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Made in Germany – do not copy?

Made in Germany – a trademark that manufacturers of German quality goods are naturally proud of and often use it as a marketing tool especially for sales to emerging markets. Initially, it was meant the other way round when the British government enforced “The Merchandise Act”, in 1887 to oblige every product to have a mark of origin to prevent possible low quality products and imitations to enter the domestic market – a boomerang as we now know.

Protection of intellectual property, and acting according to patent laws is highly demanded by manufacturers in Western economies, especially from countries in the emerging markets of Asia. The history of patents, by the way, is quite interesting.

From the early 13th century onwards, British kings issued so-called “letter patent” – these were open letters starting mainly with the words “To whom this is shown...”. This provided secured rights and privileges to run a certain business and prevent others from entering the business. It was an initiative to attract foreign experts and their know-how to come to England. Naturally, the apprentices and workers of these expert ex-pats profited from the knowledge and craftsmanship of their masters. Nowadays, one would call it “technology transfer” to boost and develop the local economy.

Copying and then developing is the most natural way of human learning. Babies for example learn their language by copying their parent’s sounds so that initially senseless burbling leads to the skilful use of comprehensible words.

Didn’t we in Europe, nowadays sitting on the noble horse of technology leadership, also copy and learn from others in former times? For example, let’s have a look at the pathmaker of the information society who in 1998 was elected by US journalists as the “Man of the Millennium” – the most important person of the second millennium.

You think that I am talking about Bill Gates or Steven Jobs? No, I am talking about Johannes Gensfleisch, better known as Johannes Gutenberg, the inventor of modern book printing using movable characters. He really was? ...the inventor? or did he copy this technology and develop it further?

As early as 1040 – 1048 AD a Chinese called Pi Cheng was reported to be printing using movable characters. Because of the quantity of Chinese characters this undertaking was not very successful. Coincidentally, Pi Cheng was also a coin maker and a metalsmith just as Gutenberg was a goldsmith. Some 200 years after Pi Cheng, 50 books entitled Sangdchon Jemun (“Moral Guidelines”) were printed in Korea using movable metal characters. Various sources imply that this knowledge found its way along the Silk Road to Constantinople where it was possibly acquired by Johannes von Kues, a delegate of the Papal Council or, by one of his bibliophile friends, such as Basilius Bessarion. An important station in von Kues’ journey through Germany in 1450 – 1452 was Mainz, where a man called Gensfleisch borrowed 1,600 gulden from the business man Johannes Fust to build a printing house. It is entirely possible that von Kues could have known Gensfleisch, from his time as a lawyer in Mainz 1425, since both men were of the same age. The famous Gutenberg Bible dates from 1454.

Just a coincidence or copying know-how and developing technology to make copying easier? Truly a man of the millennium.

The only question for me now is, will there be a trademark in future that says “Made in China” – do not copy?

Meanwhile, I hope you enjoy this original of the International PU Magazine Kind regards Frank A Gupta

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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News Page.6

No. 1 · FeBruary/MarcH 2011

CONTENT

In.person: C..McKendrick Page.16

Editorial................................................................................................ 3 News.

Industry.news..................................................................................... 6 Technology.and.product.news. .............................................................. 10 People........................................................................................... 12 Events........................................................................................... 13 In person:

Colin.McKendrick,.Global.General.Manager,.PO.–.Shell.Chemicals...........16 PU.TECH.2011.Preview........................................................................ 18 Preview Page.18

Wanhua.acquires.full.control.of.BorsodChem........................................ 30 Chinaplas.2011.celebrating.its.25th.edition........................................... 31 Sonderhoff.with.new.activities.in.India,.Israel,.and.Australia.................. 32 The.global.PU.industry.returns.to.growth.in.2010,.. but.challenges.remain......................................................................... 33 German.efficiency.generates.growth......................................................40 Pumping.and.measuring.high-viscosity.PU.components..........................44 Hennecke.invests.in.customer.centre.. for.high-volume.RTM.applications...........................................................45 Cannon.Viking.–.evolving.and.improving.. the.world’s.flexible.PU.foam.industry......................................................46 IAC.Group.chooses.KraussMaffei.as.system.supplier.. for.new.plant.in.Romania........................................................................48

Cannon.Viking.–.evolving.and. improving.the.world’s...

Page.46

Vehicle.underbody.structure.with. lightweight.PU.composite Page.61

B. W. Naber, G. Behrendt

Recycling.flexible.foam.PUR.–.part.1......................................................50 Russia.as.market.for.plastics.and.rubber.machinery..............................54 I. Sendijarevic, J. G. Harris, S. Hoffmann, S. Heric, N. Lathia, V. Sendijarevic

Polyether.polyols.from.scrap.polyurethanes.–.. for.use.in.rigid.and.flexible.foams..........................................................55 Vehicle.underbody.structure.with.lightweight.PU.composite....................61 Suppliers.list....................................................................................... 62 Publication.information.&.contacts....................................................... 66

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PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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Obituary for Hans Hinte During the night of the 9th to the 10 th December 2010, Hans Hinte, the head of our layout department, died suddenly at the age of 59.

After studying at a public school, Hans Hinte pursued the career path of a typesetter. After his appointment as master he worked in several printing houses and Hans Hinte

started, after a short spell as a freelancer, his work in our publishing house in 2000.

As head of the layout department and as a production manager, he crucially shaped the graphic appearance of our journals and books with his ideas, his rich experience and creativity and took care of meeting deadlines with caution and foresight. With particular dedication he devoted himself to the training of apprentices.

He was not only an amiable and friendly colleague, but also an important member of our “publishing house family” and a true friend. His sudden death has deeply disturbed us all. He will always remain in our memory.

Hans Hinte leaves a wife and a grown son.

