1. Edouard J. Kaeterle
27 Stuart Road
Rochester, Massachusetts 02770
Email: Ekaeterle@Yahoo.com
Home: 508-763-3689
Mobile: 774-320-0512
Career Objective:
Consulting in the process industries with a focus on advanced materials manufacturing.
Have developed highly accurate models for the optimization of Rheology, coating and drying for
slot die coating of battery slurries, fuel cells, and thin films.
Background Summary:
Consultant with 37 years of hands on experience in R&D, Scale-up, Optimization, and Modeling of
Mixing, Coating and Drying Unit Operations.
Including 7 years of experience in China and USA with optimization of Anode and LFP Cathode
electrode manufacturing.
Specializing in:
1. Fluid Mixing optimization and Rheology
2. Slot die coating configuration and optimization based on fluid (slurry) rheology.
3.Coater/ Dryer optimization (casting) based on solvent chemistry or solvent blending.
4. Coating/Drying defect characterization and resolution.
Work Experience:
November 2014 to Present: Consultant Advanced Materials Manufacturing
 Scale-up, transfer, and optimization of Slurry Rheology, mixing, coating,
and drying
 Battery slurry Rheology optimization
 Cathode (Li Fe nano phosphate) electrode manufacturing
 Anode electrode manufacturing, NMPand water based
January 2012 to 2013 Senior Principal Engineer R&D of Advanced Coated Materials (MegTec
Systems Inc.
 Optimization of Rheology, mixing, roll to roll slot die coating, and drying
strategies
 Modeling of Rheology, mixing, slot-die coating and drying conditions

2.  Optimization of coating and drying for LiFe cathode and Anode electode
production lines at Boston Power Lithium ion Battery facility in Lian China
March 2008 to 2012 Senior Principal Coating & Mixing Process Engineer (A123Systems, Inc)
 Develop and improve Coating process technologies the Watertown R&D
facility. Then transfer/scale-up and optimization at A123 coating facilities in
Changhouz, China and Romulus Michigan.
 Transferred UTI anode manufacturing process from Taiwan to CZ China, UTI
abruptly went out of business leaving A123 without a source of anode.
Transferred the entire process; mixing, coating, drying, pressing, slitting. Then
led the PSO process to qualify the line for manufacturing. Had to modify the
slurry Rheology to improve the coat-ability of the HEV anode coating process.
 Resolved the PVDF agglomeration issues in CZ by modifying the addition rate
of powder and changing the mixing speeds. Eliminated the agglomerates.
 Introduce depth filtration strategy to 32113 HEV anode process in CZ coating
factory, significantly reducing particle and drag defects.
 Introduced Mass flow meters for coating flow rate control to improve down-
web coat weight variability.
 Introduced EDI manual bolt adjustable slot die to improve cross-web coat
weight variability.
 Introduced IR web surface temperature detection technology to characterize
drying profiles in dryers. Provided the information to increase electrode
production line speeds in China by 50%.
 Used Coating/Drying Modeling to develop all Romulus Michigan electrode
coating processes. Provided initial technology training to Romulus Engineers.
Qualified the planned cathode coating speed at 20 MPM and resolved the
surface cracking problem associated with increased cathode line speed.
 Increased Anode coating/drying manufacturing capacity, by developing dryer
conditions which increased our Romulus coating speed from 20 to 40
meters/minute.
 Resolved bubble defects problem in CZ China factory. CZ was shut down due
to massive bubble issue. Systematically eliminated sources of bubbles in the
mixing and coating processes. Bubble defect rates went from shutting down the
factory to a minor level defect.

3.  Developed a mixer strategy for premix wetting of high surface area LFP powder
in the China coating plant. Replaced a center mounted high speed mixer with a
double planetary/high speed mixer with ceramic tipped blades.
 Introduced the SLIM induction mixer technology to the China coating plant to
wet powder
 Assisted in the scale up of the Romulus coating Plant, performed all
Engineering calculations for sizing coaters, mixers, and solvent recovery
systems.
 Introduced Plasma treatment of copper foil in CZ coating plant to improve
adhesion of the anode slurry to the copper collector.
 Ran quartz IR trials at MegTec on anode and cathode to increase coating line
speed, IR technology was then incorporated into dryer design in Romulus.
Demonstrated potential coating speed increases of 30 to 40%.
 Resolved the cathode recirculation line plugging problem by performing
engineering calculations to show that the 520 foot pipe pressure drop was
greater than the pump supply pressure; recommend a second pump and resolved
the issue.
 Worked on cathode gelation issues, proposed mechanism for the viscosity
increase with time, proposed both a chemical and mechanical (dynamic mixer)
solution to the issue. The Chemical additive to cathode slurries has been
demonstrated to prevent Cathode slurry viscosity growth (gelation) for 72
hours. This may become a patentable process improvement.
 Support Engineer for both CZ China and Romulus coating factories.
Responsible for support and improvements in mixing, coating, and drying
processes. Troubleshoot technical issues in these processes.
 Characterized Aqueous based SBR anode slurry Rheology, developed a
methodology for characterizing the Rheology of carbon additives.
 Improved Cathode coating line through put in CZ China coating plant.
Developed an improved coating process which increased existing cathode
coating speed from 10 MPM to 20 MPM. Increased and qualified XX650 and
32113 HEV anode line speeds from 20 to 25 MPM.
2001 to 2007 Senior Principle Engineer -Product and Process Manager (Polaroid)
 Managed 10 product lines simultaneously. Responsible for the Physical and
Financial yields of these products. Including the technical problems

