Jotun polymer — quality products for the European GRP industry

Jotun polymer — quality products for the European GRP industry

S PECIAL FEATURE m m Jotun P o l y m e r - - quality products for the European GRP industry The s e a is c l o s e l y l i n k e d w i t h t h e d ...

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Jotun P o l y m e r - - quality products for the European GRP industry The s e a is c l o s e l y l i n k e d w i t h t h e d e v e l o p m e n t o f J o t u n Polymer, a major European producer of p o l y e s t e r r e s i n and gel-coat. The c o m p a n y is s i t u a t e d in Sandei3ord, Norway, f a m o u s in t h e early 1900s for its whaling industry. When w h a l i n g died out it w a s r e p l a c e d by a large m e r c h a n t f l e e t m u c h o f w h i c h w a s p a i n t e d u s i n g marine p a i n t from J o t u n Polymer's p a r e n t company, J o t u n A / S . Today J o t u n P o l y m e r c o n t i n u e s t h e marine trad i t i o n w i t h a r o u n d 13% o f i t s b u s i n e s s b e i n g in GRP b o a t construction. Reinforced Plastics visit e d J o t u n and d i s c o v e r e d that t h e company's long history has not s t o p p e d it b e i n g o n e o f t h e m o s t forward t h i n k i n g r e s i n manufacturers in E u r o p e .

FIGURE 1: The Whaling Monument in Sandefjord is a memorial to the town's major industry in the past.

dd Gleditsch, founder of J o t u n A/S, established his first business in 1920 when he started a paint shop and ships' chandlers in Sandetjord on the eastern coast of Norway. In 1926 he bought an oil mill and changed the company's name to J o t u n Kjemiske Fabrikk A/S. The oil mill was closed and production turned over to marine paints and anti-fouling coatings. This was the beginning of what is today Norway's largest paint and varnish manufacturer. Polyester production at J o t u n began in 1954 on a small scale in a pilot plant reactor with a capacity of 50 tonnes a year. In the first 10 years business was mainly concentrated in Norway, but in the next decade the company e x p a n d e d to become the Nordic market leader for u n s a t u r a t e d polyester. This expansion was greatly helped by a merger of J o t u n and three other major Norwegian paint companies in 1972. Three of the four companies also produced polyester resins. Since the mid-1970s J o t u n ' s polyester business has moved south through Europe starting with distributors or agents and then buying established companies. J o t u n Polymer is now a group within the J o t u n A/S group. It comprises seven different companies, with production facilities in Finland, Norway, the UI~ the Netherlands and Italy.

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GRP specialists "We regard ourselves as the European glass fibre reinforced polyester (GRP) professionals, one of the few companies where the main activity of the company is polyester resin", Hans Peter Arnestad, sales and marketing director of J o t u n Polymer, told Reinforced Plastics. The c o m p a n y says t h a t 100% of its p r o d u c t s is sold to t h e GRP industry.

REINFORCED PLASTICS SEPTEMBER 1990

0034-3617/90/$3.50 © 1990, Elsevier Science Publishers Ltd.

S According to Arnestad worldwide sales in this m a r k e t in 1989 were 1.9 million tonnes, with 450 000 to n n es in Western E u r o p e and 38 000 t o n n es in the Nordic countries, and t he resin m a r k e t is growing at 4-5%. J ot un's a nn u a l p r o d u c t i o n volume is in t he region of 50 000 t o n n e s of u n s a t u r a t e d polyester (UP) resin and of gel-coat. This, Arnestad says, makes it t h e third largest E u r o p e a n supplier of UP, with 10% of t he market, and t he largest supplier of gel-coat, with a m a r k e t share of 25%. The company's growth t h r o u g h the 1980s, he says, was a r o u n d 66%, double t he growth of th e m a r k e t generally. Turnover for the polymer group was Norwegian Krone (NOK) 790.8 million in 1989, up from NOK 694.9 million in 1988. J o t u n Pol ym er 's business can be divided into t he following sectors: - - C o r r u g a t e d sheets - 9%; - - T o o l s and pipes - 13%; - - E l e c t r i c a l applications (including sheet and bulk moulding c o m p o u n d s (SMC and BMC)) - 6%; - - M a r i n e construction - 13%; and - - T r a n s p o r t (e.g. automotive, trains, and aerospace) - 19-20%.

