About Me
I'm a leader and engineer with over 15 years of experience in process engineering, technology development and project delivery.
I am currently Head of Process Tech at Greenback Recycling Technologies, where I drive the development of cutting-edge recycling technologies aimed at reducing plastic waste and creating a more sustainable future. Throughout my career, I've consistently focused on turning complex problems into innovative, scalable solutions.
Skills
- Process Engineering: Chemical and mechanical design, plant optimisation and design, P&ID generation and maintenance.
- Technology Development: Implementing complex projects from concept to reality, including hazard and risk assessments, process control design, reference and training documentation and communications.
- Leadership: Managing multi-disciplinary teams, inspiring performance, and fostering innovation.
- Plant design, construction and commissioning: From innovative pilot equipment and experiment design to full-scale plant installation, infrastructure and peripheries.
- Control Systems: Plant Design and automation, Process Control, Operator interface design, instrumentation and equipment integration, IT infrastructure and security, data logging and access.
- Communication: Reporting, technical or non-technical audiences, internal or external stakeholders.
- Project management: Collaborative working tools, priority management according to company objectives and critical paths, expectation management and communication.
- Financial: Experienced in managing engineering budgets and optimising costs to balance future requirements with future ROI.
- Engineering Tools: 2D/3D modelling (Autodesk, Blender), Allen-Bradley/Siemens programs, databases (PostgreSQL, MySQL).
- Programming: Python, PostgreSQL, PHP, HTML/CSS/JS.
Alconbury, UK
At Enval Limited, I was part of the team that developed a unique pyrolysis process to recycle flexible packaging waste. This process was designed to recover the aluminium content and produce a hydrocarbon oil, which could be used as a fuel or feedstock for the chemical industry. The process was developed from bench scale to pilot scale to demo plant, developing the elements of the plant and proving the concept.
Pilot rig
Small oven for material tests and product analysis
Small scale plant
Enval Luton team
Demo plant
Enval Alconbury team
Products
Aluminium and Oil derived from flexible packaging pyrolysis
Aluminium flakes produced
Ingots
Progression of ingots melted from flakes from packaging
Cuautla, Mexico
Enval Module Deployment:
Planned and implemented a full-scale recycling plant in Cuautla, Mexico, from the ground up. This involved designing, building, and commissioning a modular plant that could be transported and assembled on-site, reducing construction time and costs. The plant was delivered to site in December 2022, commissioned over the next few months, the first plastic was put in in March 2023 and the inauguration realised in May 2023.
Over the next months of operation we commissioned new equipment and ramped up production. Standard Operating Procedures were translated and tweaked, and process bottlenecks identified and solved. To support this I established an efficient remote supervision infrastructure, enabling seamless managerial overview and effective engineering team input from a distance.
Building preparation
Recycling plant vacant site
Modular plant transport
First full size module departing for Mexico
Plant module placement
Equipment arrives pre-fitted on frames and can be placed in 1 day
Cuautla commissioning and ops team
Plant inauguration
Cuautla team
LCA
As Principal Consultant at Enval Consulting, I used my Life Cycle Assessment skills to study flexible packaging waste disposal across the globe as part of a study commissioned by the packaging team of a global brand. It evaluated environmental impacts from raw materials, production, transportation, and disposal, tailored to dozens of manufacturing and end-user locations. By considering current and future waste disposal technologies, including the Enval technology, the analysis identified material substitutions and process improvements that could reduce environmental impact by up to 50%, providing strategic insights to keep the brand ahead of industry trends. Following publication, the study was reviewed and its findings supported the conclusions drawn.
This time spent studying environmental impacts and their principal causes has given me a thorough understanding of the importance of sustainability in engineering and packaging materials, that I apply in many areas of my work.
Research and Development:
While R&D Engineer at Enval Limited, I conducted research on the pilot plant in the Cambridge Science Park and also at the University of Cambridge, examining the pyrolysis process and heat application methods to improve our technology. Solid, liquid and gas products would all be collected and analysed, usually in a GC-MS. This knowledge then enabled us to design a reactor to treat the plastics on a larger scale.
After the demonstration plant was built in Alconbury, I expanded my reach as Head of Technology Development, shifting the focus on to improving the yield of aluminium derived from the process. We combined in-house development with external collaboration, resulting in a new design of melting furnace for low density aluminium flakes.
Key Achievements
Full-scale plant:
Planned, ordered, built, cabled, tested, commissioned and ramped up a full-scale recycling plant in Cuautla, Mexico, from the ground up. This involved designing, building, and commissioning a modular plant, that could be transported and assembled on-site, reducing construction time and costs. The plant was delivered to site in December 2022, commissioned over the next few months, the first plastic was put in in March 2023 and the inauguration realised in May 2023.