4. associated with the manufacture of photographic coating fluids using slot
die and cascade coating. Also responsible for maximizing the financial and
physical yields, of all coating production runs, through optimization of six
100 foot productions dryers.
 Developed Coating and Drying Models which predict key coating
manufacturing parameters. These parameters allow the Process team to
predict manufacturability from theoretical chemical formulations. Thereby
saving the time and expense of costly manufacturing trials.
1999 to 2000 Implementation of SAP Quality Element of the Enterprise Software System
 Was responsible for the implementation of the SAP quality control element
into 2 New Bedford Polaroid manufacturing facilities. SAP is an
international inventory enterprise software system.
1998 to 1999 Principle Engineer -Chemical Operations Department Manager (Polaroid)
 Cost center manager for a 3 shift Chemical manufacturing operation.
Managing 16 team members and 3 Exempt Team Leaders.
 Responsible for the production of all coating fluids in support of Medical
High Resolution products, Imagesetter, P3 color sheet, and P6
color sheet.
1995 to 1997 Product Manager for Negative Manufacturing (Polaroid)
 Responsible for the cross-functional coordination of negative issues and
organizing and directing plant operations in support of Hybrid negative
manufacturing.
 Assimilate all real-time sensitometric and process information; make changes
to negative structure and/or materials as necessary to maintain a consistently
high quality product.
 Responsible for the sensitometric, financial and overall quality of Hybrid
integral negative manufacturing with an annual value of ~$76 Million
 Implemented the Low Cost 1& 2 negative programs, with $235K and $450K
respective savings annually.
 Contributed to the improvement of the World Wide Bad picture Metric from
50 million in 1994 to less than 9 million in 1996, and 6 million in 1997.

5.  Developed a CH3L Photographic Emulsion Excel computer model;
significantly reducing both inventory and sensitometric B45DBal variability
(i.e., 2 sigma from 6.0 to 4.2)
 Developed the Run Engineer’s Program, which provides; real-time plot of all
sensitometric data in control chart or Cum-Sum format; overlay of all relevant
batch and process data from process computers for making real-time
statistically based product decisions. Significantly reducing unnecessary
negative structure changes.
1994 to 1995 Senior Technical Resource – Chemical Manufacturing Team (Polaroid)
 Aided with the implementation of a new operational design.
 Responsible for all fluid chemical processing in support of negative
manufacturing; dyes, interlayers, and light sensitive emulsions
 Responsible for the direct supervision of 6 Technical Supervisors, 2 Senior
Engineers and indirectly ~37 Chemical Processors.
1993 to 1994 Integral Color Film Development Engineer (Polaroid)
 Product development engineer assigned to New Bedford’s Hybrid Product
Group. Responsible for planning and immediate physical and sensitometric
data analysis for all Hybrid 4 SA Test Coater development runs.
1987 to 1993 Senior Engineer - Operations Coordinator / Process Engineer for Image Dye and
Interlayer Manufacturing (Polaroid)
 Equipment and process scale-up and trouble shooting for Dye & Interlayer
group.
 Managed the scale-up of all Polahybrid dispersion processes to include
PNEHQ, MF, CF, Tinuvin, and Scavenger raw materials.
 Coordinated the engineering efforts to reduce dye dispersion losses that
resulted in a savings of approx. $80K/year.
 Developed the scope and coordinated the implementation of approx. $550K
capital project for Polahybrid dispersion and prep/interlayer manufacturing
technology.
 Developed the scope and coordinated the implementation of a $600K capital
project for Hybrid IV prep manufacturing.

