Blown and Cast Film Extrusion Course

Memphis, TN
Tuesday, November 7, 2017

Participants in this course will learn about common resins used, and equipment from the extruder through to the winder utilized in both Blown and Cast Film applications processes.

November 7th - 9th, Memphis, TN, USA - A 3-Day Course Providing a Better Understanding of Film Extrusion Technology

Brought to you by: 

Flexible Packaging Division logo

In this introductory-to-intermediate level course, participants will learn about common resins used, and equipment from the extruder through to the winder utilized in both Blown and Cast Film applications processes.  In addition there will be discussions on troubleshooting problems such as occurrence of gels, and winding defects.  Experts in the field will discuss commonly faced problems in the cast film and blown film industry.  Please bring your questions to the class, as it is conducted in an interactive format with the attendees.

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Attendees will benefit by receiving a better understanding of film extrusion technology and the ability to use this information to improve existing film extrusion processes.  

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For maximum benefit, participants should have a very basic knowledge of film extrusion coating technology and the ability to use this information to improve existing film extrusion processes.  

This course is designed to help participants learn to:

  • Understand properties and processing issues of various film resins
  • Identify capabilities, specifications, and limitations of various film extrusion & winding equipment components
  • Think of the equipment and resin requirements for differing co-extrusion applications
  • Consider how to approach processing problems and gel issues during extrusion
  • Recognize film surface treatment options available to converters and when to apply them
  • Explain the process requirements for making cast and blown film structures
  • Understand terminology, general theory, and troubleshooting techniques used in designing extrusion screws
  • Address safety concerns in extrusion processes

Learn with Your Peers

This course is ideal for Film Converters, Equipment & Resin Suppliers, Cast Film Manufacturers & Auxiliary Equipment Suppliers.

Instructors for Blown and Cast Film Extrusion Course

Scott Marks 100x150

Scott Marks - DuPont Performance Materials - Course Chair

Scott Marks is a Senior Technical Consultant at DuPont. He holds degrees in mechanical engineering and business administration from Rutgers University of New Jersey. Since graduating from Rutgers in 1982 and joining DuPont, Scott has worked in several engineering and technical positions.  From 1986 through 2008, Scott worked for DuPont's packaging materials business covering the Asia-Pacific region performing technical troubleshooting, market development, application development, training (both internal and external), and mentoring new sales personnel.  His processes background includes extrusion coating and laminating, blown film, and cast film, including multilayer co-extrusions and end-use packaging equipment. He has also worked with coextruded sheet extrusion and tubing extrusion. Since April 2008, Scott has worked on several revitalization projects in DuPont's Lab Extrusion Facilities specifying and commissioning new equipment. He is a key member for global technical support of co-extrudable adhesive polymers, consults on technical applications with North American extrusion converters, and conducts global training programs internally and externally for technical proficiency. 

Since 1984, Scott has been as a member of TAPPI's International Flexible Packaging & Extrusion Division (formerly called PLACE in 2001-2016, and PLC in 1984-2000). He was co-chair of the International Planning Committee, has held all the Division Council positions for PLACE, remains a Chair Emeritus of the Division, and serves as Council Member At-Large.  Scott has served multiple times as session chair in the Tappi PLACE conference, presented papers, and currently chairs the Peer Review committee for the conference.  He has been an instructor for the Extrusion Coating Short Course and the Film Extrusion course for many years.

Dillon Kang v2

Dillon Kang - Chevron Phillips

Dillon Kang is a graduate from the University of Oklahoma with a degree in chemical engineering. He has worked with Chevron Phillips Chemical for 3 years primarily in blown film technical service for their polyethylene business unit and is active in the industry, being a local division board member of SPE (Society of Plastics Engineers). He currently resides and works out of Bartlesville, Oklahoma. 

Doug Harrell - Phillips 66
Doug Harrell 100x150

Doug holds a B.S. from the University of Delaware and a Ph.D. from the University of Pennsylvania, both in Chemical Engineering. He has 30 years of experience in the polypropylene industry, first with LyondellBasell and predecessor companies in R&D, process simulation and control, and manufacturing. He is now with Phillips 66 in Technical Service and Development at their Bayway, New Jersey site. He holds two patents for advanced gas-phase reactor control. He enjoys public speaking, visiting schools and churches, and has achieved the rank of Distinguished Toastmaster with Toastmasters International.

