Polymer Profile: Matthew Feldbauer, Technical Service Engineer | Blow Molding, Injection Molding, Pipe Extrusion

Technical Service Engineer | Blow Molding, Injection Molding, Pipe Extrusion

With the opening of its new polyethylene plant in Monaca, USA, Shell Polymers has been hiring a team of industry experts, known as Polymer Pioneers and Polymer Pros, with a proven track record in polyethylene. Matthew Feldbauer is a great example. With six years of polymer industry experience, he helps converters troubleshoot and solve issues as a technical service engineer across blow molding, pipe extrusion, and injection molding.

“We tailor our approach to each customer.” That’s how Matthew describes the ways technical service engineers like him help converters working with Shell Polymers. He explained the process of collecting insights and tips for converters as an example.“We try to leverage our knowledge base internally with the customer's expertise in processing to build a stronger relationship. We offer trainings around our materials, which in turn enables our customers to better service their end markets. We are also working toward offering trainings around their processes if there is a desire to upskill their staff in those regards as well.”

But sometimes, technical service engineers need to get more hands-on to help converters solve tricky problems. “We had a recent project where an injection molder wanted to offset one of their current resins with a new one in a pail application… We spent time in our Innovation Center analyzing the base resins and formulating new blend ratios that resulted in the same performance at a new ratio, despite the differences in properties.”

The Innovation Center plays an important role in helping converters and conducting new research, with Matthew offering additional insights on how various converters can get the most out of its equipment and potential: “One area I’d highlight is our pipe extrusion capability. The market is growing, and customers will have less time on their machines for development and new material work. The Innovation Center is the perfect place for them to continue experimenting.” 

Converters in the injection molding space face pressure and opportunity with new technology to improve quality. “In-mold sensors can improve the scientific injection molding process, which ultimately reduces scrap rates and costs and increases final part quality,” Matthew said. “The latest advancements with the implementation of AI into the injection molding space keeps pushing those limitations and improving processes that much more.”

“The circularity space in blow molding specifically is one that keeps evolving almost daily,” Matthew explained. “As the industry keeps pushing toward a greener environment, it's really important for our converters to understand the latest offerings on circular or low-carbon materials to ensure they stay ahead of the curve.”

Matthew put a spotlight on how infrastructure investment is impacting pipe extrusion more than other industries: “I think one of the most exciting developments in pipe extrusion right now is that the conduit market is growing quickly with the expansion of infrastructure for new neighborhoods, data centers, and manufacturing facilities. The push to move all of the previously overhead wiring underground has allowed that market to grow even through tougher economic times.”

Shell Polymers has written about the pursuit of drop-in resins before

, but Matthew flagged a new development for converters to keep an eye on. “Our next generation of chrome catalyst-based resins is a really exciting offering that’s new for these markets. These resins are a step away from the standard resins these markets are used to. They increase properties like melt strength while still producing the same output rates and part qualities. We are proud to offer these resins to the market and we’re very excited to see where our customers take them.”

At Shell Polymers, we want our customers to be the center of everything we do. To demonstrate this, our business has created a unique space unlike any other in the industry, equipped with industrial-scale machinery serving five different markets and processes. We understand the challenges associated with shutting down a production line for a trial, so we want our customers to have the luxury of utilizing this space and equipment to avoid downtime.

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