• Product development J o t u n Polymer has been one of t he most innovative E u r o p e a n resin manufacturers, Arnestad told Reinforced Plastics, having been among th e first companies to develop: -- Pre-accelerated polyester; -- T h i x o t ro p ic polyester; -- Low styrene emission (LSE) UP, this was developed in th e early 1970s in response to s t r i c t S c a n d i n a v i a n e n v i r o n m e n t a l regulations. J o t u n claims t h a t Scandinavian producers, such as itself and Neste, are leaders in low styrene technology; - - P i g m e n t e d gel-coat in a range of colours, which is said to give a more consistent product, although the cost is greater. D u r i n g t h e 1990s J o t u n p l a n s f u r t h e r d e v e l o p m e n t of its LSE Norpol polyester resins - - with th e aim of becoming t he world n u m b e r one in 15 years time. One of the main reasons for J o t u n Polymer's position in today's E u r o p e a n GRP industry is its LSE technology. For mo r e t h a n 15 years t he c o m p a n y has been working with its LSE technology, which it claims is t he m os t advanced in the industry, and is used in p r o d u c t i o n in t h r e e p ar t s of the world. The c o m p a n y believes t h a t t he system is close to the technical limits. The n e x t step, it says, is to develop the whole technology including cleaning systems,

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etc. In this devel opm ent drive J o t u n believes it has a lead owing to its high level of knowhow, gained from having to conform to Scandinavian environmental regulations. Polyester for closed mould processes is also being developed as p a r t of the company's environmental programme. Basic p r o d u c t i o n techniques can be studied in the company's newly built application centre enabling it to offer processing s u p p o r t to its customers. The gel-coat range is also subject to a n u m b e r of developments. A gel-coat p r i m e r and the GF industrial range of gel-coat have been launched. In addition, the c o m p a n y is now offering t he Polycolour system of gelcoat p i g m e n t a t i o n for improved service. The system is similar to the machines used in the pai nt industry which allows a base gel-coat to be coloured to the customer's specification. Using the system, J o t u n says it can offer small a m o u n t s of a part i cul ar colour within t hree days of receiving an order.

• Quality A quality assurance system based a r o u n d ISO s t a n d a r d 9001 was i m p l e m e n t e d in J o t u n Polymer's Norwegian factories some 2 ]/2 years ago. J o t u n says t h a t certification for ISO 9001 is e x p e c t e d by the end of 1990. The same programme, which involves a total quality philosophy with everybody in the c o m p a n y responsible, is now being implem e n t e d internationally.

Gel-coat production J ot un's gel-coat factory is, the c o m p a n y says, t he largest in Europe. All Jotun's gel-coat is m a d e at this factory. Gel-coat is m a n u f a c t u r e d according to the 'fall' principle with all the raw materials coming in on the top floor of the four storey building. Kjell Rune Johanessen, from J o t u n Polymer's marketing depart m ent , who acted as Reinforced Plastic's guide, explained t h a t the base resins are mixed with a n u m b e r of o t h e r raw materials to give the right blend. Jotun, he says, produces gel-coat in numerous different grades, m a n y tailor made, and a r o u n d 2000 colours. After mixing, t he p r o d u c t is stored for 8 hours to allow the chemical reaction to take place. Then the base polymers are piped down to the second floor where specific ingredients are added to make the gel-coat. This floor also includes a l aborat ory where each batch of gel-coat is t e s t e d for seven different specifications. Batch sizes range from 20 kg to 7 tonnes.

R E I N F O R C E D PLASTICS SEPTEMBER 1990

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FIGURE 2: All Jotun products produced at Sandefjord are distributed from the company's warehouse on the opposite side of the fjord to the gel-coat factory.

an e c o n o m i c a l way. A 20 litre can of uncoloured gel-coat is used as the starting point. Into this a c o m p u t e r controlled machine adds the precise a m o u n t of colour required and the contents are then mixed t o g e t h e r in a specially designed mixing machine. It has taken J o t u n five years to develop the system to meet its standards. It claims t h a t the mechanical and physical d a t a are the same in the Polycolour system as in the s t a n d a r d production gel-coats. Johanessen says t h a t d e m a n d for gel-coat was growing and the company is considering production elsewhere in Europe. At present, the Sandeijord factory employs some 36 people operating just one shift.

