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Mark Hanlon


Materials and Design

  • Materials selection
  • Product design
  • Product engineering
  • Tool design and sourcing


  • Blow moulding
  • Equipment
  • Injection moulding  
  • Quality assurance
  • Thermoforming  

Secondary Operations


  • Energy management
  • Expert witness and legal
  • Strategic planning and forecasting



  • General products

  • Packaging

Other Skills

  • Authoring
  • Project management
  • Training
  • Trouble shooting

Other services offered

Materials and Design

  • Tooling design

  • Tooling purchasing (well proven Asia suppliers)

  • Design for manufacturing

  • Machinery evaluation

  • Process evaluation


  • Toolmaker assessment

  • Injection moulding

  • Injection stretch-blow moulding

  • Extrusion blow moulding

  • Process control

  • Productivity improvement

  • Process capability

  • Quality assurance

Secondary Operations


  • Research

  • Development

  • Re-engineering

  • Supplier auditing

  • Procurement

  • Supplier search


  • Packaging

  • Animal health

  • Construction

  • Electrical

  • Consumer products

Other Skills

  • Plant layout and design

  • Heat transfer calculations

  • Services and ancillary equipment specifications

  • Plant maintenance

  • Project management

  • Interim management

Education and Training

  • Technical training programme and qualification development

  • Training resource development

  • Technical education and lecturing

Examples of projects completed.

  • Researched relevant injection stretch-blow moulding production equipment options for installation in a developing SE Asian market

  • Project managed installation and commissioning of the above equipment including: complete plant design and layout; determined all services equipment requirements; oversight of all equipment and services installation; oversight of and participated in all equipment commissioning through to full production; liaison with end customer to resolve product quality issues; full development of quality assurance systems and procedures; full development of plant maintenance procedures; project review and verification of project objectives all being met.

  • Similar projects to the above involving: extrusion blow moulding equipment; high speed injection moulding equipment; other injection stretch-blow moulding equipment.

  • Research and identification of new Chinese mould and equipment supply options to complement the Australasian options I am able to offer my clients. I have subsequently made frequent use of these new supplier relationships to help meet my client requirements.

  • Oversight of several pail design projects and subsequent sourcing and commissioning of tooling from overseas.

  • Investigation of product failures in the market and subsequent resolution by way of material selection and / or product design and / or processing improvements.

  • Work with product designers on material selection and refinement of technical aspects of product design.

  • Work on three different but complex legal cases as an expert witness.

  • Wrote distance learning training resources for plastics materials up to and including technician level. 

Personal Profile

The consultancy was formed in 1992 to primarily service the plastics industry and clients of the plastics industry, with a particular (but not exclusive) focus on small to medium size enterprises. The consultancy provides the opportunity for me to apply to client projects a high level of plastics technical education and training combined with an unusually broad background in the plastics industry. I invest regularly in travel to maintain both my technical knowledge and industry contacts, and have also developed strong supplier relationships in several Asian countries.

My background and interest in technical training in the industry has also resulted in on-going demand for services in qualifications design and training systems development, lecturing, and training resource development.

I take pride in a strong customer service orientation, good communication skills, appreciation of commercial imperatives, and working to clear objectives and timetables.

Prior to forming this consultancy I trained and subsequently worked in senior technical management roles for medium to large companies in both New Zealand and the United Kingdom over 24 years. These roles regularly gave me in depth exposure to leading edge technologies in the plastics industry.

More recently I have developed an interest in the governance of commercial and not for profit organisations. I have been a Board member for one organisation for the last four years and completed my first formal governance training during 2009.


 Contact Address

Hanlon Consulting Ltd., P.O. Box 307, Cambridge 3450, New Zealand.

Tel: +64 7 827 8833

Fax: +64 7 827 8833

Mobile: +64 21 99 52 33

email: mark@hanlonconsulting.co.nz

Web site: www.hanlonconsulting.co.nz