The staff of Dr. Gupta Verlag

Industry news Bayer to expand capacities in China Bayer intends to significantly expand its capacities in China by 2016. Investments of around EUR 1 billion are earmarked for five separate projects at the Shanghai Chemical Industry Park: · For polycarbonate, a new facility is scheduled to be built with a capacity of 200,000 t/y. In addition, it is planned to increase the capacity of the existing plant by 100,000 to 300,000 t/y. · In addition, Bayer wants to more than double its MDI capacities for the production of

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PU rigid foam to 1 million t/y.

To this end, it plans to build a new MDI plant with a capacity of 500,000 t/y. At the same time, the company also intends to expand its present MDI plant from 350,000 to 500,000 t/y. · The expansion of the existing HDI production as well as the construction of a further 50,000 t/y HDI production facility are also planned. · Furthermore, Bayer MaterialScience (BMS) will invest EUR 110 million to build three PU systems houses in Shang-

hai, Qingdao, and Chongqing, a new polycarbonate sheet facility in Guangzhou, and a polycarbonate colour compounding and design centre in Chongqing. · The company also intends to significantly strengthen its research and development activities in China by expanding its R&D centre for polymers in Shanghai.

Moreover, Shanghai will become the new headquarters of the global polycarbonate activities of BMS. The headquarters of the Polycarbonates Business Unit will be relocated from the main Leverkusen site to Shanghai. The

management team will also move there. The relocation has started at the beginning of 2011.

Bayer wants to increase its sales in China to around EUR 5 billion by 2015. BMS is expected to contribute at least half of this amount.

In 2009, Bayer recorded sales of EUR 2.1 billion in China, of which EUR 1.2 billion was accounted for

by BMS. In terms of sales, China is the second most important country in the world for BMS. It is already investing EUR 2.1 billion in Shanghai as part of a long-term project lasting until 2012. Together with the now announced expansions, this means a total investment of more than EUR 3 billion.

Proseat to close Belgian plant in Hulshout The Proseat Group, a joint venture of Recticel (51 %) and Woodbridge (49 %), intends to close its Belgian plant in Hulshout.

153 personnel are employed at the facility. According to Proseat, in recent years the cold-moulded foam production plant, which manufactures foam cushions for cars, has borne the full impact of the crisis in the automotive sector. For several years now, even more car manufacturers and car

seat manufacturers have decided to produce foam cushions themselves. Moreover, General Motors in Antwerp has closed its doors and Ford in Genk has put its entire production of car seats, including the production of foam cushions, into the hands of Lear Corporation. Efforts to attract production volumes to Hulshout from Ford in Cologne and Toyota Boshoku in Valenciennes among others were not successful.

Proseat is one of the European market leaders in the production of moulded foam cushions for the auto industry. The company operates eight sites in Europe (located in Belgium, Germany, France, Poland, Spain, the Czech Republic and the UK) and employs around 2,100 people. The company says it has a market share of 22 % and each year 4 million cars are produced containing its components. In 2010, the total turnover of Proseat amounted to EUR 233 million. The turnover of the Hulshout plant amounted to EUR 17 million last year.

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PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Perstorp purchases Ashland’s Penta business Perstorp Polyols Inc. has signed an agreement with Hercules Incorporated, a subsidiary of Ashland Inc., for the acquisition of its pentaerythritol (Penta) business, related technology, and certain assets. It does not include the manufacturing plant in Louisiana, MO, USA, any real estate or employees. The acquisition is expected to be

completed by early March. The purchase price was not disclosed. Perstorp is now producing the polyalcohol Penta in three different production plants in Germany, the USA, and Sweden. For Perstorp the acquisition is part of an investment campaign to increase polyol capacity. Investments will mainly take place in the company’s US facility.

3M acquires Nida-Core 3M has acquired the business of Nida-Core Corp. based in Port St. Lucie, FL, USA. The company’s portfolio of high-strength, low-weight engineered materials provides solutions in general industrial markets, including transportation, marine, and renewable energy. Offerings include a variety of structural honeycombcored and foam-cored products in either pre-cut or standard sizes, closed-moulding cores including NidaFusion, composite panels, kiln-dried end-grain balsa, as well as a variety of curing compounds and accessories common to the composites market.

The company’s foam production facilities include fully automated

computer numerically controlled equipment available with up to 150 lb/min capacity. It operates, for example, a Cannon dispensing machine, several Femco and Edge-Sweets foam block machining units, as well as a 62” wide belt sander and associated support equipment for quality polyurethane foam products. The company employs about 25 people. The deal also includes the acquisition by 3M of the business of Structiso Sarl, a company affiliated with Nida-Core. Structiso is located in Aniche, France, and operates with a workforce of three people. Financial terms were not disclosed.

Evonik and GACL to cooperate in India Evonik Industries and the Indian chemical company Gujarat Alkalies and Chemicals Limited (GACL) are planning a new multimillion project. Core elements are the construction of a new hydrogen peroxide production plant by Evonik and a propylene oxide facility by GACL. The aim is to produce propylene oxide using the HPPO (hydrogen peroxide to propylene oxide) process devel-

oped jointly by Evonik and Uhde.

Evonik and GACL have signed a Memorandum of Understanding on the proposed project in Dahej in the state of Gujarat, India.

GACL intends to acquire a license for the HPPO process to produce propylene oxide. Evonik will produce and supply the hydrogen peroxide required for the planned new propylene plant at an adjacent facility.

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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The model for this alliance in India is the world’s first industrialscale HPPO production facility.

This plant was started up in 2008

by the Korean company SKC in Ulsan, Korea, and has a capacity of 100,000 t/y.

Evonik to increase isophorone capacities Evonik Industries intends to construct a new world-scale production plant for isophorone and isophorone diamine. Production is scheduled to start in 2013. A suitable site is being sought, particularly in Southeast Asia and China.

