MADHANKUMAR. EZHUMALAI

Actively participates in environments that promote ongoing learning, driving personal and professional development.

• Conducted quality analysis of various samples in the laboratory, ensuring all testing procedures follow Good Laboratory Practices (GLP).
• Proficient in calibration and maintenance of a wide range of analytical instruments to ensure accurate and reliable results.
• Performed analysis of water samples, raw materials, and routine shift samples as part of daily quality monitoring processes.
• Prepared and standardized all laboratory reagents and chemical solutions to support analytical procedures.
• Conducted special investigations on off-spec batches, proposing corrective actions and improvements to the Production HOD for product optimization.
• Hands-on experience with key lab instruments, including turbidity meter ,PH meter, conductivity meter,pyknometer other essential quality and analytical tools
• Operated pilot plant equipment for polyester polyol process trials and scale-up activities.
• Demonstrated strong skills in chemical handling, including safe disposal of hazardous and toxic chemicals, following environmental and safety protocols.
• Gained comprehensive knowledge through training in Safety, environmental practices, and Instrumentation.
• Maintained a safe working environment, strictly adhering to all company safety rules and standards.
• Participated in customer visits, providing technical insights and resolving product or application-related issues.
• Delivered technical support to customers, ensuring satisfaction and aligning solutions with specific application requirements.

Polyester Polyol Development:

• Developed new formulation grades of aromatic polyester polyols tailored for rigid polyurethane applications.
• Formulated aliphatic polyester polyols for shoe soles, coatings, and flexible polyurethane systems.
• Designed and optimized hybrid polyester polyol systems for enhanced performance across varied applications.
• Created trans-polyester polyols utilizing fatty acids as bio-based feedstocks.
• Innovated bio-polyester polyol grades emphasizing renewable resources.
• Developed phenolic polyester polyols with enhanced fire resistance properties.
  Explored alternative phenolic sources using Cashew Nut Shell Liquid (CNSL) and Cardanol for sustainable fire-retardant polyols.

Prepolymer Development:

• Formulated TDI-based aliphatic prepolymers for cast elastomer applications.
• Developed new adhesive and sealant resin grades with improved bond strength and durability.
• Designed coating- and adhesive-based prepolymers for high-performance industrial applications.
• Engineered prepolymers for shoe soles, optimizing for flexibility and strength.
• Developed polyurea systems with enhanced mechanical and chemical resistance.

Special Grade Developments:

• Created rigid polyurethane systems for continuous and discontinuous panels, thermoware,

Spray foam insulation, water heater , pipe injection molding

• Improved physical properties and demolding times in rigid foam systems using blowing agents such as cyclopentane and n-pentane.
• Worked with a range of blowing agents traditional: HCFC-141b
  Green alternatives: Ecomate, Methylol, and Methyl Formate
• Developed filler-based polyurethane formulations for concrete mold with strong flooring applications using fatty acids, water, and inorganic fillers.

Analytical & Characterization Techniques:

• FTIR (Fourier Transform Infrared Spectroscopy) – Functional group identification and molecular structure comparison.
• Gas Chromatography (GC) – Determination of chemical purity and component analysis.
• UV-Vis Spectroscopy – Analysis of bonding nature and conjugated systems.
• Karl Fischer Titration – Precise moisture content measurement.
• Titration Methods – Determination of Hydroxyl Value and Isocyanate (NCO) Content
• Viscosity Testing : Brookfield Viscometer – For medium to high viscosity materials.
  Fann Viscometer – For low-viscosity polyurethane systems.
  Anton Paar Viscometer – Advanced viscosity and specific gravity measurement.
• Flame Photometry – Quantitative analysis of S-block elements like Na⁺ and K⁺.
• Mechanical Testing – Equipment handling for shoe sole flexibility and strength tests.

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