Nikunj Bhimani

Founder and Technical Director

Mechel Polymer • ZZP

Jul 2021 - Present • 4 yrs 10 mos

As the Founder and Technical Director of Mechel Polymer, I established and operated a plastic recycling facility in Morbi, Gujarat, bridging the gap between high-level mechanical design and practical shop-floor manufacturing. I spearheaded the complete plant engineering, designing the facility layout and optimizing material workflows to achieve a production capacity of 25–50 tons per month. My role was deeply rooted in Machine Design and R&D. I identified inefficiencies in standard equipment and engineered custom solutions to resolve them. Notably, I conceptualized and manufactured a Customized Twin-Shaft Shredder specifically for high-strength FIBC (Jumbo) bags, successfully re-engineering the blade geometry and drive train to overcome frequent jamming issues found in market-standard machines. Additionally, I designed and fabricated an in-house Pneumatic Dust Collection System, performing airflow (CFM) and pressure drop calculations to improve material recovery and plant safety. Beyond core engineering, I managed the daily maintenance of critical machinery, including extruders and injection molds, conducting root cause analysis for breakdowns and coordinating specialized repairs. I integrated this technical expertise with financial stewardship, managing the firm’s banking relations, working capital, and Cost-Benefit Analysis. This experience gave me a profound understanding of Operational Expenditure (OPEX) and ROI, equipping me with a unique "Owner's Mindset" to design machines that are not just technically sound but commercially profitable to operate.

Senior Design Engineer

Kabra Extrusion Technik Ltd. • Fulltime

Jul 2016 - Jul 2021 • 5 yrs

During my five-year tenure at Kabra Extrusion Technik, I specialized in the R&D and manufacturing of high-performance plastic extrusion machinery. My core expertise was the Design and Development of Co-rotating Twin Screw Extruders and Compact Processors, where I utilized SolidWorks and AutoCAD to transform conceptual requirements into precise dimensional drawings and main assembly layouts. My role extended beyond 3D modeling into full lifecycle project management. I acted as the custodian of engineering data, managing complex Bill of Materials (BOM) and executing Engineering Change Notices (ECN) within the SAP ERP system to ensure seamless production workflows. I bridged the gap between the design office and the factory floor, collaborating intimately with fabrication and assembly teams to troubleshoot prototypes and apply Design for Manufacturability (DFM) principles. I drove significant value through strategic cost-reduction initiatives, leading Value Engineering projects to indigenize imported components, successfully replacing expensive foreign parts with local alternatives. To enhance team efficiency, I leveraged my IT skills to develop a custom Android App for Extrusion Formulas, streamlining routine calculations. I also took ownership of post-design support, creating comprehensive User Manuals and Spare Part Catalogues to ensure robust end-user operations.