The company currently has production sites in Herne and Marl, Germany, in Antwerp, Belgium, as well as in Mobile, AL, USA. According to the company, isophorone chemistry is a core business for Evonik and the market

for isophorone and its derivatives is growing steadily. Evonik says it is the only company in the world to produce and market the entire isophorone line, consisting of isophorone, isophorone diamine, isophorone diisocyanate, and derivatives. These products are used as a component in a range of applications, e. g. in the production of industrial floorings, artificial leather, and paints and coatings as well as in composites.

Lapolla forms strategic alliances Lapolla Industries, Inc., a Houston-based manufacturer and supplier of spray foam insulation, cool roof coatings, and equipment designed to reduce energy consumption, announced two new strategic alliances. The company has formed an alliance with Momentive Performance Materials Inc., an exclusive global licensee of GE sealants and manufacturer of silicone sealants. As part of the alliance, Lapolla will distribute GE silicone roof coatings, a complement to its line of acrylic elastomeric roof coatings. Lapolla says the addition ensures that it has one of the most varied and comprehensive product suites of energy-saving solutions in the residential and commercial markets, for both new construction and retrofit applications.

Douglas Kramer, President and CEO of Lapolla commented, “Now that the roofing market is showing

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strong signs of economic recovery, the Lapolla GE silicone programme is expected to make a significant impact on our potential project opportunities and roofing market sales. Lapolla manufactures acrylic elastomeric roof coatings making GE silicone products an important and complementary line. Lapolla will be aggressively marketing and promoting GE silicone starting this month, utilising print advertisement, trade shows, project specifications and architectural channels. We are very pleased to be associated with this world-class brand and expect to see significant programme progress in 2011 and beyond.”

Furthermore, Lapolla has entered into an exclusive spray foam insulation agreement with EnergyWise Structures to supply existing EnergyWise customers with Lapolla spray foam as well as supplying all Lapolla spray foam

customers, AirTight Insulation customers, and all related market channels with EnergyWise engineering services access. As a NASA spinoff, EnergyWise is a leading thermal engineering firm in the USA. The company uses its proprietary software to build an energy analysis based on each

customer’s building plans, from which it projects heating and cooling costs. From this analysis the company is able to customise a new building plan that includes Lapolla spray foam insulation, caulking, and optimal heating and cooling system sizings.

Increasing demand for Kuraray’s diols The business unit Chemicals of Kuraray Co., Ltd. announced a production record for its unique 3-methyl-1,5-pentanediol (MPD) in 2010 at its Kashima plant in Japan. The company said that this is mainly due to an important capacity expansion by 40 % in the summer of 2010.

MPD is an amorphous diol, suitable for the polyurethane, polyes-

ter, and diacrylate production.

The demand for this chemical is increasing, especially in the fields of PU adhesives, printing inks, and soft TPUs, said the company in a statement.

Kuraray exhibits at European Coatings Show in Nuremberg, Germany (29 – 31 March 2011), hall 9, stand 9-545.

Magna Seating expands in South America Magna Seating, an operating unit of Magna International, has acquired automotive seat supplier Pabsa S.A. The new entity will operate as Magna Seating Argentina. Pabsa, previously part of the L’Equipe Monteur Group, is based in Buenos Aires, Argentina, and is a supplier of complete seats, foam products, trim covers, and seat structures. In 2010, the company recorded sales of about USD 110 million. The acquisition includes two production facilities in Buenos Aires and one in Cordoba, Argentina, as well as about 960 employees.

Furthermore, Magna Seating has taken over automotive seating

supplier Resil Minas of São Joaquim de Bicas, Brazil. In future, the company will operate under the name Magna Seating Brazil. It recorded sales of about USD 174 million in 2009 and is one of the largest suppliers of seat frames and stampings in South America. Automotive customers include Fiat, Ford, GM, VW, Iveco, and PSA. The acquisition includes three manufacturing facilities and about 1,400 employees throughout South America.

In addition, Magna Seating announced the establishment of a manufacturing facility in the São Paulo area in Brazil to produce complete seats for GM and VW.

www.pu-magazine.com PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Arkema to buy Total’s photocure and coatings resins units Arkema intends to acquire Total’s coatings resins and photocure resins businesses for EUR 550 million. The businesses concerned include the coatings resins (paints, adhesives, etc.) of Cray Valley (Europe, Asia, South Africa) and Cook Composite Polymers (USA), as well as the photocure resins (UV and electron-beam curing resins) of Sartomer (Europe, USA, Asia). With sales of about EUR 850 million and almost 1,750 employees, these activities will expand Arkema’s position in the global coat-

ings resins market and will further increase the downstream integration of its acrylics chain. With a wider product range, including emulsions, photocure resins, rheology additives, alkyd resins, powder resins, fluorinated polymers and copolymers, Arkema will become a leading material suppliers to the global coatings market. The deal is expected to close in the first half of 2011.

With operations in more than 40 countries and 14,000 employees, Arkema generates annual revenue of EUR 5.5 billion.

Bodo Möller and BASF extend distribution partnership to Poland Since 1 December 2010, Bodo Möller Chemie Polska sells and distributes the former Ciba pigments and additives of the BASF product portfolio for the lacquer, paint, and plastic industries in Poland. Since 1972 Bodo Möller Chemie was distributing

additives and pigments to the lacquer and plastic industries for Ciba-Geigy and later on for Ciba Spezialitätenchemie. After the integration of Ciba to BASF, this partnership has now been extended.

