- Email: [email protected]
Recycling dominates at K92
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Recycling dominates at K92 The K92 p l a s t i c s s h o w in D i i s s e l d o r f w a s d o m i n a t e d by the recycling t h e m e - c o m p o s i t e s w e r e no e x c e p t i o n . M o s t o f the major m o u l d e r s s h o w e d parts from recycled materials. Resin producers e m p h a s i z e d their i n v o l v e m e n t and, in many cases, claimed that t h e y w e r e n o t l a u n c h i n g n e w p r o d u c t s b e c a u s e all the m o n e y had g o n e into d e v e l o p i n g recycling s o l u t i o n s . A m a n d a Weaver reports on the activites o f s o m e o f the materials and parts producers, further reports will appear in the January 1993 issue.
1
Phenolic GRP u s e d for Cray Valley technical centre
A new development and t e c h n i c a l service c e n t r e w a s opened at Cray Valley's polyester production plant at Drocourt, France, in late October. The c e n t r e a c c o m m o d a t e s all of t h e l a b o r a t o r i e s involved in r e s e a r c h a n d applications for the group's s t r u c t u r a l resins s e g m e n t . It is d e s i g n e d to o p e r a t e intern a t i o n a l l y , in c o n j u n c t i o n w i t h t h e firm's o t h e r p r o d u c tion sites in E u r o p e a n d t h e USA. The building was converted from an existing s t r u c t u r e using r e s i n - b a s e d m a t e r i a l s m a n u f a c t u r e d by the Drocourt plant. These include phenolic cladding p a n e l s b a s e d on N o r s o p h e n resins, a n d s y n t h e t i c m a r b l e b a s e d o n N o r s o d y n e isop h t h a l i c p o l y e s t e r resins. The corrugated panels u s e d on t h e roofs a n d s o m e of t h e walls are F i b r a p h e n s h e e t s m a d e by Fibres du Hainaut. They comprise a
{
The technical centre and Cray Valley's Drocourt plant has been reconstructed using glass reinforced phenolic panels. l a m i n a t e of p h e n o l i c resin a n d g l a s s f i b r e s 1-2 m m thick, c o a t e d on b o t h sides w i t h a 250 p m layer of selfe x t i n g u i s h i n g p o l y e s t e r gelcoat. The p a n e l s are classified as M1 fire r e t a r d a n t by t h e c e n t r a l l a b o r a t o r i e s of police h e a d q u a r t e r s . The p a n e l s u s e d to m a k e t h e f a c a d e a r e d o u b l e faced glass reinforced p h e n o l i c p a nels with a polyurethane i n s u l a t i n g core. The p a n e l s u s e d in t h e m u l t i - s t o r e y section of t h e building m e a s u r e 2.85 x 3.10 m a n d t h o s e u s e d
REINFORCEDPLASTICS DECEMBER1992
in t h e single-storey section a r e 3.04 x 3.48 m, b o t h i n c o r p o r a t e s p a c e s for two windows. F i n i s h e d w e i g h t of a p a n e l is a r o u n d 60 kg. All interior and exterior decorative f e a t u r e s a r e i n c o r p o rated in the moulded panels. The f a c a d e c l a d d i n g w a s m o u l d e d by Stratiform. Initially h a n d lay-up techniq u e s w e r e used, b u t o n c e production was underway the panels were produced by resin t r a n s f e r m o u l d i n g (RTM). This allows a p a n e l to be produced in j u s t
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3 hours. T h e c l a d d i n g p a n e l s are also c o a t e d w i t h a polyes t e r gel-coat, it will be at least l0 years before any r e p a i n t i n g is r e q u i r e d says C r a y Valley. The r e n o v a t i o n , r e p r e s e n t ing an overall i n v e s t m e n t of a b o u t FF25 million, is p a r t of a large-scale m o d e r n i z a t i o n of t h e D r o c o u r t plant. In a d d i t i o n to t h e r e h a b i -
Cray Valley to produce Premix compounds F r e n c h p o l y e s t e r resin prod u c e r C r a y Valley is to m a k e thermoset moulding comp o u n d s u n d e r license f r o m P r e m i x Inc of t h e USA. The c o m p o u n d s , k n o w n as Prem i g l a s , P r e m i J e c t , TMC, Lytex a n d QC, will be m a d e at C r a y V a l l e y ' s D r o c o u r t p l a n t a n d sold t h r o u g h o u t Europe. C r a y Valley, a s u b s i d i a r y of t h e oil c o m p a n y Total, previously m a d e its own b r a n d of b u l k m o u l d i n g c o m p o u n d (BMC) called N o r s o m i x , this will be r e p l a c e d by t h e Prem i x grades. P r o d u c t i o n in a newly, h i g h l y a u t o m a t e d , c o m p o u n d p l a n t will begin early in 1993. Both p a r t n e r s h o p e t h a t the a g r e e m e n t will e n h a n c e t h e overall d e v e l o p m e n t of
litation of t h e t e c h n i c a l centre the plan includes c o n s t r u c t i o n of a p r o d u c t i o n u n i t for p h e n o l i c resins u s e d for c o m p o s i t e m a t e r i a l s a n d a polyester moulding comp o u n d s unit, a n d t h e a u t o marion of the polyester resins o p e r a t i o n s . D r o c o u r t c u r r e n t l y h a s an annual production capacity of 6000 t o n n e s THP ( t e t r a
hydro phthalique anhydride), 12 5 0 0 t o n n e s m a l e i c a n h y d r i d e , 60 000 tonnes unsaturated polyester, 5000 t o n n e s p h e n o l i c resin, a n d 7000 t o n n e s of m o u l d i n g c o m p o u n d - - rising to 10 000 t o n n e s by t h e e n d of 1993.