Warehouse facilities

All orders of gel-coat between 20 and 100 litres are now coloured using Jotun's Polyc o l o u r system. The c o m p a n y says t h a t previously it had been difficult to fit small orders into the normal production process in

Following a m a j o r fire in 1976 w h i c h destroyed much of Jotun's factories, considerably slowing the company's development, the warehousing and gel-coat production are now situated on opposite sides of the ~jord. All European distribution of materials produced in Sandetjord is carried out from

Polyester co!our pastes ana gelcoats...

REINFORCED PLASTICS SEPTEMBER 1990

S this warehouse, which is equipped with a sophisticated computerized ordering system. Paint and polyester are distributed from the same site, both account for roughly the same size of business. However, unlike Jotun's polyester business which is widely spread t h r o u g h o u t Europe, some 80% of paint sales are to the Norwegian market When goods arrive at the warehouse the pallets are sent to the first floor in a lift. On arrival the pallet is registered and given a number for identification purposes. The computerized warehousing system can follow the pallet to the places of stock and t h e n onto the packing stations. The pallet is transported by an u n m a n n e d crane which takes it to the place allocated by the stock control computer. When goods are ordered they are taken to a packing station and placed on a customer pallet. The remaining goods return to the place of stock, passing through the point of identification. The c u s t o m e r pallet is moved to the ground floor, being shrink wrapped en route, where it is stored until the delivery consignm e n t is complete.

I Laboratory and applications centre

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FIGURE 3: A Nordic MK4-4000 pultrusion machine in Jotun Polymer's applications centre.

The third J o t u n site in Sandeijord, which was originally a factory producing harpoons for the whaling industry, comprises the company's laboratory facilities and new applications centre. Five types of activity are carried Reader Enquiry No 161

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Ryland's Polyester Colour Pastes Instant despatch from stock of over 300 opaque, transparent and polychromatic colours - minimum order only 1/2kg. Special colours are quickly matched and despatched - minimum order only 5 kgs. Ryland's Polyester Gelcoats A superb range of gelcoats with using characteristics in advance of mass-produced standard alternatives. Available in Clear, White or to any colour - minimum order only 25 kgs. Our excellent direct service is supplemented by a network of distributors in the UK and throughout the world details on request.

Llewellyn Ryland Ltd. Haden Street, Birmingham B12 9DB England Tel: 021-440 2284. Telex: 335967 Ryland G Fax: 021-440 0281

REINFORCED PLASTICS SEPTEMBER 1990

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FIGURE 4: Instron testing machines in Jotun's laboratory.

out at the laboratories: development of new basic polymers, development of new gel-coat and t o p c o a t qualities, modification a n d a d a p t a t i o n of products to customer requirements, extensive testing of materials, and experimental applications in the developm e n t of new processes. Comprehensive testing of specimens is conducted using a range of equipment. In the applications laboratory, Instron 1121 and 3110 machines are used to measure tensile strength, compressive s t r e n g t h a n d the flexibility of laminates at different tempera-

This is typical of th complex precision parts we mould in reinforced thermosets for well-known companies making business equipment, computers, domestic /j electrical appliances, instrumentation and industrial switchgear. 4 We have 30 yearsexperience of helping good design ideastake shape in reinforced thermosets. And now we are starting to do the same in reinforced engineering thermoplastics. Contact Ralph Lofthouse for details of our compression/injection moulding and toolmaking capabilities. :~ I

REINFORCED PLASTICS SEPTEMBER 1990

tures. Impact testing of laminates is carried out on a Charpy p e n d u l u m machine and to measure the fire resistance of the laminates the company has oxygen index test apparatus. Gel-coat development is also underway at the laboratory with major emphasis being placed on the use of organic pigments. Johanessen says t h a t these are more expensive but the work must be carried out to meet environmental criteria; in the USA, for example, the use of lead pigment is banned. Large scale testing of polyester is carried out in the two experimental workshops. The smaller of these contains a spraying cabin which is used for the testing of polyesters designed for manual and spray application in open moulds. This workshop also contains equipment for injection moulding. The larger, new, applications centre is used for tests on polyesters designed for more advanced automatic production techniques. It also offers J o t u n the opportunity to carry out larger projects on behalf of, or with, customers. The facilities include modern production equipment for the development of SMC and BMC, extrusion of profiles and for injection moulding. I R e a d e r E n q u i r y No 172

Mawson Taylor Limited, Pioneer Mills, Radcliffe, Manchester M26 9WX Phone: 061-723 2831 Fax: 061-724 0510