Univar closes Quaron acquisition On 10 January 2011, Univar, a distributor of industrial and speciality chemicals, has completed the acquisition of the Quaron business in Belgium and the Netherlands. Quaron supplies speciality chemicals in France, Belgium, and the Netherlands. Its logistics network is supported by laboratories, tank and warehouse storage, and mixing facilities. Univar says

the acquisition brings additional added-value services such as storage, diluting, and mixing.

Univar represents over 2,500 chemical producers and has about 80,000 customers. The company operates a network of 179 distribution facilities throughout North America, Europe, and China. In 2009, Univar reported sales of USD 7.2 billion.

Purcom opens first PU technology centre in Brazil The Brazilian company Purcom Química from Barueri, São Paulo, has opened a research and development centre that will allow processors to develop, test, and implement new PU products and applications, used in the manufacture of automotive parts, furniture, electronics, sports equipment, etc. The company says the “Purcom Intelligence Center” is a pioneering initiative in Brazil. Purcom invested USD 1.5 million in the new centre, which also re-

ceived support from the Financier of Studies and Projects (FINEP). The centre is equipped with high and low pressure injection moulding machines, spray application equipment, and can also test the industrial-scale manufacture of flexible foam blocks in boxes. For confidential project development, each machine has been set up in an isolated area. In addition, the centre offers training programmes for technicians and operators.

Cutting machines state-of-the-art Fecken-Kirfel is specialized in cutting machines for processing PU flexible foam, PE foam and rigid foam as well as rubber, expanded rubber, neoprene and cork.

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Hall A, Booth C.17 Our machines set the worldwide benchmark concerning cutting precision and reliability!

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PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Tel.: +49 (0)241 18202-0 Fax: +49 (0)241 18202-13

www.fecken-kirfel.com info@fecken-kirfel.de

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Technology and product news Silcart enters 2011 with new faces for insulation boards 2010 has been a successful year for Silcart. The company based in Carbonera in Northern Italy near Treviso has been sponsoring the PU Europe Gala Dinner (held in Venice in October) and received strong and positive feedback after UTECH North America in Houston and Big 5 in Dubai. 2011 sees Silcart now launching two new flexible faces for PIR/PUR rigid insulation boards: Carboglass and Glass Coat.

Expressly designed for E.T.I.C.S (External Thermal Insulation Composite Systems), Carboglass has an extraordinary dimensional staCarboglass is very dimensionally stable thanks to its glass fibre mesh reinforcement

bility thanks to its reinforcement glass fibre mesh that makes it highly resistant to impacts and hail. The net, alkali (caustic soda, ammonia, urea, etc.) resistant, with its special high-relief structure supports a good plaster grip. In E class, Carboglass will be much appreciated by panel

manufacturers for the improved tensioning while in production phase, says the company.

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For the body panels, two-component PU adhesives were selected because of their advanced application properties regarding various curing characteristics and non-conductivity. Different curing times were a critical component due to the unique hand craftsmanship nature of Aston Martin production techniques.

The Aston Martin Rapide with adhesives technology from Dow Automotive

Glass Coat is both light and resistant

Glass Coat delivers a good combination of lightness and resistance: a glass fibre carrier is coated with a special polymeric compound that makes the product breathable (Sd 0.05 m) and waterproofing (>2 m water column) at the same time, thus preventing condensation in correspondence with fastening elements, that is there where thermal bridges usually create.

Highly UV resistant, thanks to its dark and dull colour and in E class, Glass Coat is the ideal “backstage” support for cladding and vented façades: together with Acryl Tape Coat, it guarantees the air tightness of the system.

Silcart’s new Insulation Division has presented these products at BAU in Munich, Germany, and at Klimahouse in Bolzano, Italy.

Lightweight material application for Aston Martin Rapide Dow Automotive Systems supplies structural epoxy and poly-

range to the new Aston Martin Rapide. Applications include body structure and panel bonding.

The body structure has an extremely high structural efficiency, taking into account strength, torsional rigidity, and weight. The joining technology had to provide both rigidity and allow the lowest possible weight to enable ad-

urethane-based adhesive technology from its Betamate product

vanced handling and agility. On the body structure, three aluminium types are used: aluminium extrusion, aluminium casting and aluminium sheet anodised prior to bonding. For this application, Dow Automotive Systems’ one-component toughened epoxy adhesive was used because it can bond all three aluminium types. It improves body stiffness, providing significant improvements in handling, ride and crash performance.

In terms of mechanical properties, the two-component PU adhesives provide an appropriate ratio between modulus and elongation, required to join dissimilar materials like aluminium, steel, and fibrereinforced plastics. Additionally, in order to avoid contact corrosion and provide long term durability for the different materials including aluminium, steel and composites, the adhesive also needed to be non-conductive.

Huntsman introduces new Irogran grade From Huntsman comes a new TPU that is said to offer a broader temperature operating range

than standard grades. Irogran A 92 K 5031 DP – the first grade in a new line – can be extruded or injectionThe new Irogran grade is suited for low temperamoulded to create tures down to –40 °C. elastomer components for heavy-duty engineering equipment, engines, and hydraulic systems where working conditions may be from +130 °C to –40 °C. Offering high

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

A curiosity about chemistry that never rests.

Science requires immense creativity and curiosity. These two traits are an integral part of the Human Element – driving the people of Dow to help our customers bring new possibilities to reality. New possibilities like our high-end polyols for coatings with a unique balance of properties, including low VOCs, scratch and mar recovery, hardness and flexibility. As change agents, we help

you

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w w w.d o w p o l y u r e t h a n e s .c o m ®™The DOW Diamond Logo and Human Element and design are trademarks of The Dow Chemical Company ©2011

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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strength at room temperature, a low compression set at 100 °C and consistent form retention and stability up to 120 °C, the new TPU is suited for the manufacture of pneumatic tubes, spiral hoses, timing belts, and cable jackets employed in high temperature applications such

as automotive brake and engine systems. The product’s good anti-burst properties and capacity to resist long-term exposure to oils, hydrolysis, chemicals, and abrasion also makes it a reliable base material for hy- online draulic seals.

