Education

Bachelor of Science in Mechanical Engineering Technology

BSMET

Master’s of Engineering Management

MEM

•Design of high speed powder filling machines.

•Machine speeds approaching 325 bottles per minute with a fill weight of 1Kg.

•High speed powder filler used on a retail spice packaging line filling at a rate of 670 bottles per minute.

•Chief Engineer of world’s fastest rotary auger filler.

•Complete product line development which also included final machine operational manual

•Installation supervision along with line integration.

•Chief Engineer of all container bulk hoppers and container elevators.

•Successfully led the entire product development cycle for powder fillers capable of dispensing dairy powder

•Encompassed not only design and engineering but USDA 3-A verification and inspection

•Complete design and documentation for assorted styles of powder filling machines.

•Organization in plant training programs for operational personnel, maintenance personnel and management.

•Provided on-site training of numerous powder filling machines for various Fortune 100 customers.

•Main point of contact for continuing operational support of respective developed products.

PACKAGING INDUSTRY

Key Features

•Rotary filling machine with gear drive.

•Tapered fill plate pockets to prevent product buildup.

•Change parts with single position locations for quick changeovers.

•Highest volumetric fill volume in the powder filling industry.

Performance Results:

•1 Kg powdered non-dairy creamer 275 bpm +/- 7 gram accuracy

•1 lb Powdered paprika 175 bpm+/- 1.5 gram accuracy

Rotary Auger FillerDeans Specialty Foods, McCormick, Lipton Unilever

Gear drive for main turret and input and output star wheels. This minimizes backlash and extends drive component life.

Key Design Features

•Base plate is ¾” stainless steel plate ground to 5/8” final thickness.

•Fill plate is 1” aluminum tool and jig plate. •Fill pocket design driven by the need to minimize areas where powder buildup can occur and to maximize pocket opening.

•Leading edge and trailing edge of pocket form a 30 degree knife edge to sweep away any powder buildup.

•Fill plate area contains interior and exterior baffles that are retained by clips to allow complete disassembly for clean up and sanitation.

•Fill area completely sealed and vented to allow purging of powder during filling.

Rotary Auger Filler

Responsible for modernization and improved serviceability of gear driven main drive on all rotary fillers by replacing the age old standard keyed connection with a taper lock coupling from Ringfeder.

Rotary Filler Main Gear Drive

•Lowered cost in manufacture of gear hub and main drive shaft interface since tolerances no longer need to be as tight.•Removed the need for manul fitting of key to the gear hub and main drive shaft.•In the event of a service need, the coupling is a standard off the shelf component that can be purchased worldwide that does not require fitting.•Since the introduction of this method of fitting gears to main shafts on all rotary fillers there has been no reported issue of failure.

Key Features

•4 Head powder filler.

•Meets all necessary requirements for dairy 3-A certification.

•First Nalbach filler since inception to pass 3-A inspection.

•Auger tooling mounted and retained externally.

•Auger tooling gap can be adjusted externally.

•All seals and product area penetrations are designed and engineered using acceptable 3-A practices and as such have passed an actual 3-A inspection.

Performance Results:•50g powdered dairy creamer

•35 bpm

•+/- 2 gram accuracy

•25g powdered sports drink mix

•35 bpm

•+/- 2 gram accuracy

4 Head 3-A Dairy Auger Filler

Key Features

•Access to the hopper area is gained through a opening that meets 3-A sanitary requirements by using Tri-Clover style fittings.

•These same styles of fittings are used throughout the design wherever the need exists for a connection that needs to be disassembled for cleaning and at the same time meets 3-A sanitary requirements.

4 Head 3-A Dairy Auger Filler

Key Features

•All the auger tooling meets the design requirements as specified by 3-A, which includes the following features:

•All product contact components constructed of non-corrosive materials such as the 300 series family of stainless steels.

•All gaskets and o-ring materials are made from 3-A approved materials.

•All gaskets and o-rings have the proper certifications as required by 3-A for acceptance certification.

•Any welds that are required in the fabrication process in the product contact areas shall be free of pits, folds and crevices.

•Any visual inspections areas for o-rings, gaskets and general cleanliness are constructed using acceptable 3-A practices and meet the requirements set forth in the inspection process.

4 Head 3-A Dairy Auger Filler Tooling

3-A Dairy Auger Filler (Gen 2)

Key Features

•Next Generation of sanitary auger fillers.

