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Composites merger good news for industry
Composites merger good news for industry When US carbon fibre manufacturer Zoltek began looking for strategic acquisitions, it set its sights on Engineering Technology (EnTec) and Composite Machines Company (CMC) to increase its capabilities. Spencer Wagner explains. E
ntec Composite Machines' (ECM) history goes back 38 years and is full of industry milestones and significant contributions to work in composites. Three engineers from Hercules Powder Company founded Engineering Technology (EnTec) in 1962. The company's core business was focused on supplying filament winding equipment to the defence and aeronautics industries. They made a very successful transition to multi-spindle commercial applications and designs. With the advent of computers, EnTec built the world's first computer controlled filament winding machine. These computer controlled winders have now increased in sophistication so that up to 11 axes of motion can be controlled along with fibre tension, resin mixing and spindle speed. EnTec is now a recognized and well-respected name in the composite industry. In 1992, Robert and Michael Skinner founded the Composite Machines Company (CMC) with the intent to compete directly against EnTec and other filament winding machine manufacturers, but also to expand the range of products and services offered to customers. Known for being an innovative company, CMC expanded its product line to include pultrusion machines and gantry systems while working on a new computer control system. Incorporated into its marketing strategy was lowering the cost of machines while maintaining a high level of quality and customer service. 52
REINFORC,EDplastics
September 2000
Ironically, both companies were located on the same street in Salt Lake City. This created a very competitive atmosphere and sparked a rivalry between them that was noticeable throughout the composites industry. One of the biggest obstacles that both EnTec and CMC faced was adequate resources to conduct research and development in expanding product lines. Zoltek was the answer to each company's concerns by providing the financial backing needed to reach these goals.
Company merger Zoltek provided the means for joining the two industry leaders in filament winding and composite machine manufacturing. The capabilities of ECM have
now created a competitive advantage. The company is housed in a 6975 m 2 facility located in Salt Lake City, Utah, USA, and is now the largest company in the filament winding industry. The merger has allowed the two companies to combine skills and offer increased knowledge and experience to customers. The level of experience and knowledge is evident in the fact that the company has over 600 combined (employee) years of composite industry experience. The merger is seen as having a positive effect on the composites industry. ECM is focused on providing its customers the solutions they need. Combining the product lines of both companies has broadened the capabilities of the company and made it possible 0034-3617/00/$ - see front matter © 2000 Elsevier Science Ltd. AI[ rights reserved.
Composites merger good news for industry
centre is equipped with the two filament winding machines, a five-axis gantry machine, curing oven, mandrel extractor, pultrusion machine, diamond cutoff saw, resin formulation and mixing, material hardness, strength and stiffness testing equipment and hand lay-up tables.
to combine research. W h e n asked what the primary goal is for ECM, president Michael Skinner quotes the company's mission statement, saying, "Entec Composite Machines Inc is dedicated to the profitable development, manufacture, marketing and service of the highest quality, most cost effective machinery for the worldwide fibre reinforced plastics (composite) industry." ECM is doing all it can to reach its goals and provide its customers with the best composite machinery available.
