Eugene Sadzewicz
  Injection Stretch Blow Molding Consultant

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Blow Molding Expert - Eugene Sadzewicz

Eugene has grown and developed his knowledge, skills and understanding of the injection and stretch blow molding processes with each step in his 32 years of experience in the industry. Starting out at Plastipak Packaging, he developed an understanding of the reheat/stretch blow and injection stretch blow processes and how machine issues could impact container quality. At Plastic Technologies, Inc., he honed his process skills by processing both injection molded preforms and various blow molded containers or materials daily in an R&D setting. This included all types of containers having different performance requirements and processing strategies. In this R&D setting, Eugene learned and provided valuable feedback in preform and tooling design to help optimize container development and process consistency. This led to traveling to PTI’s customer’s facilities to provide plant support, which included process development for new containers on their equipment and led to providing plant support when PTI’s customers could not solve bottle quality problems on their own. Over time, the demand for his plant support services grew until it became his primary focus. Eugene was equally adept at injection molding, reheat stretch blow process (two step), and the injection stretch blow process (one step) and has expertise in all three processes. This expertise led Eugene to his next employer, SiO2. Eugene initially provided plant support to SiO2 to resolve a process issue they hadn’t been able to resolve in the previous 6 months, on equipment Eugene never operated before, processing resin type he had never worked with before, Eugene was able to identify 4 distinct failure causes and supply solutions for all 4 issues in a short amount of time, leading to SiO2 to pursue Eugene to work at SiO2. At SiO2, Eugene learned how scientific molding is used for injection molding, and used that knowledge to develop processing studies and DOEs to optimize the injection stretch/blow process to use in an IQ/OQ/PQ validation. Eugene Led process development, optimization and validations at SiO2. Currently Eugene is performing the plant support/process engineering role on a consulting basis through his company JC Processing Services.
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PROFESSIONAL EXPERIENCE

JC Processing Services LLC: Senior Process/Service Engineer, Owner
10/2023 - present

• Process development on customer equipment
• Process studies
• Develop processes and perform qualification runs for new containers and/or materials
• Test containers on customer test equipment
• Troubleshoot process, equipment and mold issues and provide recommendations to correct.
• Overseeing/Performing IQ/OQ/PQ activities.
• Developing control plans

SiO2 Medical Products: Senior Process Engineer/Validation Engineer
10/2013 - 10/2023
Leading team in performing:

• Process risk assessments from resin pellet to final molded product
• Plan and implement risk mitigations where assessment indicates
• Pre-validation studies to identify key process inputs and outputs
• Use Minitab for statistical data for process studies
• Establishing nominal process and ranges on key process inputs
• Writing IQ/OQ/PQ protocols with quality engineers
• Overseeing/Performing IQ/OQ/PQ activities.
• Developing control plans
• Root causing analysis of process and equipment problems
• Identify and implement engineering solutions for scrap or other processing issues.
• Developing intervention and escalation protocols
• Developing work instructions for molding activities
• Writing technical/DOE reports and justifications
• CAPA investigations and resolutions
• Troubleshoot machine issues
• Work with mold/machine suppliers during tooling/machine builds
• Perform run-offs at suppliers for mold/machine acceptance
• Spec out and Purchase needed support/ancillary equipment
• Worked with machine manufacturer to develop and install certain process monitoring/feedback data collection.
• Developed trade secret process controls to overcome plastic flow issue.
• Provisional patents on a valve gate control system and multiple film application onto plunger rod tips.

Plastic Technologies, Inc. (PTI): Senior Process Technician/Process Specialist
10/1996 - 10/2013
Activities and responsibilities are as follows:

• Performed all injection/stretch blow molding process activities on Nissei injection-Stretch/Blow Platform
• Established processes for unit cavity preform sampling.
• Performed process development on Arburg injection molding equipment for various preform designs
• Worked on establishing processes during container development on Sidel reheat stretch/blow machines in process lab
• Processes stock bottles for various resin companies so they could test their reformulations/additive packages.
• Go to customers facility to establish processes on their equipment for new products, or old products with new resins.
• Help other process technicians develop processes as needed
• Plant support - Troubleshoot customer’s equipment/process to resolve quality issues by identifying the problem and then resolving the issue or at a minimum giving a recommendation to resolve the issue.
• Performed Reheat stretch blow training at customer’s facility.
• Plant support turned into my full-time responsibility; traveled almost every week.
• Co-inventor on several patents with foamed PET containers.
• Had highest utilization rate (billable time) in the company last 12 years
• Processed all or nearly all types of containers produced by stretch/blow process: CSD, Oval containers, heat set (hot fill) containers, blown finish containers, Beer bottles, water bottles (thin walled containers) and containers with vacuum requirement.
• Troubleshoot customer problems on multiple platforms (Sidel, Krones, Sig Corpoplast/KHS, Sipa linear reheat/stretch blow, Sipa injection/reheat/stretch blow (step and a half machine), Siapi, Amsler, Tetra-pack, UWM, Husky ISB, Nissei ASB, Aoki)
• Had identified equipment issues impacting part quality where the machine manufacturer's representatives didn’t.

Plastipak Packaging: Process Technician/Shift Supervisor
1/1990 - 10/1996
Activities and responsibilities:

• Initially process technician on 2L CSD lines.
• Learned mechanical influences and failure points in processes involved (reheat stretch blow molding, labeling, palletizing)
• Leveraged high performance on reheat/stretch blow molding problem solving/decision making skills to supervisory position in injection/stretch blow molding department (no previous experience)
• Led a team of 2 process techs, 2 line leaders and 8-13 packers/inspectors in the operation of 10 machine injection/stretch blow area. Duties included giving direction to team members, leading process technicians in troubleshooting problems, establishing processes for new product start-ups, performing root cause/analysis, and establishing process recording.
• Held record production on both 2L lines
• Developed alternative preform conditioning method for oval containers.

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