•Meets all necessary requirements for dairy 3-A certification.

•Auger tooling mounted and retained externally.

•Auger tooling gap can be adjusted externally.

•Seamless sanitary conditions inside product hopper.

•Large access ports for service and sanitary inspection.

•Designed with provisions for MAP gassing.

•3-A Sanitary funnels with visual inspection gaps for sanitation

•Domed hopper lid construction for proper drainage.

•Sourced from tank suppliers at a modest cost.

3-A Recent News3-A Recent News

Press ReleaseNALBACH LAUNCHES NEW U.S.D.A 3A CERTIFIED AUGER FILLER FOR SANITARY APPLICATIONSCountryside, IL (USA). July, 2009.

Expanding on its product solutions for dispensing powders, Nalbach Engineering Company announces the release of a new auger filling system that is inspected and certified to comply with the USDA 3A sanitary standard.

This system employs a domed hopper to optimize drainage during cleaning, sanitary pipe clamps and gaskets, polished product contact surfaces, and welded to comply with 3A standards.

Additionally, the system includes the ability to make auger tooling adjustments without the need to remove the hopper, as well as sanitary inspection and tooling access ports for ease of operation and maintenance.

Many suppliers “build” to 3A specification, but do not include certification. This requires the end-user to get the system inspected and certified themselves after it is installed. The Nalbach system is built, inspected and certified at the factory to comply with the USDA 3A specification eliminating any guesswork at time of installation and start-up.

3-A Dairy Auger Filler (Gen 2)

Oversize bearings for added moment resistance.

Self aligning ball bearings to deal with variations in tooling.

3-A Compliant seal manufactured by Windy City Seals per 3-A specifications.

3-A Dairy Auger Filler (Gen 2)

Servo grade coupling

Two row angular contact bearing to isolate thrust from

servo motor.

Stock CNC grade tooling quill with only minor modifications.

Large access ports for ease of adjustment.

Key Features

•All stainless steel construction.

•All design work is done in 3-D and laser shop is provided panels in their flat shape with instructions for forming.

•100% emptying of hopper at the end of run cycle.

•Assembly is done using weld studs and alignment pins that are integral in the panel’s shape.

•Large capacity, 125 cu ft

Bulk Hoppers & Elevators

Key Features

•All stainless steel construction.

•Minimum amount of panel surfaces that are in the horizontal position

•100% emptying of hopper at the end of run cycle.

•Hopper and elevator completely enclosed for sanitary reasons

Bulk Hoppers & Elevators

•By working with sheet metal suppliers we where able to develop a “NO DETAIL” approach to all components made from sheet metal.

•Sheet metal suppliers are provided CAD files of flat patterns with appropriate bend deductions already factored in.

•Forming directions are noted on flat patterns as well as represented in drawings for clarity

•This resulted in a 60% reduction in part documentation for manufacturing

•90% reduction in scrap parts as a result of flat pattern inaccuracies.

Process Improvements

•Machine designer in the R & D department for one of the premier manufacturers of high speed meat slicing and meat forming machinery in the world.

•Breakthrough project design involved the design of a servo driven proprietary worm gear drive system sharing a common centerline that feeds 4 loafs of preformed meat into a high speed knife slicing head.

Key Features

•As noted on the Formax website, one of the main striking points of the new PowerMax4000 meat slicer is the four independent product drives

Key Features

•At the heart of the upper loaf feed drive is a unique drive system where each of the four possible conveyors is driven independently while at the same time sharing a common centerline.

•In order to keep cost as low as possible the gearbox design evolved around a gear set available through Cone Drive as an off the shelf component.

Key Features

•Completing the upper loaf drive system package is the lift cylinder and the drive packaging.

•Maximum efficiency of space utilization was required in order to route and feed the servo cables back in to the base cabinet while at the same time maintaining a reasonable allowance for maintenance needs

Key Features

•High performance floating seals and guides in the lift cylinder allow for lift breakaway to within 2psi.

s

•Each of the four upper loaf drive conveyor has a certain amount of rotational movement in order to vary the amount of overhead feed pressure.

•This feed pressure is actuated via 8 mini pressure cylinders built into the under side of the lift cylinder

Key Features

•Air for the lift cylinder and the upper conveyor pressure cylinders is routed through the side plates which also serve as the mounts for the conveyor drives

•A cross over allows the routing of the necessary servo cables to one side of the machine for a clean and uncluttered upper superstructure

Key Feature

•Each upper loaf conveyor is removable for easy cleaning.