Andy Christie 100x150Andy Christie - SAM North America

Andy Christie is currently Managing Director of SAM North America.  This company is the sales, service, and support group of SAM (Sung An Machinery), a South Korean converting machinery manufacturer of printing, coating, laminating, and extrusion coating machinery.  SAM North America, is sales and service organization for North and South America, and operates a state of the art high speed co-extrusion coating and laminating line with up to 14 layer co-extrusion for converter customers product development needs.

Prior to working for SAM, in 2002 had Andy founded Optex Process Solutions, an extrusion process consultancy. Optex provided extrusion system design and technical process support to the continuous extrusion converting industry, particularly coatings and films.  Optex worked with OEM's as well as packaging and specialty converters worldwide until 2016 when it discontinued operation due to the growth of SAM's American business.

Prior to starting Optex, Andy spent 15 years with Black Clawson Converting Machinery in engineering design, applications, and management.  After graduating with his BSME degree from Rochester Institute of Technology he held various machine design engineering positions at several companies.

Andy has been active in SPE & TAPPI where he has authored, co-authored, and presented at many conferences and symposiums.  He is a past Chair of the TAPPI Film Extrusion Committee, and has been a co-instructor at several TAPPI short courses.  He is the inventor of three US Patents relating to screw design and a co-extrusion feed-block, and has an additional patent application pending for an improved extruder screw mixing device. Andy lives in the heart of New York State with his wife Mary.  They enjoy outdoor activities with their two sons families including their three grandchildren.

Christine Ronaghan 100x150Christine Ronaghan - Cloeren Incorporated 

Christine Ronaghan holds BE and ME degrees in Polymer Engineering from Stevens Institute of Technology as well as an MBA in Management of Innovation and Technology from Rutgers University.    She spent many years at Davis-Standard LLC responsible primarily for extrusion and screw design for Cast Film and Extrusion Coating.  Chris is currently Technical Director at Cloeren Incorporated, working on feed-block and die design as well as providing extrusion process support industry wide.  She has been involved in various technical organizations, including Tappi and the Society of Plastics Engineers among others.   Chris has been a speaker in a variety of training classes, and has presented papers in a number of conferences throughout her career.  

Sam Iuliano 100x150Sam Iuliano - Nordson/Extrusion Dies Inc.

Sam Iuliano has 25 years of experience in the industry for extrusion dies and related components.  He graduated in 1992 from McMaster university in Hamilton, Canada with a Bachelor's degree in Engineering and Management, specializing in Chemical Engineering.  As Senior Technical Manager at Nordson EDI, he consults with processors to provide recommendations for high performance extrusion tooling and brings the voice of the customer back to Nordson EDI for new product development. Sam is a frequent presenter at industrial conferences and a long-time TAPPI Extrusion Coating Short Course Instructor.

Karen Xiao 100x150Karen Xiao - Celgard

Karen Xiao is currently the Extrusion Technology Leader for Celgard, LLC based in Charlotte, NC. She is responsible for product & process development, and improvement of microporous membrane film applications. Prior to this position, Karen was the R&D Director for Brampton Engineering, a blown film equipment machinery company, and was responsible for developing multilayer blown film dies and extrusion screws.  Karen was intimately involved in the design and commercialization of the first 10-layer and 11-layer blown film dies in the world.  Karen has authored and co-authored more than 40 publications including 2 book chapters in the field of die and screw design, and has 4 pending patents in the field of battery separator technology. Karen has been a member of the Board of Directors of the SPE Extrusion Division since 2009. She was the Technical Program Chair in 2013, the Extrusion Division Chair in 2014-2015 and was elected SPE Fellow in 2016. Karen received her B.A.Sc. in Chemical Engineering from the University of Toronto, her M.A.Sc. and Ph.D. in Chemical Engineering from the University of Waterloo in Ontario, Canada.  Karen and her husband have two daughters, and resides most of the time in Toronto, Ontario.

