Plastics Industry Consultant

Contact: Larry W. Crovatt

2322 Malysa Place
Pensacola, FL 3250
U.S.

Phone: (850) 438-6778
Fax: (850) 438-6778

Website

E-mail

Hello, I'm Larry Crovatt. Welcome to my Web site.

I have over forty years of plastics technology experience with Major Medical Companies and Polymer Manufacturers
(i.e. Johnson & Johnson Medical, Monsanto Plastics Corporation, and others).

*
My major strengths are in Engineering Polymers with Specialty in Polyurethanes; including Polymer Synthesis, Melt Processing Technology, Equipment Design, Selection, and Layout.

* Principal Areas of Experience include:
* Polymer Materials Selection
* Raw Materials Selection, including Colorants, and Additives
* Formulation and Process Developments in:
* Polymer Synthesis
* Extrusion
* Compounding
* Wire Coating
* Injection Molding

* 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 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 to the 'combined expertise' that I have not only in the Polymer Chemistry technology but also in the Process Engineering technology area. Most Plastics Consultants do not carry a full complement of both disciplines.

* This level of technical strength together with good teamwork and communication that I strive to provide gives 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

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

* Medical Devices Extrusion, Molding Process Development, and Troubleshooting
* Design of Experiments, including Process Validation, Equipment Selection and Layout
* Polyurethanes, Polysulfones, Polycarbonates, Silicones and other

* Balloon & IV Catheter tubing extrusion process developments.

* Specialty in Medical Grade Polyurethanes
* Lab Scale Custom Synthesis through Pilot Plant and Production level scale-up.
* Experienced in Continuous and Batch Polymer Manufacture
* Pre-polymer and One-Shot Method Processes
* Lab and plant facility floor plans
* Reactor Equipment selection
* Meter Mix & Dispense Reactors
* Twin Screw Compounding Reactors
* Stirred Kettle Reactors

* Turn-key Startup, through Equipment, Process and Product Validations
* Personnel training through validation

* 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 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'

* Gel-free Extrusion and Molded Products
* Achieved through the utilization of state-of-art filtration technology combined with other requirements in equipment design, setup and processing conditions

* High Performance Engineering Polymers
* Expertise in the molding and extrusion process in the Industrial Applications end-use area
* Injection, Ram, and Compression molding
* Tubing extrusion (e.g. brake cable liners, misc automotive and electrical extruded
* Monofilaments extrusion (e.g. consumer personal and industrial brushes)
* 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

* 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
* Good 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
* Molecular Weight Investigation Considerations (e.g. GPC)
* Crystallinity/morphological studies where needed
* Moisture analyses (accuracy +- 0.002%)
* 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

CONSULTING SERVICES: (1993-present)
(Some Principal Areas of My Consulting Experience)

* Polyurethane thin wall medical tubing extrusion
* Extrusion line equipment selection
* Facility (floor plan) set-up
* Product and Process development
* Personnel training
* Turn-key through process qualification and validations

* Custom Medical Grade Polyurethane Materials Development
* Lab synthesis through Pilot plant and Production scale-up
* Lab and Plant facility design (batch and continious)
* Equipment selection and installation assistance
* Startup through process validation and personnel training

* Medical Grade Wire Coating (Ultra-Thin wire and coating)
* Equipment and Tooling Selection and Installation Assistance
* Raw Materials Selection including Colorants
* Process Development through Validation and Personnel Training




* Medical Devices Injection Molding Process Developments and Troubleshooting
* Polyurethanes
* Polysulfones
* Polycarbonates, and others

* Balloon Catheter (Tubing Extrusion Process Developments)

* Implantable devices
* Biocompatible plastic component materials selections
* Mold design
* Molding process conditions, for highest quality surface properties (e.g. artificial heart components)




* Polymer Crystalline Properties Influence
* Analysis and control of crystalline properties influence on certain polymers... for optimization of long term in-dwell end-use performance




* Patent (Expert Witness)
* Assisted client regarding infringement concern upon their company patent by the conducting of key chemical and physical analysis investigations (document issued) on other party materials to aid in making court determinations





***

PROFESSIONAL EXPERIENCE (Continued)

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




* My 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:
*
J&J Medical Inc. Quality Recognition Award (1990)







***

PROFESSIONAL EXPERIENCE (Continued)




MONSANTO PLASTICS COMPANY (1960 – 1985)
Senior Technologist, 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 scale:
* Polymerizations
* Processing technology in:
* Screw extrusion
* Injection molding
* Compounding (Twin-screw and FCM equipment)
* Polymer Blending
* Polymer Alloying
* 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


*
Including larger scale polymer modifications influence using:




* Fillers
* Reinforcing materials (fibers)
* Impact modifiers
* Flame retardants
* Lubricants








* Four years career experience in:
* 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 Polymer Products


* 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 (1958-1960)
* Post Graduate Research




* University of North Carolina (1958)
* M.S. in Chemistry
* Major: Organic Chemistry
* Thesis: Synthesis and Addition Polymerization Initiator Properties
of Benzenesulfonyl Peroxide








* University of Georgia (1954)
* B.S. in Chemistry
* Major: Organic Chemistry







AFFILIATIONS

* American Chemical Society


* Society of Plastics Engineers


REFERENCES

Available on Request