thermoset composites m o u l d i n g s as well as reinforcing t h e c o m p a n i e s ' m a r k e t positions. O t h e r p r o d u c e r s of polyester resins have expressed concern that Cray Valley's m o v e will bring it directly into competition w i t h its c u s t o m e r s .
cover, w h i c h w a s o n e of t h e f i r s t c o m m e r c i a l p a r t s to c o n t a i n recycled s h e e t a n d bulk moulding compound (SMC/BMC), will be u s e d in a n e w m o d e l o f t h e car. I n t e r e s t i n g l y t h e decision to use a c o m p o s i t e m a t e r i a l for this p a r t w a s m a d e before t h e recycling ,.solution w a s d e v e l o p e d . The s p a r e w h e e l c o v e r c o n t a i n s 15% recycled material. Mitras has developed a sun r o o f f r a m e for W e b a s t o w h i c h will be u s e d in a r a n g e of cars, including BMWs, a n d p a r t s a r e b e i n g m a d e for a Telekom telephone booth. The f r o n t e n d of t h e new ~vV P a s s a t in being m o u l d e d inh o u s e by VW at its Wolfsburg p l a n t using a m a t e r i a l develo p e d by Menzolit. This conrains Ercom recyclate and w h e n p a i n t e d h a s a class A surface. K e l d e r m a n says t h a t German automotive companies are n o w looking to E r c o m to help them recycle repair p a r t s . A s i m i l a r s i t u a t i o n is d e v e l o p i n g in F r a n c e , h e claims, w h e r e landfill prices a r e e x p e c t e d to i n c r e a s e 25% a y e a r until 1995/96 w h e n t h e cost of landfill will be s a m e as c h e m i c a l p r o c e s s i n g of waste. French a u t o m o t i v e c o m p a n i e s are a l r e a d y exp r e s s i n g i n t e r e s t in t h e Valcor composites recycling s c h e m e - - a c o n t r a s t to G e r m a n y w h e r e t h e SMC m o u l d e r s t o o k t h e initiative.
Cray Valley Total; tel: + 3 3 - 1 - 4 2 - 9 1 - 3 4 - 71; .fax: + 33-1-42-91-34-68.
1
Recycled part in class A application
An i m p r e s s i v e a r r a y of p a r t s c o n t a i n i n g recycled c o m p o sites p r o c e s s e d by G e r m a n v e n t u r e E r c o m , w a s on disp l a y a t K92, i n c l u d i n g a class A a u t o m o t i v e part. H a n s K e l d e r m a n of DSM, a s p o k e s m a n for Ercom, told us t h a t t h e Audi s p a r e wheel
The VW Passat front-end is moulded using recyclate containing material from Menzolit. A class A finish is obtained after painting.
Cray Valley; tel: + 3 3 142-91-68-68; .fax: +33-147-76-07-18.
Dr Peter Schaefer, Erco~t c/o B W R Bizerba; tel: + 4972-22-599-134; f a x : + 4972-22-599-185.
REINFORCED PLASTICS DECEMBER 1992
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Mitras is now producing this electrical cabinet from SMC containing recycled material. The characteristic marbled surface is said to degrade less quickly than virgin SMC.