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Perstorp to present new products at ECS 2011 Perstorp will introduce its latest developments at the European Coatings Show 2011 from 29 – 31 March 2011 in Nuremberg, Germany. The focus will be on new product launches for more eco-friendly technologies.

Perstorp’s products are used in resins for coatings and inks, and formulated coatings and adhesives. This includes products that can be used directly in formulations. For example Tolonate aliphatic polyisocyanates, which are crosslinkers for PU coatings and adhesives, and Capa polycaprolactones, which reduce the need for solvents thanks to their low viscosity, while achieving good abrasion resistance and flexibility at low temperatures. It also includes building blocks for PU dispersions, ranging from dispersing monomers (Bis-MPA, Ymer N120), polyols (Oxymer polycarbonate diols and Capa polycaprolactones), and isocyanate monomers (HDI, IPDI, TDI).

In addition, Perstorp will present Voxtar, the world’s first pentaerythritol platform based on renewable raw materials and energy. According to the company, Voxtar cuts the carbon footprint by 65 %. Based on patented technology, the company’s Easaqua grades are self-emulsifiable polyisocyanates, used as crosslinkers of eco-friendly waterborne PU alternatives to conven-

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tional solvent-based coatings. A new grade will be introduced during the show.

Furthermore, Perstorp has recently launched its Charmor range now also for plastic materials. Charmor polyols are rich carbon sources to be combined with a suitable nitrogen or phosphoric acid donor for producing intumescent systems. The new grade, Charmor PP100, is designed specifically for thermoplastics and able to meet new fire regulations. It provides an intumescent system that slows combustion, cuts heat and smoke release rates, and reduces melt dripping. It also enables more light-weight plastic than mineralbased flame retardants, says Perstorp. Charmor PP100 offers a low melting point which is below most thermoplastic processing temperatures. Combined with its good polymer compatibility, the new product is said to offer a wide processing and formulation latitude. Being a polymer, Charmor PP100 becomes part of the polymeric system of the plastic. This improves the flow during thermoplastic processing and gives more robust, reproducible and reliable mechanical and fire properties, according to Perstorp. Charmor is also non-hazardous, heavy-metal and halogenfree, and compliant with RoHS/ WEEE.

People PFA appoints new President Effective 1 January 2011, Dimitri Dounis, the Corporate Director of Marketing and Foam Research of Hickory Springs Manufacturing Company, Hickory, NC, USA, was elected to serve as President of the Polyurethane Foam Association (PFA).

Dounis is credited with the creation and development of the world’s first commercial bio-content flexible PU foam. He earned his Ph.D. in Chemical Engineering with an emphasis in polymer science from Virginia Polytechnic Institute and State University, Blacksburg, in 1995. He received his Bachelor of Science degree in Chemical Engineering in 1990 from Michigan State University, East Lansing, while working in

the Composite Materials and Structures Center. Before joining Hickory Springs ten years ago, Dounis worked as a research scientist for a PU chemical supplier.

His technical papers have been published in several scientific journals.

Dimitri Dounis

Generation change at Rampf With effect from 1 January Additionally, Matthias Rampf con2011, Matthias Rampf, 33, tinues to be responsible as Mantook over as CEO of Rampf Eco- aging Partner of Rampf Holding systems GmbH & Co. KG based for the fields of research and dein Pirmasens, Germany. He is velopment. He has a degree in following in the footsteps of his business administration and has father Rudolf Rampf, 66, who been employed in the family firm has retired from active opera- since 2005. Before being aptional management of the Rampf pointed as Managing Partner in Group with effect from the end of the F.l.t.r.: Michael, Rudolf and Matthias Rampf year 2010. From now on, the company founder’s role will be limited to that of Chairman of the Board of the umbrella company Rampf Holding GmbH & Co. KG.

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

2008, he was in Osaka establishing Rampf Group Japan.

The owning family took a first step towards securing the management succession back in 2005, when the founder’s eldest son Michael Rampf, 36, joined

the management of the umbrella company. He has since been responsible in the role of Managing Partner for Sales and Marketing, Quality Management, IT, Security and HR within the Group.

Events

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Polymer Tech-Trends in Wires and Cables 2011 Plexium India and Chatsworth-Hall Pte. Ltd. are jointly organising the second international conference on Polymer Tech–Trends in Wires and Cables. The one-day event is set to take place on 30 March 2011 in Mumbai, India, and includes more than eight papers, a mini expo, and a “technical open forum”. The organisers expect over 150 delegates.

PARIS MARCH 29-30-31, 2011 Paris Porte de Versailles 27,700

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Contact: Plexium India · K. G. Chandan Tel. +91 22 259309-40/-41/-36 E-mail info@plexiumindia.com · Internet www.plexiumindia.com

PDA Europe Applicator Spray Course The PDA Europe Applicator Spray Course will take place from 4 – 7 April 2011 at the facilities of Elmico AS in Galterud, Norway.

The four-day course will impart the prerequisites for the successful application of polyurea coatings. It will identify the many elements involved in the successful set up and operation of polyurea spray equipment. Commercially available equipment designs and necessary hardware components (machines, spray guns, etc.) will be presented in theory and practice. The key success factors, such as machine parameters and surface preparation, will be explained. Additionally, the course features a practical polyurea spray application.

Contact: PDA Europe · Françoise Maon Tel. +32 2 7611611 · Fax +32 2 7611699 E-mail pda-europe@kelleneurope.com · Internet www.pda-europe.org

A comprehensive overview on these and other upcoming events can be found on the internet at www.pu-magazine.com under the heading of events. The listing provides links to the event websites for detailed information and online registration for your convenience.

