Hello, I'm Larry Crovatt. Welcome to my Web site.
I have over forty years of Plastics Technology experience with Major Medical Device Companies and Industrial Polymer Manufacturers
(i.e. Johnson & Johnson Medical, Monsanto Plastics Corporation, and others).My major strengths are in Industrial Engineering Polymers with added Specialty in Polyurethanes and Nylons; Including Polymer Synthesis, Extrusion and Melt Processing Technology, Equipment Design, Selection, and Facility Layout.
- Principal Areas of Experience include:
- Polymer Materials Selection
- Raw Materials Selection, including Colorants, and Additives
- Formulation and Process Developments in:
- Polymer Synthesis
- Extrusion
- Injection Molding
- Wire Coating
- Compounding
- Set up of Complete Line Systems comprising:
- Extrusion lines (tubing, wire coating, monofiliments, film, and other)
- Polymer Synthesis (Polyurethanes, Nylons, Polyesters, and other)
- Injection Molding Operations and Materials Handling systems
- Product Testing and Packaging
- SPC turn-key Process Validation and Training
- Strength in problem solving with the proven ability to get the job done:
- This includes having good working relationships with highly reliable outside testing laboratories; and close contact with other plastics technologists, associates that I can readily call upon for additional technical support whenever needed.
- I attribute the success in my consulting service to my combined expertise of Polymer Chemistry with Process Engineering. Most Plastics Consultants don’t carry this combination of both disciplines.
- It is this level of technical strength together with the attention placed on teamwork and communication that gives the added assurance of successful projects with my clients.
I invite you to give me a call or email to discuss your program needs and determine how I may be of assistance in helping you achieve your goals in the most cost effective and time saving manner
After hearing from you I would be very happy to then supply you with my Consulting Fee Schedule for your review and consideration. The schedule also outlines the general manner in which I conduct my service and can be modified to best serve the clients needs.
AREAS OF EXPERTISE (HANDS ON SUPPORT)
- Polymer Materials Selection and Sourcing (Medical & Industrial Applications)
- Custom polymer synthesis
- Raw material monomer ingredients expertise
- Additive modifiers
- Stabilizers
- Colorants
- Reinforcing agents
- High Performance Engineering Polymers
- Expertise in the molding and extrusion process in the Industrial Applications end-use area (e.g. Nylons, Polyurethanes, Polyesters, Polyacetals, Polycarbonates, Polysulfones, and others)
- Injection, Ram, and Compression molding
- Tubing extrusion (e.g. brake cable liners, misc automotive and electrical extruded parts)
- Monofilaments extrusion (e.g. consumer personal and industrial brushes)
- Extruded rod, sheet, profile, and slab
- Extruded film (lay-flat and blown film)
- Wire coating (e.g. cable, industrial and automotive)
- Equipment Sourcing and Selection Assistance
- Turn-key Startup, through Equipment, Process and Product Validations
- Personnel training through validations
- High Performance Medical Polymers Extrusion and Molding Process Development and Troubleshooting
- Design of Experiments, including Process Validation, Equipment Selection and Floor Plan Layout
- FDA (IQ/OQ/PQ) Validations
- Polyurethanes, Polysulfones, Polycarbonates, Silicones, PEEK and others
- Balloon & IV Catheter tubing extrusion process developments.
- Specialty in Medical Grade Polyurethanes Polymer Synthesis
- Lab Scale Custom Synthesis through Pilot Plant and Production level scale-up.
- Experienced in Continuous and Batch Polymerization Manufacture
- Pre-polymer and One-Shot Method Polymerization Processes
- Lab and plant facility floor plans
- Reactor Equipment selection
- Meter Mix & Dispense Reactors
- Continuous Twin Screw Compounding Reactors
- Stirred Kettle Batch Reactors
- Turn-key Startup, through Equipment, Process and Product Validations
- Personnel training through validation and startup productions
- Extrusion Expertise in Medical Tubing and Monofilaments
- R&D through Manufacture scale-up
- Heart pacemaker lead tubing
- Intravenous and Balloon Catheter tubing
- Surgical Suture monofilaments
- Specifying of equipment components and installation
- Turn-key Startup including Equipment, Process and Product Validations
- Screw design selection
- Tooling (die designs) selections
- Training of lab and manufacturing personnel
- Achieving high yield final product quality
- Wire Coating Extrusion Expertise
- R&D through Manufacture scale-up in ultra-thin layer “fluoropolymer” coated Medical grade wire
- Specifying of equipment components and installation
- Turn-key Startup including Equipment, Process and Product Validations
- Screw design selection
- Tooling (die designs) selections
- Training of lab and manufacturing personnel
- Achieving high yield final product quality
- Biocompatible Plastic Component Materials Selection (Implantable devices)
- Injection mold design
- Molding process development through validations
- Superior quality
- Smooth surface properties
- Significantly reduced or eliminated 'stress cracking tendency'
- Preparation of Polymeric Wear Debris Particles for FDA Biological Response Studies
- Gel-free Extrusion and Molded Products
- Achieved through the utilization of special design state-of-art micron filtration technology combined with other requirements in equipment design, setup and processing conditions
- Polymer Alloys, Reinforcements, Colorants, Stabilizers, and Blends Technology
- Twin Screw Compounding Extrusion
- Equipment selection and process development
- Troubleshooting Stress Cracking Problems in Molded Parts
- Causes of & Corrective Action
- Materials Testing and Specification Requirements
- Recommendations on Incoming Raw materials and Finished product
- Statistical Process Control Implementation and Training
- Chemical and Physical Properties Testing Expertise
- Excellent knowledge and working relationships with highly reliable outside testing laboratories including several university lab services.