1
I I Recycling in evidence at Mitras Parts made from recycled sheet moulding compound (SMC) w e r e m u c h in evid e n c e on t h e Mitras stand. The G e r m a n m o u l d e r is a m e m b e r of t h e E r c o m recycling c o n s o r t i u m . The first c o m m e r c i a l p r o duct, a n electrical cabinet, e n t e r e d p r o d u c t i o n in late October, Roland B a u e r told Reinforced Plastics. Mitras c u r r e n t l y p r o d u c e s s u c h cab i n e t s for a n u m b e r of clients with three or four major customers accounting for s o m e 80% o f p r o d u c t i o n . With the customer's app r o v a l t h e f i r m p l a n s to c o n v e r t m o s t of the c a b i n e t p r o d u c t i o n .to the recyclate c o n t a i n i n g m a t e r i a l in t h e n e x t few years. The costs of p r o d u c i n g t h e recycled cabinet are t h e s a m e as for t h e virgin version. But it weighs 2-3% less t h a n t h e p r e v i o u s m o d e l b e c a u s e the recyclate is lighter t h a n t h e m a t e r i a l it replaces. This h e l p s to red u c e t h e cost as t h e price is
d e p e n d e n t on t h e w e i g h t of t h e m a t e r i a l . The n e w version of t h e c a b i n e t h a s a m a r b l e p a t t e r n e d surface as a result of t h e fibre rich recycling m a t e r i a l . This will a c t u a l l y s h o w less d e g r a d a t i o n t h a n t h e s t a n d a r d surface, says Bauer. In a d d i t i o n to t h e cabinet, Mitras has a number of p r o d u c t s u s i n g recycled m a terial at t h e t e s t stage. This includes a sunroof frame w h i c h will be s u p p l i e d to W e b a s t o a n d u s e d in t h e BMW 3 Series cars. BMW, which last year expressed its r e s e r v a t i o n s a b o u t t h e use of c o m p o s i t e s b e c a u s e of t h e difficulty in recycling t h e m , is said to be h a p p y w i t h t h e p r o d u c t . The f r a m e h a s b e e n t e s t e d to 15 000 cycles, e q u i v a l e n t to t h e c a r ' s lifetime, a n d h a s p e r f o r m e d satisfactorily. Mitras says t h a t it h a s h a d to c h a n g e its p r o d u c t i o n of SMC in o r d e r to i n c o r p o r a t e the recycled material. A means of adding the s h r e d d e d c o m p o s i t e s to t h e SMC h a s h a d to be i n c l u d e d in t h e p r o d u c t i o n line. E v e r y SMC p r o d u c e r will h a v e to m a k e such a n i n v e s t m e n t in the future, says Bauer. Mitras is c o n f i d e n t t h a t it c a n i n c o r p o r a t e u p to 30% recycled m a t e r i a l in new SMC if required. It also says t h a t it can produce parts which h a v e a class A surface w h e n painted. In t h r e e to five y e a r s t h e firm p l a n s to c o n v e r t all its reinforced plastic products to i n c o r p o r a t e recycled m a terials. This is said to be an a i m o f all t h e m o u l d e r s involved in Ercom. T h e r m o s e t s are s t a n d i n g u p to t h e r e c e s s i o n m u c h better than thermoplastics, says Mitras, w h i c h also h a s t h e r m o p l a s t i c activities. This is a c o m m e n t r e p e a t e d by a n u m b e r of t h e c o m p a n i e s Reinforced Plastics s p o k e to.
R o l a n d Bauer, Mitras K u n s t s t o f f e G m b H ; tel: +49-9-61-89-231; fax: + 49-9-61-89-201.
REINFORCED PLASTICS DECEMBER 1992
] ] Jotun continues European expansion Ten y e a r s ago J o t u n Polymer's business was almost exclusively based on the Scandinavian market. Today t h e p o l y e s t e r resins a n d gelc o a t s firm h a s m o r e t h a n 60% of its activities o u t s i d e t h e Nordic region. This is t h e result of h e a v y i n v e s t m e n t d u r i n g t h e 1980s a n d early 1990s, in p a r t i c u l a r this year. H a n s P e t e r A r n e s t a d told Reinforced Plastics t h a t this l a t e s t effort h a s b e e n focused on E a s t e r n E u r o p e . J o t u n now has distributors and stockists in E s t o n i a a n d Poland, a n d is looking to set u p a s i m i l a r a r r a n g e m e n t in t h e St P e t e r s b u r g area. Following a e x t e n s i v e exp l o r a t i o n of t h e possibilities on the Czech m a r k e t , a 5 0 / 5 0 cooperation agreement has been entered into with Czech c o m p a n y Spolek. Spolek a l r e a d y p r o d u c e s u n s a t u r a t e d p o l y e s t e r resins to its own f o r m u l a t i o n s , as p a r t of t h e n e w a g r e e m e n t it will also h a v e a toll m a n u f a c t u r ing a g r e e m e n t w i t h J o t u n . E x i s t i n g c a p a c i t y is 15 00020 000 t o n n e s a y e a r of resins. No gel-coat is produced at the moment a l t h o u g h A r n e s t a d says t h a t it will be in t h e future. The agreement means that Jotun n o w h a s s o m e 60 000 t o n n e s of p o l y e s t e r p r o d u c t i o n cap a c i t y in E u r o p e . A sales c o m p a n y , Jospol, h a s b e e n e s t a b l i s h e d to attend to the sale of the a s s o r t m e n t of p r o d u c t s f r o m J o t u n a n d Spolek. In I t a l y J o t u n t o o k full control of J o t u n Itoc SpA. It a l r e a d y o w n e d 50% of t h e 15 000 t o n n e p o l y e s t e r fact o r y built w i t h its d i s t r i b u t o r J o t u n Itoc in 1988. J o t u n h a s now secured for itself a wholly owned production p l a n t in Italy, w h i c h it says is t h e l a r g e s t m a r k e t for unsaturated p o l y e s t e r in Europe. O t h e r d e v e l o p m e n t s in-
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clude t h e e s t a b l i s h m e n t of J o t u n P o l y m e r F r a n c e SA January and Jotun Polymer (UK) L t d ' s a c q u i s i t i o n of I n t e r n a t i o n a l P a i n t ' s polyes t e r a n d gel-coat p r o d u c t i o n . A r n e s t a d says t h a t J o t u n is c u r r e n t l y in f o u r t h p l a c e in the European polyester market, b u t is t h e m a r k e t l e a d e r in gel-coat. The n e w gel-coat f a c t o r y in M i t c h a m , UK, is d u e to c o m e o n - s t r e a m in late 1993. This is b e i n g built as a r e s u l t of t h e I n t e r n a tional P a i n t acquisition. Southern France, Spain a n d P o r t u g a l offer possibilities for J o t u n to c o n t i n u e its European expansion, says Arnestad. Alternatively the firm m a y look at t h e Middle or F a r E a s t e r n m a r k e t . J o t u n believes it c a n offer t e c h n i c a l i m p r o v e m e n t s to m o u l d e r s in t h e Middle East, a n d not just compete with existing s u p p l i e r s on price. T h e f i r m s a y s t h a t its growth p r o g r a m m e d o e s not include the acquisition of d o w n s t r e a m c o m p a n i e s . It wishes to r e m a i n as p u r e l y a resin p r o d u c e r . In 1991 J o t u n ' s p o l y m e r c o m p a n i e s h a d a t u r n o v e r of NOR616 million compared w i t h N O K 7 0 3 m i l l i o n in 1990.