Products/customers
New technology/products W h e n Michael Skinner founded CMC, he wanted to set the c o m p a n y apart from other filament winding manufacturers. He wanted to provide a full range of products. His vision has carried over to ECM and is becoming a reality. "I want to be the one-stop-shop for composite machines," says Skinner. The c o m p a n y took one step closer at the SAMPE 2000 show, where ECM showcased some of its new products. The entire b o o t h consisted of machines, two of which had never before been displayed at any of the previous SAMPE shows. The largest and most impressive was its new gantry system. The gantry machine provides a platform for fibre placement, industrial routing, plug fabrication, water jet cutting, trimmi!lg, inspection and part handling. The show allowed people the opportunity to see the machine up close and ask specific questions. "We wanted to make a bold statement at the show," says J o h n Green, director of worldwide sales and service. "We want people to know what we're about and how we can help companies." The other machine that made its debut appearance at SAMPE was the new Alpha Series pultrusion machine. ECM has developed a complete line of pultrusion machines: the Alpha, Beta, Delta and G a m m a Series. The machine attracted plenty of attention and helped illustrate and educate the pultrusion process. The pultrusion industry is seen to have a lot of potential growth. With the new
series of machines, ECM feels it can offer what customers want and have a positive effect within the industry. Also displayed at SAMPE was the new ECM1 computer control system. This control system combines the latest computer technology with a rackmount industrial computer. Instead of using the keyboard, mouse and separate control panel, this control system uses a TFT flat panel touchscreen to operate its filament winding machines. This allows the user to point and touch to execute each c o m m a n d . "We want the new ECM1 control system to be the next generation control package," states Skinner. Expectations are high for this new control system. The newest service offered is the 1116 m 2 composite technology developm e n t centre. It is designed to help develop filament winding or pultrusion processes, prototype winding or identify how filament winding or pultmsion can be used for customer products. The
ECM machines have been used to make a wide range of products. Along with building the world's first computer controlled filament winding machine, ECM has built the world's largest five-axis computer controlled filament winding machine. The machine is located in Italy where it is used to produce large wind turbine blades for power generation. The machine can wind a part 55 m in length and more than 7 m in diameter. Originally filament winding was used to help produce missile casings and nose cones but the commercial use of the machines has broadened the range of products manufactured. Sporting goods manufactured include carbon wound golf shafts, racquetball and tennis rackets, hockey sticks and mountain bike frames. Many closed-end vessels are manufactured. Some examples are natural gas tanks, oxygen tanks and other high-pressure vessels. The oil, gas and chemical industries are discovering how cost effective filam e n t wound parts are versus metal parts. To eliminate the rapid rate of metal corrosion, filament wound parts are replacing pipes, tanks and other metal parts. ECM is currently working with a number of companies. These include Gamesa Eolica, (Spain), which is producing carbon fibre wind turbine blades, while Shanghai Composite Cylinders (China) is producing self contained breathing apparatus tanks (SCBA) and compressed natural gas tanks (CNG) and FILMTec (Minnesota) is producing water filtration units. Mitsubishi Rayon (Japan) is conducting R&D projects using carbon fibre, and United Technologies Corporation (California) is producing advanced rocket motor cases.
September 2000
REINFORCEDplastics
53
Composites merger good news for industry
The future for composites Composites were first used in the defence and aeronautics industries. The trend over the past few decades has gone from high-tech applications to commercial applications. The reason for this change may be down to one thing, attitude. The attitude of society to accept composite s as a stronger, lighter and more cost-effective alternative is taking shape. In fact, it appears that composites have come full circle because now the high-tech companies are using the same proven techniques to manufacture products that commercial companies have been using for years. However, commercial uses for composites will continue to grow and expand. Where are composites going? In the future, what industries will use composites? Director of engineering, Shawn Kozak sees composites breaking into the main infrastructure and becoming a dominant player. "You will see composite products break into the housing/architectural industry, the marine industry along with the transportation/automotive industries on a much wider scale than now," states Kozak. A recent trend has seen customers demanding shorter delivery times for their filament winding machines. A reason for this is shorter product life cycles. Technology is changing so rapidly, customers need to act quickly to secure and capitalize on their product ideas or applications. This challenge has created an opportunity for the company to reexamine its processes and make the necessary changes to meet the demand. ECM has taken a different approach to building filament winding machines. "We believe that standard components build custom machines," explains Kozak. "We want the customers to decide what components they need for their machine, then this will define what machine will fit their specifications." It is a simple concept, which will reinforce the idea that the customer's machine is custom built to meet their specifications.
54
Another observation has shown that companies are moving towards 'lean manufacturing' versus 'batch and queue.' Lean manufacturing utilizes the Japanese just-in-time principle to maximize production flow. By working together with lean companies ECM has put together work cells. These work cells consist of a creel, resin system, winding machine, curing oven and extractor. All of the machines are automated to work together to help increase speed and efficiency.