- Broad background knowledge in this area, including:
- Applied Melt Rheology (MFI and Instron Melt Rheometry)
- Molecular Weight Investigation Considerations (e.g. GPC)
- Crystallinity/morphological studies and influence of properties
- Moisture analyses (accuracy +- 0.002%) and influence
- DSC, DMA, TGA, FTIR, HPLC, SEM, other
- Physical properties (tensile, modulus, impact, creep, etc.)
- Patent Documentation Assistance
- Expert Witness (e.g. Research assistance on Patent Infringement questions/issues)
- Personnel Training
- Laboratory and Plant Operations
***
PROFESSIONAL EXPERIENCE PLASTICS INDUSTRY CONSULTING
JOHNSON & JOHNSON MEDICAL (1985 – 1993)
Principal Scientist, R&D, Implantable Products
Materials Research & Process Development Department
- My responsibilities included:
- Plastic materials selection
- Polymers synthesis (R&D and Scale up)
- Melt processing development
- Tubing extrusion
- Injection molding
- Compounding
- Materials handling
- Provided technical support on existing products and leadership responsibility in new medical product development functions in the manufacture of:
- Polyurethane Extruded Intravenous Catheter Tubing in multiple gauges
- Numerous molded medical device components
- Other responsibilities included:
- Statistical process control implementation
- Quality improvement process
- Cause and effect analysis and design of experiment
- Raw materials and end product characterization
- Analytical equipment procurements
- Laboratory staffing and training
- Guided a highly successful polyurethane formulation development and polymer synthesis process development for a new product Polyurethane (Optically Clear Radiopaque) medical grade intravenous catheter tubing in multiple gauge sizes
- Met stringent state of the art requirements (commercial launch achieved)
- Three U.S. Patent applications were filed (1992)
- Product was commercialized by J&J in 1993. (remains commercial)
- Project leader in the development of a state-of-art extrusion line and manufacturing process for producing polyurethane catheter tubing, which included:
- Selection of all equipment and implementation of process control systems
- Raw materials selection, polymerization equipment, compounding, drying, and feeding systems
- Extrusion screws and die designs
- Extrusion line quenching and haul off equipment
- Cutting, packaging, and other necessary extrusion downstream equipment selection and operation
- Recipient of:
MONSANTO PLASTICS COMPANY (1966– 1985)
Senior Technologist, Group Leader R&D
Engineering Plastics Product & Process Development Department
- Extensive technology (R&D) career experience and background acquired in engineering thermoplastic polymers for Extrusion and Injection molded applications
- Nylons
- Polyesters
- Polyacetals
- Polycarbonates
- Additional experience in polyolefins and thermoplastic elastomers
- Chief functions (hands-on) in laboratory and pilot plant scaleup:
- Polymerizations
- Processing technology in:
- Screw extrusion
- Injection molding
- Compounding (Twin-screw and FCM equipment)
- Polymer Blending
- Polymer Alloying
- Polymer Reaction Reaction Grafting
- Applications Research experience in:
- Injection and Compression Molding
- Extruded tubing
- Extruded Monofiliments
- Extruded Blown film
- Extruded Sheet and Profile
- New product developments aimed at special high performance environmental demand end-use areas requiring a good working knowledge of:
- Polymer crystallinity/morphology
- Additive agents stabilizations:
- UV
- Thermal
- Oxidative
- Hydrolytic
- Fillers
- Reinforcing materials (fibers)
- Impact modifiers
- Flame retardants
- Lubricants
- Monsanto’s Plastics Marketing Technical Service (1976 - 1980)
- Responsible for:
- New Pilot and Commercial polymer resin product introductions
- Assistance to customers in materials selection in special high performance applications
- Troubleshooting in Extrusion processing (e. g. tubing, filaments, film, sheet, wire coating)
- Troubleshooting in Injection molding processing
CAREER HIGHLIGHTS
- Principal Developer in Commercial Launches of over 10 New Industrial Engineering Polymer Products (1966-1985)….most remaining commercial success today.
- Principal Developer in Commercial Launch of State of the Art ‘Optically Clear Radiopaque’ IV Catheter Tubing…J&J Medical (1993)…This product remains a high commercial success today.
- Primary Inventor on Seventeen (17) U.S. Patents
- Recognition Awards:
- Monsanto Plastics (1983 and 1984)
- Johnson & Johnson Medical (1993)
EDUCATION
- Baylor University Department of Chemistry
- Post Graduate Research
- University of North Carolina
- M.S. in Chemistry
- Major: Organic Chemistry
- Thesis: Synthesis and Addition Polymerization Initiator Properties
of Benzenesulfonyl Peroxide
- University of Georgia
- B.S. in Chemistry
- Major: Organic
AFFILIATIONS
- American Chemical Society
- Society of Plastics Engineers
REFERENCES
Available on Request
FEE SCHEDULE
I would be very happy to supply you with my Consulting Fee Schedule for your review and consideration. The schedule also outlines the general manner in which I conduct my service and can be modified to best serve the client’s needs.
Call me at (850) 438-6778
or
Email Me: Crovatt@Cox.Net
© 2004-2009, Larry Crovatt
All Rights Reserved