Hans Peter Arnestad, Jotun Polymer; tel: +47-3461-000; f a x : + 47-34-64 614.
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Worms GMT plant sold
The glass m a t t h e r m o p l a s tic (GMT) fabrication b u s i n e s s m Worms. Germ a n y , o p e r a t e d by BASF's E l a s t o g r a n subsidiary, h a s b e e n sold. T h e p u r c h a s e r is R S c h l i n g - G r u p p e a Germ a n i n d u s t r i a l group. The sale w a s c o n c l u d e d on 1 October. BASF announced its i n t e n t i o n to sell t h e p l a n t earlier in t h e year. Saying t h a t it did n o t fit in w i t h i t s a c t i v i t i e s as a r a w materials producer.
Seat shells made from glass mat reinforced polypropylene.
1
GMT finds n e w applications
cers in E u r o p e are BASF a n d Symalit. BASF h a s a p r o d u c tion c a p a c i t y of a b o u t 10 000 t o n n e s at p r e s e n t a n d could m a k e 2000-5000 t o n n e s in a s e c o n d line, if required.
All noise shields in BMW, M e r c e d e s a n d Audi c a r s are n o w m a d e f r o m glass m a t t h e r m o p l a s t i c (GMT) m a t e Hans-Hubert Wald, Reacrial, including BASF's Elas- tive Resins Business Unit, topreg. BASF AG; tel: + 49-621-60GMT is also b e g i n n i n g to 4-24-03; foot: + 49-621-60-2be u s e d for d a s h b o a r d s , says 16-#7. H a n s - H u b e r t Wald of BASK The d a s h b o a r d on the Merc e d e s S class c a r is m a d e f r o m it a n d t h e m a t e r i a l is Low Cost - High Quality - Fast Delivery s c h e d u l e d to go into a new • Filament Winding Machines M e r c e d e s model. The firm is • Fiber Placement Machines w o r k i n g w i t h o t h e r c a r pro• Gantry Robots For Routing & Cutting d u c e r s to d e v e l o p s i m i l a r • Pultrusion Machines applications and believes • Resin Baths, Rollers & Creels t h a t d a s h b o a r d s a r e one of • Tensioner.,; & Takeup Systems t h e m o s t p r o m i s i n g growth • Resin Mixing Systems a r e a s for GMT. R e a r s e a t b a c k s are an• Tape Wrapping Machines other growing application. • Extractors, Saws, Grinders & Threaders All Audi 80 a n d 90 m o d e l s • Curing Ovens, Mandrels & Tooling f e a t u r e GMT s e a t b a c k s a n d • Control Systems & Application Software an e s t a t e version of the Audi • Custom Machinery & Turn-Key Systems 100 will also use it. • Winding Machine Retrofits And Rebuilds B u m p e r s in t h e Mercedes S class are also GMT, in this New Modular Filament Winding System case i n c o r p o r a t i n g 45% glass • 5, 10 & 20 Spindle Production Winders for a b o u t h a l f of which is uniGolf Shafts, Ski Poles and Baseball Bats directional. Wald e s t i m a t e s t h a t t h e • Multiple Spindle Winders for CNG Tanks c u r r e n t E u r o p e a n m a r k e t for • Low Cost Winders for University Laboratories GMT is a b o u t 15 000 tonnes. • 6 Axis Winders for Aerospace Applications BASF r e g a r d s itself as t h e All Models Computer Controlled, High Speed Winders m a r k e t l e a d e r in E u r o p e , he says. G r o w t h in t h e n e x t t h r e e y e a r s is difficult to a n t i c i p a t e b u t BASF e x p e c t s a f u r t h e r positive development. C u r r e n t l y t h e m a i n produ-
REINFORCEDPLASTICS DECEMBER1992
KREPORTS l
Recycling dominates at K92 The K92 p l a s t i c s s h o w in D i i s s e l d o r f w a s d o m i n a t e d by the recycling t h e m e - c o m p o s i t e s w e r e no e x c e p t i o n . M o s t o f the major m o u l d e r s s h o w e d parts from recycled materials. Resin producers e m p h a s i z e d their i n v o l v e m e n t and, in many cases, claimed that t h e y w e r e n o t l a u n c h i n g n e w p r o d u c t s b e c a u s e all the m o n e y had g o n e into d e v e l o p i n g recycling s o l u t i o n s . A m a n d a Weaver reports on the activites o f s o m e o f the materials and parts producers, further reports will appear in the January 1993 issue.