REINFORCEDplastics September 2000
The opportunities are there. The merger has put EMC into a position in which we can accomplish the goals our company has. The industry needs change and ECM is ready for the challenge. •
Spencer Wagner, marketing director, Entec Composites Machines Inc, 2975 South 300 West, Salt Lake City, UT 84115, USA; tel: +1-801-486-8721; fax: +1-801-4844363; e-mail: [email protected]
ntec Composite Machines' (ECM) history goes back 38 years and is full of industry milestones and significant contributions to work in composites. Three engineers from Hercules Powder Company founded Engineering Technology (EnTec) in 1962. The company's core business was focused on supplying filament winding equipment to the defence and aeronautics industries. They made a very successful transition to multi-spindle commercial applications and designs. With the advent of computers, EnTec built the world's first computer controlled filament winding machine. These computer controlled winders have now increased in sophistication so that up to 11 axes of motion can be controlled along with fibre tension, resin mixing and spindle speed. EnTec is now a recognized and well-respected name in the composite industry. In 1992, Robert and Michael Skinner founded the Composite Machines Company (CMC) with the intent to compete directly against EnTec and other filament winding machine manufacturers, but also to expand the range of products and services offered to customers. Known for being an innovative company, CMC expanded its product line to include pultrusion machines and gantry systems while working on a new computer control system. Incorporated into its marketing strategy was lowering the cost of machines while maintaining a high level of quality and customer service. 52
REINFORC,EDplastics
September 2000
Ironically, both companies were located on the same street in Salt Lake City. This created a very competitive atmosphere and sparked a rivalry between them that was noticeable throughout the composites industry. One of the biggest obstacles that both EnTec and CMC faced was adequate resources to conduct research and development in expanding product lines. Zoltek was the answer to each company's concerns by providing the financial backing needed to reach these goals.
Company merger Zoltek provided the means for joining the two industry leaders in filament winding and composite machine manufacturing. The capabilities of ECM have
now created a competitive advantage. The company is housed in a 6975 m 2 facility located in Salt Lake City, Utah, USA, and is now the largest company in the filament winding industry. The merger has allowed the two companies to combine skills and offer increased knowledge and experience to customers. The level of experience and knowledge is evident in the fact that the company has over 600 combined (employee) years of composite industry experience. The merger is seen as having a positive effect on the composites industry. ECM is focused on providing its customers the solutions they need. Combining the product lines of both companies has broadened the capabilities of the company and made it possible 0034-3617/00/$ - see front matter © 2000 Elsevier Science Ltd. AI[ rights reserved.
Composites merger good news for industry
centre is equipped with the two filament winding machines, a five-axis gantry machine, curing oven, mandrel extractor, pultrusion machine, diamond cutoff saw, resin formulation and mixing, material hardness, strength and stiffness testing equipment and hand lay-up tables.
to combine research. W h e n asked what the primary goal is for ECM, president Michael Skinner quotes the company's mission statement, saying, "Entec Composite Machines Inc is dedicated to the profitable development, manufacture, marketing and service of the highest quality, most cost effective machinery for the worldwide fibre reinforced plastics (composite) industry." ECM is doing all it can to reach its goals and provide its customers with the best composite machinery available.