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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13

Plastics in automotive engineering 2011

Blowing Agents & Foaming Processes 2011

The 35th international congress Plastics in automotive engineering will be organised by VDI Wissensforum in cooperation with VDI Gesellschaft Kunststofftechnik (VDI Society for Plastics Technologies) from 6 – 7 April 2011 in Mannheim, Germany. This high quality event is widely recognised as the meeting-place for the automotive industry. The congress features a technical conference and a trade exhibition, including a motor vehicle show displaying the latest model developments from car and commercial vehicle manufacturers. The conference provides an overview of current developments in plastics at the German manufacturers of passenger cars and commercial vehicles. Conference languages are English and German with simultaneous translation.

iSmithers and sister company Smithers Rapra invite to the the 13th international Blowing Agents and Foaming Processes conference, to be held from 10 – 11 May 2011 in Düsseldorf, Germany. The established event is dedicated to blowing agents in foamed plastics, polyurethane, and rubber and discusses commercial polymeric foams and their applications, technologies and future industry trends. The programme includes five sessions focusing: blowing agents, blowing gases and specialities; extrusion – biodegradables and particle foams; laser, foam basics and new findings; polyolefin foams – new aspects; extrusion machinery and products.

Contact:

Polyurethanes: An Introduction – Science, Applications, Technology

VDI Wissensforum GmbH Tel. +49 211 6214-201 · Fax +49 211 6214-154 E-mail wissensforum@vdi.de · Internet www.kunststoffe-im-auto.de

PMA Annual Meeting 2011 The 40th Anniversary Annual Meeting & Supplier Showcase of the Polyurethane Manufacturers Association (PMA) will take place from 10 – 12 April 2011 at Amelia Island Plantation outside of Jacksonville, FL, USA. During the meeting, technical paper presentations will showcase latest technical developments. PMA will also present an award to the best paper as selected by meeting attendees.

Contact: Polyurethane Manufacturers Association (PMA) Tel. +1 414 4313094 · Fax + 1 414 2767704 E-mail info@pmahome.org · Internet www.pmahome.org

Greenbuilding and Solarexpo 2011 Expoenergie srl has started work on Greenbuilding, the international exhibition and conference on energy efficiency and sustainable architecture, to be held at the Verona Exhibition Centre, Italy, on 4 – 6 May 2011. Greenbuilding will be held alongside Solarexpo, the international exhibition and conference on renewable energy and distributed generation. Greenbuilding and Solarexpo together form Italy’s leading event dedicated to renewable energy and sustainable architecture. The 2010 event saw 1,268 exhibitors on a total of 105,000 m2 floor space plus 54 conferences, workshops, courses and seminars with 415 national and international speakers and 5,320 registered attendees.

Contact: Expoenergie srl Tel. +39 0439 8498-55 · Fax +39 0439 8498-54 E-mail info@greenbuildingexpo.eu · Internet www.greenbuildingexpo.eu

14

The iSmithers training course Polyurethanes: An Introduction – Science, Applications, Technology will take place two times this year in Shawbury, Shropshire, UK. Available course dates are 10 – 11 May 2011 and 1 – 2 November 2011. The course provides a simplified explanation of the manufacture of polyurethanes, the chemistry, and how additives are used to achieve the modifications that make these materials so versatile. The structure of the polyurethanes supply chain will also be explained in relation to the process stage and application.

Polymers for Implantable Medical Devices iSmithers and Smithers Rapra will host the first conference on Polymers for Implantable Medical Devices from 6 – 7 December 2011 in Dublin, Ireland, and are currently recruiting speakers.

Abstracts can be submitted until 1 April 2011 on topics such as: bioresorbable/biodegradable implantable polymers, bioactive biomaterials, biocompatibility testing, implantable systems for drug delivery, polymeric strategies for tissue engineering, regulatory challenges, polymeric coatings, implantable active electronics, implants for bone repair, etc.

Contact: iSmithers · Sharon Garrington Tel. +44 1939 252421 · Fax +44 1939 251118 E-mail sgarrington@ismithers.net · Internet www.polymerconferences.com

Brasilplast 2011 The 13th international plastic industry trade fair Brasilplast will take place from 9 – 13 May 2011 in São Paulo, Brazil. Organised by Reed Exhibitions Alcântara Machado, the fair is expected to bring together 1,300 exhibitors from 63 countries, occupying 78,000 m2 of exhibition space, as well as 65,000 visitors. The scope of the trade show includes the entire plastic industry production chain, from raw

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

materials to moulds and tools, machines and equipment, end products, and services.

Contact: Reed Exhbitions Alcântara Machado · Antonio Alves Tel. +55 11 30605019 · Fax +55 11 30604946 E-mail antonio.alves@reedalcantara.com.br

Medical Grade Polymers 2011 AMI’s international conference for the medical manufacturing industry, Medical Grade Polymers, will be held from 13 – 14 September 2011 in Philadelphia, PA, USA. Among other topics, the programme includes papers on high performance implantable materials, coatings, cardiovascular devices, antimicrobials, and hygiene.