1
Phenolic GRP u s e d for Cray Valley technical centre
A new development and t e c h n i c a l service c e n t r e w a s opened at Cray Valley's polyester production plant at Drocourt, France, in late October. The c e n t r e a c c o m m o d a t e s all of t h e l a b o r a t o r i e s involved in r e s e a r c h a n d applications for the group's s t r u c t u r a l resins s e g m e n t . It is d e s i g n e d to o p e r a t e intern a t i o n a l l y , in c o n j u n c t i o n w i t h t h e firm's o t h e r p r o d u c tion sites in E u r o p e a n d t h e USA. The building was converted from an existing s t r u c t u r e using r e s i n - b a s e d m a t e r i a l s m a n u f a c t u r e d by the Drocourt plant. These include phenolic cladding p a n e l s b a s e d on N o r s o p h e n resins, a n d s y n t h e t i c m a r b l e b a s e d o n N o r s o d y n e isop h t h a l i c p o l y e s t e r resins. The corrugated panels u s e d on t h e roofs a n d s o m e of t h e walls are F i b r a p h e n s h e e t s m a d e by Fibres du Hainaut. They comprise a
{
The technical centre and Cray Valley's Drocourt plant has been reconstructed using glass reinforced phenolic panels. l a m i n a t e of p h e n o l i c resin a n d g l a s s f i b r e s 1-2 m m thick, c o a t e d on b o t h sides w i t h a 250 p m layer of selfe x t i n g u i s h i n g p o l y e s t e r gelcoat. The p a n e l s are classified as M1 fire r e t a r d a n t by t h e c e n t r a l l a b o r a t o r i e s of police h e a d q u a r t e r s . The p a n e l s u s e d to m a k e t h e f a c a d e a r e d o u b l e faced glass reinforced p h e n o l i c p a nels with a polyurethane i n s u l a t i n g core. The p a n e l s u s e d in t h e m u l t i - s t o r e y section of t h e building m e a s u r e 2.85 x 3.10 m a n d t h o s e u s e d
REINFORCEDPLASTICS DECEMBER1992
in t h e single-storey section a r e 3.04 x 3.48 m, b o t h i n c o r p o r a t e s p a c e s for two windows. F i n i s h e d w e i g h t of a p a n e l is a r o u n d 60 kg. All interior and exterior decorative f e a t u r e s a r e i n c o r p o rated in the moulded panels. The f a c a d e c l a d d i n g w a s m o u l d e d by Stratiform. Initially h a n d lay-up techniq u e s w e r e used, b u t o n c e production was underway the panels were produced by resin t r a n s f e r m o u l d i n g (RTM). This allows a p a n e l to be produced in j u s t
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3 hours. T h e c l a d d i n g p a n e l s are also c o a t e d w i t h a polyes t e r gel-coat, it will be at least l0 years before any r e p a i n t i n g is r e q u i r e d says C r a y Valley. The r e n o v a t i o n , r e p r e s e n t ing an overall i n v e s t m e n t of a b o u t FF25 million, is p a r t of a large-scale m o d e r n i z a t i o n of t h e D r o c o u r t plant. In a d d i t i o n to t h e r e h a b i -
Cray Valley to produce Premix compounds F r e n c h p o l y e s t e r resin prod u c e r C r a y Valley is to m a k e thermoset moulding comp o u n d s u n d e r license f r o m P r e m i x Inc of t h e USA. The c o m p o u n d s , k n o w n as Prem i g l a s , P r e m i J e c t , TMC, Lytex a n d QC, will be m a d e at C r a y V a l l e y ' s D r o c o u r t p l a n t a n d sold t h r o u g h o u t Europe. C r a y Valley, a s u b s i d i a r y of t h e oil c o m p a n y Total, previously m a d e its own b r a n d of b u l k m o u l d i n g c o m p o u n d (BMC) called N o r s o m i x , this will be r e p l a c e d by t h e Prem i x grades. P r o d u c t i o n in a newly, h i g h l y a u t o m a t e d , c o m p o u n d p l a n t will begin early in 1993. Both p a r t n e r s h o p e t h a t the a g r e e m e n t will e n h a n c e t h e overall d e v e l o p m e n t of
litation of t h e t e c h n i c a l centre the plan includes c o n s t r u c t i o n of a p r o d u c t i o n u n i t for p h e n o l i c resins u s e d for c o m p o s i t e m a t e r i a l s a n d a polyester moulding comp o u n d s unit, a n d t h e a u t o marion of the polyester resins o p e r a t i o n s . D r o c o u r t c u r r e n t l y h a s an annual production capacity of 6000 t o n n e s THP ( t e t r a
hydro phthalique anhydride), 12 5 0 0 t o n n e s m a l e i c a n h y d r i d e , 60 000 tonnes unsaturated polyester, 5000 t o n n e s p h e n o l i c resin, a n d 7000 t o n n e s of m o u l d i n g c o m p o u n d - - rising to 10 000 t o n n e s by t h e e n d of 1993.
