Experience

R.E. Darling Company Inc.

• United States
• Defense and Space Manufacturing
• 1 - 100 Employee

• Chief Facilities Engineer

  • Apr 2022 - Present



Self Employed

• United States
• 700 & Above Employee

• Independent Consultant

  • Nov 2021 - Apr 2022

  Applying skills honed over 38 years in trouble shooting, debottlenecking, and improvement of chemical and other industrial processes. Review and advise on organizational structure to best utilize personnel. Applying skills honed over 38 years in trouble shooting, debottlenecking, and improvement of chemical and other industrial processes. Review and advise on organizational structure to best utilize personnel.



Apache Nitrogen Products, Inc.

• United States
• Chemical Manufacturing
• 1 - 100 Employee

• Operations Director

  • Sep 2017 - May 2021



PolyOne

• United States
• Chemical Manufacturing
• 700 & Above Employee

• Sr. Engineering & Facilities Manager

  • Aug 2012 - Aug 2017

  After accepting a Sr. Process Engineering role at the Pasadena, TX site, I quickly advanced to Maintenance & Reliability Manager (Seabrook Site) in August 2013. In October 2015 I assumed the leadership of the process engineering group in addition to the M&R Team. I have effectively managed capital budgeting and execution. Alleviated process bottlenecks by developing and implementing capital and procedural changes. Improved utility efficiency, lowering annual energy costs by $160K. Vigilant management of outside contractors to hold or reduce expenditures. Effective personnel management; Recognized expertise and reorganized personnel to reduce external service expenditures by $400K annually. Successfully reduced maintenance downtime by 37% while holding the annual budget constant. Reports: 8 salaried and 14 hourly Show less



Independent

• Process Technology Consultant

  • Sep 2011 - Jul 2012

  Continuation of work as outlined in Director, Process Technology position. Continuation of work as outlined in Director, Process Technology position.



Agrifos Fertilizer

• Transportation/Trucking/Railroad
• 1 - 100 Employee

• Director Process Technology

  • May 2011 - Sep 2011

  Developing several business projects to maximize assets idled or underutilized by the recent business model transition: Identified the potential of another company’s byproduct to be a replacement raw material in our current operation. Development and implementation should result in an increase in annual net income of $10MM. Performed due diligence on a manufacturing site for possible acquisition. Overseeing agronomic studies on an innovative fertilizer which blend inorganics with sterilized organics.Reports: Contractors and consultants as needed for projects. Show less

• COO & Site Manager

  • Nov 2007 - May 2011

  Responsible for an annual operating budget of $177 MM and sales of $205 MM. Had two most profitable years since the company’s purchase of the site in 1998. Responsible official for the site in safety and environmental matters. Negotiated collective bargaining agreements. Served as site representative for EHCMA and Pasadena Citizen’s Advisory Council; member of steering committee to form Galena Park –Jacinto City Community Industry Partnership. Improved safety programs through implementation of STOP for Supervisors and was one of the first sites in the nation to complete the OSHA Challenge Pilot Program. Led site to recovery after Hurricane Ike in which the plant was hit by a tornado & 6-foot-high flood water. All operations were functional after only 28 days.Reports: 99 hourly and 58 salaried, all disciplines; 91 nested contractors. Show less

• Production Manager

  • Feb 2006 - Nov 2007

  Negotiated Collective bargaining agreements. Identified process bottleneck and resolved by improving dilution method for sulfuric acid in the phosphate rock digestion process, improving production rates when running 98% sulfuric.In Sep. 2007, chronic rainfall in the Houston area resulted in an environmental release and triggered a unified command situation led by EPA. Successfully developed and implemented a plan to upgrade the water treatment plant to minimize the impact to the local environment.Reports: 56 hourly and 9 salaried, 18 nested contractors Show less

• Sr. Engineer/Technical Representative

  • Feb 2003 - Feb 2006

  Provided technical service for products and customer concerns. Developed and maintained product data sheets.Managed tank rebuilds. Managed technical issues and logistics of the Superphosphoric Acid (SPA) railcar fleet.Reports: Contractors and consultants as needed for projects.

• Operations Manager

  • Jan 2000 - Feb 2003

  Accepted position in the latter part of a $50MM expansion and upgrade of a phosphate – based fertilizer production facility. Modified concept designs in the granulation plant to achieve peak instantaneous rates. Improved chain mill entrance design to allow for higher DAP production rates. Developed operations contingencies for potential work stoppage during CBA negotiations.Reports: 44 hourly and 6 salaried, 14 nested contractors



Elementis Chromium

• Technical Manager - Oxides

  • May 1994 - Jan 2000

  Progressively moved up in the department, rising to Technical Manager in 1998. Additional positions held were Technical & Operations Supt., Operations Supt., and Product Development Supervisor. Responsibilities for the sole chromic oxide and chrome hydrate production facilities in the United States included: Provided technical service for customers. Established and controlled operational and capital budgets. Changed manufacturing philosophy which enabled successive production records in 1994, 1995, and 1996. This was accomplished without any major capital expenditures.Reduced fixed costs / ton of production by 15%.Modified the process to safely produce G-5099 through a single pass operation, saving operating costs and increased the product’s performance for refractory customers.Identified and led a project to modify water treatment process which takes a cost (treatment and disposal) and turns it into a revenue. Total expected net profit $1MM / yr.Reports: 30 hourly and 8 salaried personnel, including production, maintenance, lab, and packaging / shipping functions Show less

• Sr. Development Supervisor - Technical Dept.

  • Apr 1990 - May 1994

  Performed feasibility studies for byproducts of the company’s core businesses. Developed and implemented the quality control plan for the 1994 Rotary Hearth refractory lining replacement ($2.2 MM).Managed capital project ($1.5 MM) to relocate a Chrome Hydrate pigment production facility from Slatington, PA to Corpus Christi, TX; included redesign, construction, and start up.Made process changes to the Chrome Hydrate unit which reduced solid waste generation by 71%.Reports: Contractors and consultants as needed for projects Show less

• DCS Plant Superintendent

  • Nov 1983 - Apr 1990

  Progressively moved up in the DCS Department, rising to Superintendent in 1988. Additional positions held were Technical Supervisor, Assistant Superintendent. Provided engineering support for the DCS Plant and vacation relief for shift supervisors. In Jan 1986, assumed responsibility for the daily operations of the DCS Plant while the Superintendant was on temporary assignment. In Jan 1988 was promoted to full responsibility of all aspects of the department. During my tenure I set the primary production record which stood for 12 years. Accomplished wet end debottlenecking to allow for more efficient processing of chromate liquors. Established a goggle policy which reduced eye injuries by over 75%. Improved raw material efficiencies by 14%.Reports: 38 hourly and 8 salaried personnel, both operations and maintenance functions Show less