Internet www.brasilplast.com.br Contact:

PFA General Business Meeting and Technical Program The Polyurethane Foam Association (PFA) invites to its spring General Business Meeting and Technical Program from 18 – 19 May 2011 in Baltimore, MD, USA. It will be a conjoined meeting with the Carpet Cushion Council and features the “Flexible Polyurethane Foam Hall of Fame Recognition”. The fall General Business Meeting and Technical Program is set to take place on 2 – 3 November 2011 in Phoenix, AZ, USA. Contact: PFA · Robert Luedeka Tel. +1 865 6579840 · Fax +1 865 3811292 E-mail rluedeka@pfa.org · Internet www.pfa.org/pfameet.html

FIP Solution Plastique 2011

Applied Market Information Ltd. · Becky Merriott Tel. +44 117 9249442 · Fax +44 117 3111534 E-mail rm@amiplastics.com · Internet www.amiplastics.com

Utech Asia & PU China 2011 The Utech Asia will for the third time be held in conjunction with PU China from 6 – 8 September 2011 at the Shanghai New International Expo Center in Pudong, China. The event is organised by Crain Communications Ltd. in partnership with the China Minmetals Group and the China Polyurethane Industry Association. It comprises an exhibition of suppliers of basic PU raw materials, processing equipment, and specialist PU manufacturers and features a series of company-sponsored product seminars. The three-day event is one of the most important meeting places for PU professionals from China and the Asia Pacific region.

Contact: Crain Communications Ltd. · Paul Mitchell

The plastics industry exhibition FIP Solution Plastique will be held concurrently with the fourth international rubber and polymer industry exhibition Caoutchouc Caucho Gomma (CCG) from 24 – 27 May 2011 in Lyon, France. According to the organiser Idice SAS, FIP is the only French trade show that brings together all plastics industry players in one place. FIP 2009 was attended by 406 exhibitors and 5,937 visitors. More than 500 exhibiting companies and over 8,000 visitors are expected at this year’s event.

Contact: Idice SAS · Danielle Rousseau Tel. +33 474 734233 · Fax +33 474 734522 E-mail info@idice.fr · Internet www.f-i-p.com

Medical Device Polymers 2011 Applied Market Information (AMI) will host its international Medical Device Polymers conference from 7 – 9 June 2011 in Cologne, Germany. The event focuses on polymer materials and processing technology for the medical device manufacturing industry.

Further topics include market trends, production, testing, standards and certification, durability, biocompatibility, medical device technology, and approvals.

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Tel. +44 207 4571431 · Fax +44 207 4571440 E-mail pmitchell@crain.com · Internet www.utechasia.nl

Powtech 2011 Powtech, the international trade fair for mechanical processing technologies and instrumentation, will be held together with TechnoPharm, the international trade fair for life science process technology in pharmaceuticals, food, and cosmetics, from 11 – 13 October 2011 in Nuremberg, Germany. Powtech will highlight new powder, granule, and bulk solids technologies. The event focuses on processes for size reduction, milling, screening, mixing or for granulating powders or bulk solids, which are required for the production of pharmaceuticals, detergents, body care articles, cosmetics, plant protection agents, fertilisers or pesticides. Technologies for the ceramic, building material, and plastic industries will also be on show. According to the organiser NürnbergMesse, almost 1,000 exhibitors presented their products and services to about 16,490 visitors in 2010.

Contact: NürnbergMesse GmbH · Willy Viethen Tel +49 911 86068160 · Fax +49 911 8606-8281 E-mail willy.viethen@nuernbergmesse.de · Internet www.powtech.de

15

Interview with C. McKendrick

In person:

will this technology be extended into other regions and product lines in the near future?

Colin McKendrick, Global General Manager, PO – Shell Chemicals PU Magazine: PO and derivatives are only a small part of the Shell Chemicals portfolio, however, at a recent press event, Ben van Beurden stated that it was not a poor relation and the company was looking to build on its strengths in this business. Can you expand upon this comment and explain the role of the PO and especially the derivatives business in the Shell business environment.

PU Magazine: Following the global downturn in 2009 how have PO and derivative markets performed in 2010?

Colin McKendrick: We have experienced significant demand recovery in most regions and in the majority of end-use applications over 2010. We have seen strong demand recovery in the automotive segment, while the building and the comfort segments have also demonstrated clear improvements. Demand levels are returning to pre-downturn benchmarks in certain areas,

16

This is an attractive technology which provides cost advantages as well as additional product quality benefits and very pleased with the investment in Pernis. We are always looking for opportunities to grow our business organically in a sustainable way to meet the growing and changing needs of our customers and expect this continuous process to be at the heart of future derivative investments.

PU Magazine: How has the new Caradol product (for use in low density, low TDI flexible foams) been accepted since its launch earlier this year? Is the product mainly aimed at developing markets to improve foam quality or is it being used in more established markets?

Colin McKendrick: The PO and derivatives business is a core part of Shell Chemicals' portfolio and committed to being a major player for the long term.

We have leading technologies for PO production (SMPO) and for PO derivatives, e. g. continuous flexible polyols process, and strong market positions in the key growth markets geographically and by end-use application, both directly and through strategic partnerships. This is a growth business for Shell Chemicals and indeed looking at future growth opportunities for both PO and derivatives capacity. A number of locations in the Middle East and Asia Pacific are under consideration. Access to advantaged feed, proximity to markets and value from leveraging integration with existing sites will factor significantly in any decision regarding location.

Colin McKendrick:

however we are cautiously optimistic about 2011 as there are still some macroeconomic risks that could derail the recovery.

Colin McKendrick:

Shell Chemicals has experienced strong growth in demand in China (interview in Shell Chemicals Magazine spring/summer 2010), how much has been due to your new supply channel of local distributors?

The launch of Caradol MD250-10 has been successful through introducing a low density polyol that increases the hardness of foam without using additional TDI, so it has both cost and safety benefits. We have interested customers from all over the globe, however the majority of the demand comes from developing markets such as India and Middle East.

Colin McKendrick:

PU Magazine:

We have been very pleased with the new growth realised from our new distributors in East China – they know their markets and customers very well. Together with our direct channels, we are able to reach a wider range of customers than before, driving growth. In addition, Shell’s Caradol polyols have a strong brand name known for high quality and consistent product performance. Also significant is Shell’s global reach whether it is in manufacturing, logistics network or technical know-how and all of this creates a very strong backbone to support our growth aspirations in markets like China.