thermoset composites m o u l d i n g s as well as reinforcing t h e c o m p a n i e s ' m a r k e t positions. O t h e r p r o d u c e r s of polyester resins have expressed concern that Cray Valley's m o v e will bring it directly into competition w i t h its c u s t o m e r s .
cover, w h i c h w a s o n e of t h e f i r s t c o m m e r c i a l p a r t s to c o n t a i n recycled s h e e t a n d bulk moulding compound (SMC/BMC), will be u s e d in a n e w m o d e l o f t h e car. I n t e r e s t i n g l y t h e decision to use a c o m p o s i t e m a t e r i a l for this p a r t w a s m a d e before t h e recycling ,.solution w a s d e v e l o p e d . The s p a r e w h e e l c o v e r c o n t a i n s 15% recycled material. Mitras has developed a sun r o o f f r a m e for W e b a s t o w h i c h will be u s e d in a r a n g e of cars, including BMWs, a n d p a r t s a r e b e i n g m a d e for a Telekom telephone booth. The f r o n t e n d of t h e new ~vV P a s s a t in being m o u l d e d inh o u s e by VW at its Wolfsburg p l a n t using a m a t e r i a l develo p e d by Menzolit. This conrains Ercom recyclate and w h e n p a i n t e d h a s a class A surface. K e l d e r m a n says t h a t German automotive companies are n o w looking to E r c o m to help them recycle repair p a r t s . A s i m i l a r s i t u a t i o n is d e v e l o p i n g in F r a n c e , h e claims, w h e r e landfill prices a r e e x p e c t e d to i n c r e a s e 25% a y e a r until 1995/96 w h e n t h e cost of landfill will be s a m e as c h e m i c a l p r o c e s s i n g of waste. French a u t o m o t i v e c o m p a n i e s are a l r e a d y exp r e s s i n g i n t e r e s t in t h e Valcor composites recycling s c h e m e - - a c o n t r a s t to G e r m a n y w h e r e t h e SMC m o u l d e r s t o o k t h e initiative.
Cray Valley Total; tel: + 3 3 - 1 - 4 2 - 9 1 - 3 4 - 71; .fax: + 33-1-42-91-34-68.
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Recycled part in class A application
An i m p r e s s i v e a r r a y of p a r t s c o n t a i n i n g recycled c o m p o sites p r o c e s s e d by G e r m a n v e n t u r e E r c o m , w a s on disp l a y a t K92, i n c l u d i n g a class A a u t o m o t i v e part. H a n s K e l d e r m a n of DSM, a s p o k e s m a n for Ercom, told us t h a t t h e Audi s p a r e wheel
The VW Passat front-end is moulded using recyclate containing material from Menzolit. A class A finish is obtained after painting.
Cray Valley; tel: + 3 3 142-91-68-68; .fax: +33-147-76-07-18.
Dr Peter Schaefer, Erco~t c/o B W R Bizerba; tel: + 4972-22-599-134; f a x : + 4972-22-599-185.
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Mitras is now producing this electrical cabinet from SMC containing recycled material. The characteristic marbled surface is said to degrade less quickly than virgin SMC.
