Polymer Failure & Defects: Product & Process Problem Solving



Dr. Yash P. Khanna, recipient of two international awards in the areas of Plastics and Analytical Sciences, has over 40 years of highly diversified industrial experience. His career is credited with over 120 research publications, 25 U.S. patents, Society of Plastics Engineer’s International “Engineering/Technology” Award (2001) and North American Thermal Analysis Society’s Fellowship (1988) and its highest honor, the International Mettler Award (1997). A highpoint of Dr. Khanna’s career has been to identify several new phenomena in common polymers, already in existence for 40-60 years. His industrial affiliations include Chief Technology Officer at Applied Minerals (2013-2015), Senior Technology Fellow / Director of Technology at Imerys (2005-2009), a $5B minerals company, and Manager of Reinforced Engineering Thermoplastics Program at Rayonier (2001-2004), a $3B forest products company. The great majority of his career was at Honeywell (1975-2001) formerly AlliedSignal, a $40B conglomerate company at its Corporate Research & Technology Center as a Research Group Leader / Senior Principal Scientist. During 1990-2001, he also held positions as Business Unit Liaison to Specialty Films and key technologist for Packaging Resins, where scientific fundamentals formed the basis of new product / process development as well as technology marketing in North America and Europe. These significant business contributions were recognized through 5 Special Recognition awards and 3 business awards (“Growth,” “Sale of the Year,” and “Save of the Year”). Now at InnoPlast Solutions, Dr. Khanna’s technology driven business experience is playing a key role in offering “Value-Driven” conferences and courses.

Below are the specific areas where Dr Khanna has demonstrated experience:

PATENT INFRINGEMENT

  • Expert witness in a winning litigation between two Fortune 100 companies. $800M Settlement
  • Participated in a winning patent infringement case between two Fortune 100 companies held in Canada.
  • Prepared documents for patent disputes handled by arbitragers.

POLYMER FAILURE & DEFECTS: Solving PRODUCT & PROCESS Problems

  • Demonstrated expertise in Thermal — Mechanical — Rheological — Barrier properties of materials.
  • Uniquely skilled in demonstrating if & why product A is different from product B using a coordinated analytical sciences approach.
  • Successfully solved numerous production, customer, and scale-up problems.
  • Successfully solved manufacturing problems occuring during Injection Molding, Blow Molding, Thermoforming, Cast and Blown Film operations.

NYLONS/POLYAMIDES

  • Credited with pioneering work on nylons (PA6, PA66, PA46, PA12, Amorphous Nylons)
  • Demonstrated expertise in structure-property-processing relationships: crystallinity, crystallite size, orientation, melt-rheology, dimensional stability, manufacturing problems.

POLYMERS/PLASTICS

  • Studied, published, and lectured on numerous polymers such as polyethylene (PE), PP, polyvinyl chloride (PVC), polyvinylidene chloride (PVdC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polystyrene (PS), polycarbonate (PC), fluoropolymers such as Teflon, PFA, PVdE, and PCTFE.

PLASTIC PACKAGING RESINS

  • R&T’s Business Unit Liaison to Specialty Films Business (1994-1995) and key technologist for Packaging Resins Business (1994-2001).
  • Demonstrated expertise in structure-property-processing relationships: crystallinity, crystallite size, orientation, melt-rheology, dimensional stability, manufacturing problems.

POLYMERS / PLASTICS

  • Studied, published, and lectured on numerous polymers such as polyethylene (PE), PP, polyvinyl chloride (PVC), polyvinylidene chloride (PVdC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polystyrene (PS), polycarbonate (PC), fluoropolymers such as Teflon, PFA, PVdF, and PCTFE.

PLASTIC PACKAGING FILMS

  • R&T’s Business Unit Liaison to Specialty Films Business (1994-1995) and key technologist for Packaging Resins Business (1994-2001).
  • Led “Emerging Technologies” to improve Moisture and or Oxygen gas barrier of plastic films by modified Metallization and other coatings such as SiOx / AlOx via plasma enhanced chemical vapor deposition (PECVD), E-beam vaporization.
  • Continuously solved problems related to plastic films such as dimensional stability, optical properties, adhesive / cohesive failure, occurrence of gel defects, and bubble instability during blown film process.
 

COMPOUNDING & ADDITIVES

  • Commercialized a cost-effective & high performance lubricant for Nylon plastics
  • Demonstrated skills in nucleating agents & clarifiers
  • Experienced in detecting unexpected benefits of additives & developing new applications
  • Experienced in “Specialty Compounding”


PERFORMANCE MINERALS

  • Developed the most definitive understanding to date of CaCO3–Stearic Acid interactions, resulting in “New Business Win” and $950K in annual savings at the production plant.


NATURAL FIBERS-PLASTIC COMPOSITES

  • Led the project to a decision point. Fibers evaluated included wood fiber, wood flour, highly purified cellulose, kenaf, and rayon in comparison to glass fibers. Plastics evaluated included polypropylene (PP) and nylons (PA6 or N6).
  • Maximized the mechanical properties of composites such as flexural stiffness, flexural strength, notched Izod strength, heat distortion temperature.
  • Developed a novel compounding process to achieve high dispersion at commercially acceptable throughputs.