Products/customers
New technology/products W h e n Michael Skinner founded CMC, he wanted to set the c o m p a n y apart from other filament winding manufacturers. He wanted to provide a full range of products. His vision has carried over to ECM and is becoming a reality. "I want to be the one-stop-shop for composite machines," says Skinner. The c o m p a n y took one step closer at the SAMPE 2000 show, where ECM showcased some of its new products. The entire b o o t h consisted of machines, two of which had never before been displayed at any of the previous SAMPE shows. The largest and most impressive was its new gantry system. The gantry machine provides a platform for fibre placement, industrial routing, plug fabrication, water jet cutting, trimmi!lg, inspection and part handling. The show allowed people the opportunity to see the machine up close and ask specific questions. "We wanted to make a bold statement at the show," says J o h n Green, director of worldwide sales and service. "We want people to know what we're about and how we can help companies." The other machine that made its debut appearance at SAMPE was the new Alpha Series pultrusion machine. ECM has developed a complete line of pultrusion machines: the Alpha, Beta, Delta and G a m m a Series. The machine attracted plenty of attention and helped illustrate and educate the pultrusion process. The pultrusion industry is seen to have a lot of potential growth. With the new
series of machines, ECM feels it can offer what customers want and have a positive effect within the industry. Also displayed at SAMPE was the new ECM1 computer control system. This control system combines the latest computer technology with a rackmount industrial computer. Instead of using the keyboard, mouse and separate control panel, this control system uses a TFT flat panel touchscreen to operate its filament winding machines. This allows the user to point and touch to execute each c o m m a n d . "We want the new ECM1 control system to be the next generation control package," states Skinner. Expectations are high for this new control system. The newest service offered is the 1116 m 2 composite technology developm e n t centre. It is designed to help develop filament winding or pultrusion processes, prototype winding or identify how filament winding or pultmsion can be used for customer products. The
ECM machines have been used to make a wide range of products. Along with building the world's first computer controlled filament winding machine, ECM has built the world's largest five-axis computer controlled filament winding machine. The machine is located in Italy where it is used to produce large wind turbine blades for power generation. The machine can wind a part 55 m in length and more than 7 m in diameter. Originally filament winding was used to help produce missile casings and nose cones but the commercial use of the machines has broadened the range of products manufactured. Sporting goods manufactured include carbon wound golf shafts, racquetball and tennis rackets, hockey sticks and mountain bike frames. Many closed-end vessels are manufactured. Some examples are natural gas tanks, oxygen tanks and other high-pressure vessels. The oil, gas and chemical industries are discovering how cost effective filam e n t wound parts are versus metal parts. To eliminate the rapid rate of metal corrosion, filament wound parts are replacing pipes, tanks and other metal parts. ECM is currently working with a number of companies. These include Gamesa Eolica, (Spain), which is producing carbon fibre wind turbine blades, while Shanghai Composite Cylinders (China) is producing self contained breathing apparatus tanks (SCBA) and compressed natural gas tanks (CNG) and FILMTec (Minnesota) is producing water filtration units. Mitsubishi Rayon (Japan) is conducting R&D projects using carbon fibre, and United Technologies Corporation (California) is producing advanced rocket motor cases.
September 2000
REINFORCEDplastics
53
Composites merger good news for industry
The future for composites Composites were first used in the defence and aeronautics industries. The trend over the past few decades has gone from high-tech applications to commercial applications. The reason for this change may be down to one thing, attitude. The attitude of society to accept composite s as a stronger, lighter and more cost-effective alternative is taking shape. In fact, it appears that composites have come full circle because now the high-tech companies are using the same proven techniques to manufacture products that commercial companies have been using for years. However, commercial uses for composites will continue to grow and expand. Where are composites going? In the future, what industries will use composites? Director of engineering, Shawn Kozak sees composites breaking into the main infrastructure and becoming a dominant player. "You will see composite products break into the housing/architectural industry, the marine industry along with the transportation/automotive industries on a much wider scale than now," states Kozak. A recent trend has seen customers demanding shorter delivery times for their filament winding machines. A reason for this is shorter product life cycles. Technology is changing so rapidly, customers need to act quickly to secure and capitalize on their product ideas or applications. This challenge has created an opportunity for the company to reexamine its processes and make the necessary changes to meet the demand. ECM has taken a different approach to building filament winding machines. "We believe that standard components build custom machines," explains Kozak. "We want the customers to decide what components they need for their machine, then this will define what machine will fit their specifications." It is a simple concept, which will reinforce the idea that the customer's machine is custom built to meet their specifications.
54
Another observation has shown that companies are moving towards 'lean manufacturing' versus 'batch and queue.' Lean manufacturing utilizes the Japanese just-in-time principle to maximize production flow. By working together with lean companies ECM has put together work cells. These work cells consist of a creel, resin system, winding machine, curing oven and extractor. All of the machines are automated to work together to help increase speed and efficiency.
REINFORCEDplastics September 2000
The opportunities are there. The merger has put EMC into a position in which we can accomplish the goals our company has. The industry needs change and ECM is ready for the challenge. •
Spencer Wagner, marketing director, Entec Composites Machines Inc, 2975 South 300 West, Salt Lake City, UT 84115, USA; tel: +1-801-486-8721; fax: +1-801-4844363; e-mail: [email protected]