6.  Developed an Excel based Computer Model of the Offline chemical
processing unit operations; such as Pre-slurry high speed mills, vertical and
horizontal small media grinding mills, and attritors. This model was used to;
- Identify significant capacity constraints and processing bottlenecks
during the scale-up of Polahybrid 4 and Hybrid 4 RA negative
development programs
- Is currently used by the Chemical Manufacturing Group for X500 run
planning and the scheduling of raw material processing into aqueous
dispersions for all X500 color negative prototypes.
 Successfully proposed the first high performance, high energy density
horizontal grinding mill for New Bedford Off-Line Team, thereby eliminating
a Scavenger raw material processing bottleneck which would have prevented
Polahybrid and Hybrid 4 product programs from meeting their production
goals.
- Successfully presented two $400K Dynomill capital projects to
Hybrid 4 program managers; upgrading the Off-Line Team's particle
size attrition capability and capacity to state of the art grinding
technology.
- Reduced Scavenger dispersion processing time from 20 days to 78
hours.
 Identified a 79% workload increase in raw material dispersion processing
resulting from new more complex negative prototypes such as Polahybrid and
Hybrid 4.
- Successfully proposed a $700K capital program to increase
automation and computerization of material handling and batch
manufacturing for the Off-Line Team.
- Reduced workload increase from 79% to 9%
Developed and implemented a $20K foam control capital program to minimize or
eliminate foam generation during Al, Bl, Cl and CD prep manufacturing.
-Projected savings to the On-Line Dispensing Team is approx.
$200K. Annually
1984-1987 Technical Supervisor, Dye & Interlayer Manufacturing (Polaroid)
 Supervised the day to day activities of seven (7) Chemical Processors, processing
coating fluids in support of Negative manufacturing.
 Technical responsibility for chemical operations such as; polymer and image dye
prep making, oil-water emulsions, homogenization, horizontal and vertical

7. grinding mills, high speed mixing mills, and various support processes in real-
time direct support of X500 negative manufacturing
 Area Product Manager for P2, P3, TZ, Star, Black Back and Panda negative
prototypes. Was responsible for meeting the product specifications of all coating
fluids manufacturing.
 Developed Chem Operations Menu of programs to calculate coating fluids batch
sheets, acid/Base batch adjusts, Chemical addenda adjusts for simultaneous
solution of multiple offsets, and display filter and process specification
information.
1982-1984 Associate Scientist, Central Analytical Lab (Polaroid)
 Problem solving and analytical methods development
 Regular reporting both written and oral at Financial/Sensitometric Run
Reviews of all negative prototypes.
 Statistical annual product reports for all prototypes with the Reproducibility
Group to select coverage Production shutdown criteria and set laboratory
precision.
 Supervisor for nine technicians in Central Analytical, Process Water, R/S and
Satellite Laboratories.
1973-1982 Assistant Scientist, Central Analytical Lab (Polaroid)
 Methods development in X-ray fluorescence, HPCL, Total Organic Carbon, IR,
UV/VIS Spectroscopy, Atomic Absorption, Thermal Analysis, and
Titrimetry in direct support of the Dye & Interlayer chemical operations.
 Computerized x-ray and wet digestion Q.C. analysis for coated negative to
include statistical reports and negative coverage and cross-web graphics.
 Supervised three (3) technicians in the x-ray/wet digestion and Rapid
Sensitometry Laboratories.
Education:
B. S. Chemistry 1981 at University of Massachusetts

8. Additional Courses and Seminars:
Kepner Tregoe Problem Solving
Coating, Drying, & Adhesion Technology
Coating Rheology I – Surface Active Agents
Coating Rheology II – Pigment Dispersion
Coating Rheology III – Crosslinking in Coatings
Polymer Chemistry Fundamentals
Polymer Chemistry Aqueous Resin Chemistry and Thermoplastic Technologies
Polymer Chemistry of Thermosetting Polymer Technologies
Slide Coating
SAP Training as Quality Implementation Team Leader for the NB site
Computer Science, Boston University
Rheology of Polymeric Fluids, M.I.T.
Photographic Imaging Science, R.I.T.
Polaroid Imaging Science Seminar, Polaroid Corp.
Statistical Engineering Training Program, Polaroid Corp.
Surface Chemistry, Tufts University
RS1 Training, Polaroid Corp.
RS/E Statistical Modeling Training, Polaroid Corp.
Total Quality Ownership Awareness Program, Polaroid Corp.
Managing for Excellence, Polaroid Corp.
EVA Training, Polaroid Corp.
Principles of Teamwork, Polaroid Corp.
Polaroid 6 Sigma Training, Polaroid Corp.
Team Metrics, Polaroid Corp.
Train the Trainer, Polaroid Corp.
Computer Skills:
Completed formal courses in Fortran, Basic and PASCAL programming
Proficiency in use of Kepner Tregoe problem solving Anaylsis
Statistical Engineering Software, and 6 Sigma
Proficient in PC based Microsoft Office Professional
Process Modeling of Chemical Processes with Excel
Personal Affiliations:
American Chemical Society
Federation of Societies for Coatings Technology