Michael Taylor 100x150Michael Taylor - Alpha Marathon

Since graduating with a degree in Chemistry from the University of Waterloo, Mike has a working career spanning more than 39 years.   He started work as an analytical chemist in an industrial consulting laboratory.  He then joined Tetrapak, and his career included positions covering numerous countries spread over 5 continents, in roles dealing with quality, plant management, R&D, project management, and managing director. Mike has been responsible for the creation, commissioning, and start-up of 4 flexible packaging converting/development operations in 4 different countries on two different continents, such that within these projects each piece of equipment, each process, raw material, and employee were part of the selection and execution of the project.  Technologies included;  prepress (graphics design, laser image setters, platemaking), printing (lithographic, gravure, and flexographic), extrusion (coating, cast, sheet, and blown), converting (slitting, bag making, pouch making, laser perforation), up to and in some cases including customer conversion such as FFS, sterilization equipment/processing. In Mike's current role at Alpha Marathon, he provides technical and commercial support for customers and projects as it relates to raw materials, intended outcomes of products from designed/manufactured equipment around the globe with a primary focus on the USA and multinationals.

Laura Martin 100x150Laura Martin - Brampton Engineering

Laura first joined the plastics industry as an undergraduate in Chemical Engineering, and has since worked in numerous technical and market segments including compounding, injection molding, blow molding, profile extrusion, and extrusion lamination, for rigid packaging, automotive, and electrical applications. Since joining Brampton Engineering as Director, Process & Rheology in 2015, she has enjoyed learning about blown film extrusion, particularly multi-layer film structures for food packaging.   At BE, the Process & Rheology Team is charged with ensuring that the provided equipment is optimal for producing the required films, which includes communicating with the potential customers prior to quotation, specifying the right components, designing the SCD® co-extrusion die, and providing process expertise afterwards.  Laura is also a key member of the Product Development team behind the innovative new single-entry, streamlined Vector® air ring.  She is a firm believer in asking the right questions and using the appropriate analyses and visualizations to enable the best data-based decisions.

Bill Hellmuth 100x150Bill Hellmuth - Davis-Standard

Bill has over 38 years in the Film industry.  He spent the first 10 years as a Process Engineer and Production Manager, working with flexible PVC packaging films, modified PE stretch wrap films, and TPU blown films.   The past 28 years, Bill has worked in Technical Sales and Marketing for Gloucester Engineering (now part of the Davis-Standard Group), supporting Blown Film machinery globally.  Bill is a profession member of Tappi and SPE, and had published numerous papers on Blown Film equipment and processing.   Film has taught in a number of training seminars around the world.   Bill is a past chair of the Tappi Film Extrusion committed, and has been a co-chair of the Film extrusion class.

Rory Wolf 100x150Rory Wolf - ITW/Pillar Technologies

Rory Wolf is currently the Business Unit Manager for ITW's Pillar Technologies, Hartland, WI, USA and a recognized industry resource in the field of polymer surface modification. He has 31 years of experience within international positions in the plastics and packaging industries, and specific experience in polymer-based flexible packaging, polymer surface modification systems, and printing industry segments.  Prior to joining Pillar, Rory worked for several companies including Enercon Industries where he championed the growth of plasma treating technologies. He has published 33 technical papers,41 industry articles, and 3 books on the topic of plastic surface modification by atmospheric plasma technology.   Rory is a professional member of Tappi, SPE, and AIMCAL.

Ted Schnackertz 100x150Ted Schnackertz - NDC Infrared Engineering

Ted has over 40 years of experience in the process control industry with real-time on-line measurement and control systems in the paper and plastics industry. He has held positions as a field engineer, systems engineer, project manager, applications engineer and currently is the OEM Sales Manager for NDC.  Ted studied electronics engineering at CCNY (New York) and electrical engineering at Lowell Institute of Technology in Lowell, MA.  Ted is a TAPPI member and has instructed in a variety of Short Courses and delivered TAPPI PLACE conference papers since 1998.