Over the next months of operation we commissioned new equipment and ramped up production. Standard Operating Procedures were translated and tweaked, and process bottlenecks identified and solved. To support this I established an efficient remote supervision infrastructure, enabling seamless managerial overview and effective engineering team input from a distance.
This involved integrating cutting-edge remote monitoring and supervisory systems to ensure ongoing operational success. This approach reduced on-site requirements while maintaining high standards of safety, efficiency, and communication.
Process tank design:
Designed, calculated, simulated, sized, built and incorporated a new design of process tank for the module. Complex design elements to enhance the process yield and efficiency and minimise downtime. Pleasingly the design objective was achieved on the first test.
Plant data access upgrade:
Upgraded the plant data access system from a storage hungry database and slow file-based logs to a PI-based system with compression, exception handling and archiving functionality. I further expanded the functionality with integration of PI Vision front-end and an assset database to allow for multi-lingual and user-customisable dashboards and displays and, crucially, remote monitoring and analysis of the plant operations. The resulting system improved data loading times by of the order of 10 or 20.
Electrical drawing and control panel upgrade:
Upgraded the electrical drawings for the plant from non-searchable and incomplete pdfs to ePlan, ensuring that all components were accurately represented, providing a valuable resource for future rollouts. Panels were designed to offer geographic flexibility by incorporating transformers, and module flexibility, should the ancillary equipment requirements vary by site.
As Head of Process Technology, I took the lead on the electrical and control side of the production of the second full-size recycling plant. This involved drawing together all the learnings from the first plant, managing improvements and changes, specifying the control system and integrating plant instrumentation, with a focus on designing in flexibility in the plant and dramatically shortening installation times.
Peer-reviewed LCA study:
Commissioned by the packaging team of a global brand to perform a cradle-to-grave life cycle assessment of packaging materials across multiple countries. The study evaluated environmental impacts from raw materials, production, transportation, and disposal, tailored to dozens of manufacturing locations. By considering current and future waste disposal technologies, the analysis identified material substitutions and process improvements that could reduce environmental impact by up to 50%, providing strategic insights to keep the brand ahead of industry trends. Following publication, the study was reviewed and its findings supported the conclusions drawn.
University of Cambridge:
Masters degree and BA degree in Chemical Engineering (2:1) from the University of Cambridge. My first year was in the General Engineering Tripos, which provided an excellent base to start from, including mechanical engineering, structures, materials, electrical and information engineering, mathematical methods, structural design, product design, presentation skills, drawing, laboratory experiments and computer programming. The following three years were specialised in Chemical Engineering with modules including fluid mechanics, process calculations, thermodynamics, separations, biotechnology, maths, chemistry, sustainability, CFD, and rheology.
Leadership and Team Development
Leading engineering teams is not just about managing projects — it's about inspiring growth, fostering creativity, and ensuring that every team member is empowered to contribute their best work. Here’s how I approach leadership:
My Leadership Philosophy:
My leadership style emphasises empowerment, innovation, and performance. I believe in providing my colleagues with the tools and environment they need to feel valued, respected and confident to work independently. Each person needs to feel free to express their ideas and opinions, otherwise bold ideas may never be voiced, and I foster a culture of regular presentation and discussions. This philosophy extends beyond the internal team to our relationships with external contractors and suppliers. By encouraging open dialogue and collaborative feedback, we build strong partnerships that help identify opportunities for innovation and optimisation. Together, we can efficiently achieve the company's objectives.
My leadership extends beyond physical presence. While commissioning a full-scale plant in Mexico, I established a robust remote supervisory infrastructure that ensured operational excellence even from afar. This approach demonstrates my ability to leverage technology and timezones to enhance team performance, regardless of location.
Engineering Standards:
I hold myself and my colleagues to the highest engineering standards, ensuring that every project is executed with precision, safety, and excellence. This commitment to quality is reflected in our detailed specifications, rigorous testing, thorough documentation, and ultimately positive process outcomes.
- Team Leadership: Leading multidisciplinary teams in high-pressure, innovative environments.
- Project Management: Experience with budgets, deadlines, and risk management.
- Innovation: Cultivating a culture of innovation and continuous improvement in engineering teams.
- Communication: Clear, concise communication with team members, stakeholders, and external partners.
- Strategic Planning: Driving engineering strategies aligned with organisational goals, particularly in transitioning innovative concepts into commercially viable technologies.