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I I Recycling in evidence at Mitras Parts made from recycled sheet moulding compound (SMC) w e r e m u c h in evid e n c e on t h e Mitras stand. The G e r m a n m o u l d e r is a m e m b e r of t h e E r c o m recycling c o n s o r t i u m . The first c o m m e r c i a l p r o duct, a n electrical cabinet, e n t e r e d p r o d u c t i o n in late October, Roland B a u e r told Reinforced Plastics. Mitras c u r r e n t l y p r o d u c e s s u c h cab i n e t s for a n u m b e r of clients with three or four major customers accounting for s o m e 80% o f p r o d u c t i o n . With the customer's app r o v a l t h e f i r m p l a n s to c o n v e r t m o s t of the c a b i n e t p r o d u c t i o n .to the recyclate c o n t a i n i n g m a t e r i a l in t h e n e x t few years. The costs of p r o d u c i n g t h e recycled cabinet are t h e s a m e as for t h e virgin version. But it weighs 2-3% less t h a n t h e p r e v i o u s m o d e l b e c a u s e the recyclate is lighter t h a n t h e m a t e r i a l it replaces. This h e l p s to red u c e t h e cost as t h e price is
d e p e n d e n t on t h e w e i g h t of t h e m a t e r i a l . The n e w version of t h e c a b i n e t h a s a m a r b l e p a t t e r n e d surface as a result of t h e fibre rich recycling m a t e r i a l . This will a c t u a l l y s h o w less d e g r a d a t i o n t h a n t h e s t a n d a r d surface, says Bauer. In a d d i t i o n to t h e cabinet, Mitras has a number of p r o d u c t s u s i n g recycled m a terial at t h e t e s t stage. This includes a sunroof frame w h i c h will be s u p p l i e d to W e b a s t o a n d u s e d in t h e BMW 3 Series cars. BMW, which last year expressed its r e s e r v a t i o n s a b o u t t h e use of c o m p o s i t e s b e c a u s e of t h e difficulty in recycling t h e m , is said to be h a p p y w i t h t h e p r o d u c t . The f r a m e h a s b e e n t e s t e d to 15 000 cycles, e q u i v a l e n t to t h e c a r ' s lifetime, a n d h a s p e r f o r m e d satisfactorily. Mitras says t h a t it h a s h a d to c h a n g e its p r o d u c t i o n of SMC in o r d e r to i n c o r p o r a t e the recycled material. A means of adding the s h r e d d e d c o m p o s i t e s to t h e SMC h a s h a d to be i n c l u d e d in t h e p r o d u c t i o n line. E v e r y SMC p r o d u c e r will h a v e to m a k e such a n i n v e s t m e n t in the future, says Bauer. Mitras is c o n f i d e n t t h a t it c a n i n c o r p o r a t e u p to 30% recycled m a t e r i a l in new SMC if required. It also says t h a t it can produce parts which h a v e a class A surface w h e n painted. In t h r e e to five y e a r s t h e firm p l a n s to c o n v e r t all its reinforced plastic products to i n c o r p o r a t e recycled m a terials. This is said to be an a i m o f all t h e m o u l d e r s involved in Ercom. T h e r m o s e t s are s t a n d i n g u p to t h e r e c e s s i o n m u c h better than thermoplastics, says Mitras, w h i c h also h a s t h e r m o p l a s t i c activities. This is a c o m m e n t r e p e a t e d by a n u m b e r of t h e c o m p a n i e s Reinforced Plastics s p o k e to.
R o l a n d Bauer, Mitras K u n s t s t o f f e G m b H ; tel: +49-9-61-89-231; fax: + 49-9-61-89-201.
REINFORCED PLASTICS DECEMBER 1992
] ] Jotun continues European expansion Ten y e a r s ago J o t u n Polymer's business was almost exclusively based on the Scandinavian market. Today t h e p o l y e s t e r resins a n d gelc o a t s firm h a s m o r e t h a n 60% of its activities o u t s i d e t h e Nordic region. This is t h e result of h e a v y i n v e s t m e n t d u r i n g t h e 1980s a n d early 1990s, in p a r t i c u l a r this year. H a n s P e t e r A r n e s t a d told Reinforced Plastics t h a t this l a t e s t effort h a s b e e n focused on E a s t e r n E u r o p e . J o t u n now has distributors and stockists in E s t o n i a a n d Poland, a n d is looking to set u p a s i m i l a r a r r a n g e m e n t in t h e St P e t e r s b u r g area. Following a e x t e n s i v e exp l o r a t i o n of t h e possibilities on the Czech m a r k e t , a 5 0 / 5 0 cooperation agreement has been entered into with Czech c o m p a n y Spolek. Spolek a l r e a d y p r o d u c e s u n s a t u r a t e d p o l y e s t e r resins to its own f o r m u l a t i o n s , as p a r t of t h e n e w a g r e e m e n t it will also h a v e a toll m a n u f a c t u r ing a g r e e m e n t w i t h J o t u n . E x i s t i n g c a p a c i t y is 15 00020 000 t o n n e s a y e a r of resins. No gel-coat is produced at the moment a l t h o u g h A r n e s t a d says t h a t it will be in t h e future. The agreement means that Jotun n o w h a s s o m e 60 000 t o n n e s of p o l y e s t e r p r o d u c t i o n cap a c i t y in E u r o p e . A sales c o m p a n y , Jospol, h a s b e e n e s t a b l i s h e d to attend to the sale of the a s s o r t m e n t of p r o d u c t s f r o m J o t u n a n d Spolek. In I t a l y J o t u n t o o k full control of J o t u n Itoc SpA. It a l r e a d y o w n e d 50% of t h e 15 000 t o n n e p o l y e s t e r fact o r y built w i t h its d i s t r i b u t o r J o t u n Itoc in 1988. J o t u n h a s now secured for itself a wholly owned production p l a n t in Italy, w h i c h it says is t h e l a r g e s t m a r k e t for unsaturated p o l y e s t e r in Europe. O t h e r d e v e l o p m e n t s in-
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clude t h e e s t a b l i s h m e n t of J o t u n P o l y m e r F r a n c e SA January and Jotun Polymer (UK) L t d ' s a c q u i s i t i o n of I n t e r n a t i o n a l P a i n t ' s polyes t e r a n d gel-coat p r o d u c t i o n . A r n e s t a d says t h a t J o t u n is c u r r e n t l y in f o u r t h p l a c e in the European polyester market, b u t is t h e m a r k e t l e a d e r in gel-coat. The n e w gel-coat f a c t o r y in M i t c h a m , UK, is d u e to c o m e o n - s t r e a m in late 1993. This is b e i n g built as a r e s u l t of t h e I n t e r n a tional P a i n t acquisition. Southern France, Spain a n d P o r t u g a l offer possibilities for J o t u n to c o n t i n u e its European expansion, says Arnestad. Alternatively the firm m a y look at t h e Middle or F a r E a s t e r n m a r k e t . J o t u n believes it c a n offer t e c h n i c a l i m p r o v e m e n t s to m o u l d e r s in t h e Middle East, a n d not just compete with existing s u p p l i e r s on price. T h e f i r m s a y s t h a t its growth p r o g r a m m e d o e s not include the acquisition of d o w n s t r e a m c o m p a n i e s . It wishes to r e m a i n as p u r e l y a resin p r o d u c e r . In 1991 J o t u n ' s p o l y m e r c o m p a n i e s h a d a t u r n o v e r of NOR616 million compared w i t h N O K 7 0 3 m i l l i o n in 1990.