Jim Stobie 100x150Jim Stobie - Macro Engineering

Jim has been involved in the Film and related industries throughout his career. Prior to his current position at Macro Engineering, held sales positions with Sherman Treaters, and Brampton Engineering.  Jim was a Sales Manager for Macro Engineering, and then Brampton Engineering.  He returned to Macro Engineering to become VP Sales & Marketing and then moved up to his current role as CEO of Macro in March 2013.  Overall, Jim has over 30 years in the film and sheet extrusion machinery sector, with the past 19 years spent in leadership roles.   Jim is a former President of the Plastic Film Manufacturers Association of Canada and an active member of TAPPI and SPE. 

Joe Lutz 100x150Joe Lutz - Pelletron Corporation

Currently the R&D Manager for the Pelletron Corporation, Joe has a decade of experience developing bulk material handling products and processes for the plastics industry. He earned his B.S. degree in Mechanical Engineering from West Virginia University and began his work career developing novel automated manufacturing equipment. His career at Pelletron began as an R&D Engineer spending a lot of time in the pneumatic conveying test lab but over the years he has designed and commissioned countless pneumatic conveying and dedusting systems in the “real world” too.  This combination of experience makes him a unique asset to the industry.

Scott Weber 100x150Scott Weber - Celanese

Scott Weber is an Application Development and Technical Support Engineer at Celanese working in their EVA Polymers group.  Scott holds a BS in Mechanical Engineering Technology which he earned at Miami University of Oxford, Ohio.   As an industry veteran, Scott has over 25 years of experience in extrusion coating and lamination, blown and cast film which focused on flexible packaging applications.  Scott currently has one patent and has been involved in the development of other products that have also been patented during his career.   Continuing to help others develop and grow in the industry is very important to Scott.  This has led him to become involved with TAPPI.  Scott has chaired the TAPPI Extrusion Coating Short course for the past four years and will be chairing again in 2017.  Scott resides in West Chester, Ohio his wife Lori.  Together they enjoy spending time at Lake Cumberland, Kentucky with their family and friends.  Scott is the proud father of two daughters and grandpa of three grandsons.

R Duane Smith 100x150R. Duane Smith - Davis-Standard

R. Duane Smith is Process Manager, Web Handling & Specialty Winding at Davis-Standard, LLC. 
Duane has over 45 years of experience, and is widely known throughout the paper, film and nonwoven industries for his technical knowledge on web handling and winding. He has been awarded two patents in winding. Duane has made over 85 technical presentations, and published over 30 articles in major international trade journals and magazines. He is the author of the Winding Chapter of the TAPPI Film Extrusion Manual and is currently working on the Unwinding/Splicing and Winding chapters of the upcoming 5th edition of the TAPPI Extrusion Coating manual. He has been an instructor at 18 TAPPI short courses and has published three books through TAPPI Press. He is the editor of TAPPI Press' first e-book, The Ultimate Roll and Web Defect Troubleshooting Guide. Duane has been active in TAPPI for over thirty five (35) years.   In 2011 Duane was named a TAPPI Fellow by the TAPPI Board of Directors.

Lou Piffer - Davis-Standardlou piffer

Lou Piffer is a Senior Sales Engineer for Davis-Standard LLC, Converting Systems for the past 28 years.  He received a BS in Chemical Engineering from Drexel University in 1985. Lou is a former Tappi Chairman and Leadership award winner.  He has taught at the extrusion coating course for over 15 years. Lou supports the Extrusion Coating and Cast Film product lines for Davis-Standard.

Rich KanarskiRichard Kanarski - Davis-Standard

Rich Kanarski is a chemical engineer who began his professional career in polymer extrusion process development. He held a process engineering role at Coperion, responsible for conducting twin screw extrusion technology scale-up, various process developments, and developing research programs serving the polyolefin, bio-plastics, food, ceramics, and pharmaceutical industries. Rich than has expanded his process expertise by joining Davis Standard where he focuses on the process development of larger scale polymer converting lines, including the single screw extrusion technology and many of the various upstream and downstream technologies composed in cast film and extrusion coating products. His responsibilities extended on projects across the world and correspondences with people of various cultures, gaining business experiences with a vast network of other polymer professionals and industrialists. Rich has been a member of the SPE Extrusion Division since the beginning of his career in the plastics industry and now serves on the Board of Directors Extrusion Division. 



