Polystyrene as

flexible electrodes in fuel cells”, International Conference – ICAER; IITM, Chennai April 2009

AFFILIATIONS AND HONORS

Inventor - Filled 3 patents on Specialty ADDITIVES and New formulation development within Elastomers, commodity plastics and Wax market segments. Jan- August 2015

Honored with Special Recognition Award on two occasions at GENERAL CABLE for successfully completing Cost-Saving and New Product Development projects. November 2012

Certified on Green Belt, lean six sigma methodology at General Cable March 2013

Adjudged Distinguished and Active Member of Tau Beta Pi – Engineering Honor Society, UF. August 2011- Dec 2011

Accepted on Both RISE- Germany and CRCC-Asia prestigious International Fulltime Internships for Engineering and Research opportunities at Fortune 500 companies. April 2011

Member of SASE (Society of Asian Scientists and Engineers) at University of Florida September 2010 – December 2011

Presented a paper on "Electrospinning of Polystyrene nanofibers containing graphene for energy storage applications" at

Plastindia International Conference, India. Feb 2009

Secured 1st Rank in Bachelors of Polymer Technology and was awarded Gold Medal by Indian Plastics Institute

Won “Outstanding Student Award” for overall performance in Bachelors of Technology Program April 2009

Active member of Indian Plastics Institute (IPI), India June 2005- December 2011

Recipient of Prestigious Plastindia Scholar Award from Plastindia Foundation & Indian Plastics Institute (IPI) - Recognition for Research and excellence in academics May 2009

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