Hans Peter Arnestad, Jotun Polymer; tel: +47-3461-000; f a x : + 47-34-64 614.
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Worms GMT plant sold
The glass m a t t h e r m o p l a s tic (GMT) fabrication b u s i n e s s m Worms. Germ a n y , o p e r a t e d by BASF's E l a s t o g r a n subsidiary, h a s b e e n sold. T h e p u r c h a s e r is R S c h l i n g - G r u p p e a Germ a n i n d u s t r i a l group. The sale w a s c o n c l u d e d on 1 October. BASF announced its i n t e n t i o n to sell t h e p l a n t earlier in t h e year. Saying t h a t it did n o t fit in w i t h i t s a c t i v i t i e s as a r a w materials producer.
Seat shells made from glass mat reinforced polypropylene.
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GMT finds n e w applications
cers in E u r o p e are BASF a n d Symalit. BASF h a s a p r o d u c tion c a p a c i t y of a b o u t 10 000 t o n n e s at p r e s e n t a n d could m a k e 2000-5000 t o n n e s in a s e c o n d line, if required.
All noise shields in BMW, M e r c e d e s a n d Audi c a r s are n o w m a d e f r o m glass m a t t h e r m o p l a s t i c (GMT) m a t e Hans-Hubert Wald, Reacrial, including BASF's Elas- tive Resins Business Unit, topreg. BASF AG; tel: + 49-621-60GMT is also b e g i n n i n g to 4-24-03; foot: + 49-621-60-2be u s e d for d a s h b o a r d s , says 16-#7. H a n s - H u b e r t Wald of BASK The d a s h b o a r d on the Merc e d e s S class c a r is m a d e f r o m it a n d t h e m a t e r i a l is Low Cost - High Quality - Fast Delivery s c h e d u l e d to go into a new • Filament Winding Machines M e r c e d e s model. The firm is • Fiber Placement Machines w o r k i n g w i t h o t h e r c a r pro• Gantry Robots For Routing & Cutting d u c e r s to d e v e l o p s i m i l a r • Pultrusion Machines applications and believes • Resin Baths, Rollers & Creels t h a t d a s h b o a r d s a r e one of • Tensioner.,; & Takeup Systems t h e m o s t p r o m i s i n g growth • Resin Mixing Systems a r e a s for GMT. R e a r s e a t b a c k s are an• Tape Wrapping Machines other growing application. • Extractors, Saws, Grinders & Threaders All Audi 80 a n d 90 m o d e l s • Curing Ovens, Mandrels & Tooling f e a t u r e GMT s e a t b a c k s a n d • Control Systems & Application Software an e s t a t e version of the Audi • Custom Machinery & Turn-Key Systems 100 will also use it. • Winding Machine Retrofits And Rebuilds B u m p e r s in t h e Mercedes S class are also GMT, in this New Modular Filament Winding System case i n c o r p o r a t i n g 45% glass • 5, 10 & 20 Spindle Production Winders for a b o u t h a l f of which is uniGolf Shafts, Ski Poles and Baseball Bats directional. Wald e s t i m a t e s t h a t t h e • Multiple Spindle Winders for CNG Tanks c u r r e n t E u r o p e a n m a r k e t for • Low Cost Winders for University Laboratories GMT is a b o u t 15 000 tonnes. • 6 Axis Winders for Aerospace Applications BASF r e g a r d s itself as t h e All Models Computer Controlled, High Speed Winders m a r k e t l e a d e r in E u r o p e , he says. G r o w t h in t h e n e x t t h r e e y e a r s is difficult to a n t i c i p a t e b u t BASF e x p e c t s a f u r t h e r positive development. C u r r e n t l y t h e m a i n produ-
REINFORCEDPLASTICS DECEMBER1992