Learn with Your Peers

This course is ideal for Film Converters, Equipment & Resin Suppliers, Cast Film Manufacturers & Auxiliary Equipment Suppliers.

Blown and Cast Film Extrusion Course

This course is brought to you by the International Flexible Packaging and Extrusion Division of TAPPI.

Crowne Plaza Hotel - Memphis, Tennessee


8:00 - 8:15        Welcome TAPPI Antitrust

8:15 - 9:15         Product Structures - Scott Marks, DuPont Performance Materials

9:15 - 10:00       Polypropylene for Blown & Cast Films - Dillon Kang, Chevron Phillips  

10:00 - 10:15     Polyethylene for Blown & Cast Films (cont'd) - Dillon Kang, Chevron Phillips  

10:15 - 10:45     Specialty Resins for Film Extrusion - Scott Marks, DuPont Performance Materials

11:45 - 12:45     Group Lunch

12:45 - 1:30      Polypropylene for Cast Film & Blown Film - Doug Harrell, Phillips 66

1:30 - 2:30        Extruders for Cast & Blown Extrusion, and 'Extruder Configurations' Blown vs. Cast - Steve Post, Davis Standard

2:30 - 2:45        Break

2:45 - 3:30        Screw Designs for Blown vs. Cast Film - Andy Christie, SAM North America

3:30 - 4:15        Cast Film Feedblock Technologies:  Fixed Plane, Movable Vanes, Layer Multipliers and Nanolayer, - Christine Ronaghan, Cloeren Incorporated

4:15                    Panel Q & A (if desired by class)

5:00 - 7:00      Reception and Table Top Exhibits

Limited number of table top exhibits available please contact Shannon Warchalowsky, for details.


8:00 - 8:10        Welcome TAPPI Antitrust

8:10 - 9:00        Cast Film Dies - Sam Iuliano, Nordson/Extrusion Dies Inc.

9:00 - 9:45        Break

10:00 - 11:00     Blown Film Dies:  Nested Spirals, Stacked Plates, Stacked Cones, IBC vs. Non-IBC Designs - Karen Xiao, Celgard / John Perdikoulias - Compuplast

11:00 - 11:45      Blown Film "Nano-Layer" Dies - Michael Taylor, Alpha Marathon

11:45 - 12:45     Group Lunch

12:45 - 1:30      Air Rings for Blown Film: Single Lip, Dual Lip, Stacked Air Rings, Auto Adjusting Air Rings, Segmented Air Rings (Linked to Gauge Control) - Laura Martin & Winston Lewis, Brampton Engineering

1:30 - 2:15       Blown Film Haul-Off Systems - Bubble Cages (Stabilizers and Bubble Sizing Systems): Collapsing System (Rollers/Slats/Covered Slats, etc); and Horizontal & Vertical Oscillating Systems - Bill Hellmuth, Davis-Standard

2:15 - 2:30       Break

2:30 - 3:15       Corona & Plasma Systems for Blown & Cast Film Extrusion - Rory Wolf, ITW/Pillar Technologies

3:15 - 4:00       Extruder System Purging/Resin Transitions - Scott Marks, DuPont Performance Materials

4:15                  Panel Q & A (if desired by class)


8:00 - 8:10        Welcome TAPPI Antitrust

8:10 - 8:50        Online Measurement for Blown & Cast Film Extrusion - Ted Schnackertz, NDC Infrared Engineering

8:50 - 9:40        Winders: Surface, Center, Center-Surface, Gap Mode Winding for Blown & Cast Films - Jim Stobie, Marco Engineering

9:40 - 10:00       Break

10:00 - 10:50     Tools for Process Improvement - Andy Christie, SAM North America

10:50 - 11:30     Pneumatic Conveying Technologies: Practical Guide for the Plastics Industry - Joseph Lutz / Paul Wagner, Pelletron

11:30 - 12:45     Group Lunch (*Allows extra time for those checking out)

12:45 - 1:30       Extrusion Processing: "Gel" Troubleshooting - Steve Post, Davis Standard

1:30 - 2:15        Extrusion Processing: "Safety" & "Process" Troubleshooting - Scott Weber, Celanese

2:15 - 3:00        Challenges of Web Handling and Winding in Blown Film & Cast Film - Duane Smith, Davis-Standard

3:00 - 3:15        Break

3:15 - 4:00        Case Studies in Applying Web Handling and Winding in Blown Film & Cast Film - Duane Smith, Davis-Standard

4:00                 Turn in Evaluations / Hand out Certificates

4:15                  End

Download a copy of the course schedule.  

