David Bolliger Blow Molding Specialist

PET and Flexible Packaging Consultant David Bolliger

Blow modling and plastic packaging consultant David Bolliger
PET Stretch Blow Molding and Packaging expert David Bolliger
James (David) Bolliger is a highly motivated specialist with 25 plus years of expertise in product development, project management and quality assurance in the PET industry. David has plenty of experience in the single layer and multi-layer passive and scavenger barriers for PET and is often able to cut costs for plastic film related activities. He is a true leader that can develop test methods and processes which will help ensure success. ​
  • Proven results in project management and quality assurance methodologies providing value added solutions that cut costs and improved productivity in diverse manufacturing environments.
  • Able to see the “big picture” of a process or problem and break it down into the smallest components for analysis and resolution.
  • Works well in a team environment and facilitates a positive approach when working with others.
  • Expert in single and Multi-material polyethylene terephthalate (PET) injection systems and stretch blow molding
  • Proven problem solving capabilities in product design, injection, blow molding, or general product performance
  • Heavy experience in statistical data analysis
  • International experience with Lithuania, Germany, France, and South Korea
Experience
2010 – Present
Private Practice                                                                      
  • Specialist on single layer and multi-layer passive and scavenger barrier polyethylene terephthalate (PET)  
  • Provide counsel on product development (barrier and non-barrier) from concept to commercialization with practical applications in injection and container manufacture. Primary polymer is PET and also experienced in extrusion in Polypropylene (PP) and High-density polyethylene (HDPE).
  • Solve customer issues with product design, injection, blow molding issues or product performance.
  • International accounts included Lithuania, Germany, France, and South Korea.
  • Multiyear agreement contract as technical support representative for a large passive and active barrier resin manufacturer.  The primary contact for
    • Day to day customer plant issues
    • Sales and marketing managers questions
    • New customers and new product introduction to existing customers
    • Business manger's questions on barrier markets and applications 
  • Increased scope of responsibility to include flexible packaging 
  • Created a Technical / Sales product tool for multi-layer structure of flexible or rigid packaging for new product development and pricing along with
  • Estimation of "shelf life" Included is retort shock of EVOH in comparison to other multi and single layer structures
  • Estimation of Raw material costs comparison of structures
 
1998 – 2010
Senior Project Engineer / Manager Research and Development, Ball Plastics Corporation, Broomfield, Colorado
  • Development and commercialization of new single and multi-layer plastic containers for oxygen sensitive products to meet the customer’s unique specifications.
  • Responsible for all aspects of the project from quality assurance, manufacturing process stability to the customer’s ability to utilize the container in production.
  • The “go to” person in the R&D group for data statistical analysis. 
  • Developed a standard tool design that fit the process window of the multi-layer process thus reducing variation in the process and reduced substandard production.
  • Developed a new quality assurance test reducing the need for outside testing saving $50,000 annually.
  • Led the development group research on new materials.
  • Improved materials performance by 3 fold for a supplier.
  • Developed a new test method and mathematical analysis tool to characterize the behavior of a new class of material.
  • Primary technologies - Single and Multi-material polyethylene terephthalate (PET) injection systems and stretch blow molding
 
1995-1998
Senior Project Engineer / Manager Research and Development, CONSTAR International Inc.                                                                                  
  • Development and commercialization of new custom containers to meet the customer’s unique specifications. 
  • Commercialized 3 - 5 container projects per year, each project contributed no less than 30 million units to meet the sales plan / budget.
  • Increased process feedback and reduced the time to test materials using near Infrared spectroscopy correlation to process and article performance.
  • Thermal imaging correlation to process conditions and product performance.
  • Developed and implemented a standardized tooling design algorithm that reduced time to market.  
  • Primary technologies - Husky injection systems, Sidel Stretch blow molding, Nissie Injection/Stretch Blow, Aoki stretch blow.