•Outer upper loaf conveyors are engaged with its corresponding drive via a sliding coupling, which can also be disengaged from the drive in order to remover the upper loaf conveyors as a unit for complete cleaning.

•Inner upper loaf drives are engaged internally be a linking shaft that passes through the outer upper loaf conveyor pulley

•Design of automated welding gantries used in barge and ship building facilities.

•Spans from 20’ to in excess of 40’.

•Worked as an independent consultant for a local machine design consulting firm on various design team projects.

•Projects ranged from continued support for Ogden Welding Systems projects.

•To equipment for a local aluminum reduction mill.

LARGE SCALE MACHINERY

•Semi-automated gantry welding platforms used in barge manufacturing and ship building.

•Multiple welding head configurations and positions.

•Spans from 20’ to 40’

•Uncoiling, tension control and re-direction for a continuous sheet coating line in a aluminum re-processing mill.

•Part of a larger project handled by a local consulting firm.

•Maximum coil width is 46”

•Drive stand for coil processing line.

•All design work performed in Solidworks with component analysis done in MathCAD.

•Responsible for the design of drive and positioning systems utilized on high precision industrial grinding equipment.

•Project designs based on existing OEM configurations with emphasis placed on process and accuracy improvements.

MACHINE TOOL INDUSTRY

Key Features

•Mechanical regulating wheel positioning system replaced with ball screw package having the largest size that can fit in the OEM casting.

•All dresser drives converted from lead screw to servo driven ball screws.

•Regulating transmission replaced with servo driven unit for variable speed drive.

.

Performance Results:

•Regulating wheel positional accuracy 20 millionths•Regulating wheel positional repeatability +/- 10 millionths

Delphi Suspension Division

Cincinnati Milacron Series 300 Grinder

Key Features

•Mechanical Cam and timer switching eliminated with servo driven ball screw positioning systems.

•Unique ball screw drives that utilize stationary shafts and rotating nuts.

•System lube integral in ball screw.

•Part feeder able to cut cycle time from 30 sec to 5 sec.

Performance Results:

•Positional Accuracy +/-0.00015 in•Machine Speed 20 Parts/minute

Delphi Steering Division

Bryant Cent-Align-C Retrofit & Rebuild

Early days

•Design of liquid filling and automated packaging systems including complete project design from conceptual idea to all necessary production drawings and documentation.

•Responsible for project management including machine assembly supervision, control logic flowchart establishment, machine debugging and final testing.

•Team leader in the establishment of company wide ECO/ECR program.

•Engineering department coordinator in part reduction program.

Key Features

•In Line glass jar lid placer and lid stomper.

•Machine picked lids nested in line having one diameter and placed them on jars, nested in line, having a different diameter.

•Vacuum used for pick and place.

Performance Results:

110~125 Jars / minute

American Greetings

Key Features

•Low cost semi pick and place machine to facilitate the assembly of a cap with an integral spoon into a container.

•Cap and container synched by a star wheel driven by container back pressure.

•Pneumatic hollow rod cylinder used to vacuum place cap on top of container.

•Placement of cap is on centerline of container and has a final press to ensure a good start during capping.

•Machine has adjustments for future container size change.Can be easily moved from conveyor centerline and brought back to position with minimum setup.

Performance Results:

55~58 Assembled Containers / minute

Medical Chemical

Skills

•Thorough use of current versions of AutoCAD, Mechanical Desktop, and Autodesk Inventor 2009 and Solid works 2008.

•In depth use of Microsoft Word, Excel & PowerPoint utilized in engineering and documentation applications.

•MathCAD 14 to perform engineering calculations in an environment suited to capture intellectual content and to hypothesize design ideas during the conceptual design phase.

•The design of the upper loaf drive and loaf lift system for the Formax meat slicer was conceptualized mathematically prior to CAD design work.

•Performance results measured at startup where within 10% on a number of key metrics.

•Fluent in Polish and facilitated as a translator at various company functions.

Future Goals

•Successfully complete the FE exam and the PE exam.

•Take the PMP (Project Management Professional) exam.

•Look at the possibility for completing a Masters in Engineering degree, with a focus in Mechatronics.

•Learn a third language; currently leaning toward Spanish.

•Continue on a motivated and ambitious engineering career leading into management and passing on a optimistic approach to the profession.