Learn with Your Peers

This course is ideal for Film Converters, Equipment & Resin Suppliers, Cast Film Manufacturers & Auxiliary Equipment Suppliers.

Registration Fees and Dates

Check out the rates for this informative course and how to become a tabletop sponsor.

Sponsorship Opportunities

Register for this revamped 3-day course featuring presentations from top industry experts.

  Before October 9th After October 9th
 Meeting Registration          
 Member  $ 925  $ 1025
 Join or Renew and Save  $ 1099  $ 1199
 Young Professional under 30 Join or Renew and Save  $ 1037  $ 1137
 Non-member  $ 1695  $ 1800
 Speaker Full Conference Registration    
 Complimentary Speaker  $ 0   $ 0
 Group Meeting Registration, per person (3+ people from the same  location)    
 Member  $ 845  $ 950
 Join or Renew and Save  $ 1019  $ 1124
 Young Professional under 30 Join or Renew and Save  $ 957  $ 1062
 Non-member  $ 1435  $ 1540
 Member  $ 845  $ 950


Payment Policy
TAPPI requires that all registration fees are paid in full prior to the start of the course. Attendees paying by check will be registered for the course only after the payment has been received.

Cancellation Policy:
If you find that you have to cancel, your full registration fee will be refunded if TAPPI's Registration Department receives written notification (fax acceptable at  +1.770.209.7206 by (October 7th, 2017). Please note:  There will be a 50% refund for all written cancellations made after (October 7th, 2017) but no later than 5 business days prior to the start of the course (November 2nd, 2017). Understandably, after November 2nd, 2017, no refunds can be issued.  Substitutions, however, will be accepted any time without a penalty.
100% - Cancellation received by (October 7th, 2017)
50% -  Cancellations received after (October 7th, 2017) and no later than (November 2nd, 2016).  
NO REFUND - Cancellations received after (November 2nd, 2017).

Learn with Your Peers

This course is ideal for Film Converters, Equipment & Resin Suppliers, Cast Film Manufacturers & Auxiliary Equipment Suppliers.


Crowne Plaza Outside

Crowne Plaza Memphis Downtown
300 North Second Street
Memphis, Tennessee  38105
Hotel Front Desk: 1-901-525-1800

Hotel Room Rate:  $129.00 plus tax and fees

Hotel Cut-off Date:  Friday, October 6, 2017

Each individual guest must make their own reservations by call 901-525-1800 or toll free at 800-2CROWNE by 10/6/17.


Crowne Inside

Learn with Your Peers

This course is ideal for Film Converters, Equipment & Resin Suppliers, Cast Film Manufacturers & Auxiliary Equipment Suppliers.

TAPPI Press Publications for You

Books on table

The Ultimate Roll and Web Defect Troubleshooting Guide - PRINT
Course discount:  $119

The Ultimate Roll and Web Defect Troubleshooting Guide - E-BOOK
Course discount:  $119

The Ultimate Roll and Web Defect Troubleshooting Guide - (E-BOOK and PRINT)
Course discount:  $179

Extrusion Coating Manual, Fifth Edition $190 / $247

Course discount:  $175

Winding Machines: Mechanics and Measurements
Course discount:  $130

Film Extrusion Manual, Second Edition
Course discount:  $122

2016 PLACE Conference Proceedings
Course discount:  $69

Corrugated Adhesives Preparation, Fifth Edition
Course discount:  $75

2017 Standard and Tips on CD
Member: $175   Non-member: $619



Learn with Your Peers

This course is ideal for Film Converters, Equipment & Resin Suppliers, Cast Film Manufacturers & Auxiliary Equipment Suppliers.

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