Looking ahead, does Shell Chemicals expect the PU industry to face higher production costs in 2011 and if so will this destabilise market growth and development?

PU Magazine:

PU Magazine: Having introduced your continuous production technology for flexible polyols at Pernis,

Colin McKendrick: Our pricing has always reflected market and supply-demand dynamics and the same methodology will continue in the future. We do not comment on future pricing.

PU Magazine: Shell Chemicals is an important supplier of polyols into India. How does the company manage to supply this highly fragmented market when the country’s infrastructure remains a challenge in terms of logistics (perhaps there have been improvements lately)?

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Colin McKendrick:

PU Magazine:

We have an excellent distributor partner, Overseas Polymers Pvt. Ltd. in India. Together we have focused on establishing an efficient supply and distribution chain for targeted customers rather than attempting to serve the whole market. This approach so far has been very effective.

What do you think differentiates Shell Chemicals from its competitors in the PU industry?

PU Magazine: Do you see India as a major growth market for your business? In terms of PU production it is growing fast, but remains at a small volume, especially when considered in terms of per capita demand for PU.

Colin McKendrick: Shell Chemicals is committed to the Indian market and its growth in the polyurethane industry and excited by its growth prospects. With the consumer population increasing both in numbers and in disposable income, demand for cars, higher quality mattresses, and other durable goods, we see healthy growth. What may be a small base now will become substantial in a few years.

PU Magazine: Shell has developed its product range for the large flexible and rigid foam markets, but what plans does the company have for the CASE sector, which in many markets is becoming a fast growing part of the PU industry? Can a large producer like Shell Chemicals respond to the more specialist demands of this sector?

Colin McKendrick: Shell Chemicals has been a significant supplier of Caradol polyols to the CASE sector for many years and believe we compete effectively in this sector. In fact, we are in the process of expanding our capability to produce CASE grades in Pernis in support of the growth needs of our CASE customers. We are a complementary partner to our CASE customers – we do not compete with our customers in their market, but provide the polyol components for our customers to add value through formulation expertise and tailor-made solutions for their customers and markets.

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Colin McKendrick: Shell Chemicals has been supplying Caradol polyols to the polyurethanes industry for over 50 years. We offer a good product grade range, technical services for key customers, and advice on health, safety and environment issues. Our world-class integrated manufacturing facilities use our competitive proprietary technologies and are strategically located in markets to best serve our customers while providing security of supply along the value chain. Through upstream integration into base materials and our global supply chain operations, we are in close contact with global developments. We provide high quality base polyol components to our customers to add value through their (proprietary) formulations and application knowledge, whilst targeted technical support is available from our Bangalore application laboratory to assist our key customers on specific developments.

PU Magazine: Going forward what challenges will the global PO and polyol (or just PU) markets face in 2011?

Colin McKendrick: While cautiously optimistic about prospects in 2011, some threats still remain to the global economic recovery, e. g. government stimulus packages being replaced by austerity measures in many developed economies, high unemployment. These could put a dampener on demand and further delay recovery in some sectors such as construction and housing. As an industry, we could expect continued and greater scrutiny from regulatory authorities and the public on the safe use of chemical products. The entire chemicals industry put in an enormous effort to meet the 2010 deadline for registration requirements for the required products under the EU REACH programme and there is more to come. We have to continuously demonstrate to the authorities and the general public that we are responsible manufacturers and marketers of our products. 

17

PU TECH 2011 Preview

Exhibitors list C08, C09

Air Products Asia

Airtech cooling Process Pvt. Ltd. Alba Powerspack Tooling India Pvt. Ltd.

The Indian Polyurethane Association (IPuA) presents the third polyurethane exhibition and conference in India, PU TECH 2011. The triennial event will comprise a three-day exhibition and a one-day conference highlighting latest developments in the polyurethane industry, processing techniques, machinery, raw materials, and finished goods. The event will be held between 9 – 11 March 2011 at the state-of-the-art India Expo Centre, Greater Noida, New Delhi.

Albrecht bäumer Gmbh & co. KG

Managed by Expomedia Group Plc, the venue meets world class exhibition standards: its halls are complete with modern international quality infrastructure and offer high safety standards. The India Expo Centre provides two fully air-conditioned halls with approximately 3,500 m2 each for the PU TECH India exhibition plus 1,000 m2 for the conference.

The polyurethane industry is one of the rapidly growing industries in India which has registered double digit growth during the past five years and is expected to double every four years in the coming decade.

According to the International Monetary Fund (IMF) the GDP for India will rise from an estimated USD 1,430 billion in 2010 to estimated USD 2,412 billion in 2015. As population will only grow from 1.2 billion to 1.3 billion in the same period the disposable income per capita should grow by double digit numbers over the next years. This usually leads to more consumption of comfort products as for example mattresses and refrigerators.

H18

Aromatic - Kangam chemicals co. Ltd.

F19

Impianti Oms S.p.a.

G15

Industrial Foams Pvt. Ltd.

H06

G19 H22 – H26

Inoac corporation Jumax Foams

E04

K. b. Polychem (I) Pvt. Ltd.

H29

Karthikeya Impex Pvt. Ltd.

H16 H27

Aromatic Agencies / Sunkist chemical (Taiwan)

A18

KPL International Ltd.

Arvind International Ltd.

H14

Kracht Gmbh

F12

AS Enterprises

C07

KraussMaffei Technologies Gmbh

A17

Asia Polyurethane Mfg. Pvt. Ltd.

E22

Kromatiks & Insulants Pvt. Ltd.

G20

Autoline co., Ltd.

A11

Kuwait Polyurethane Industry W.L.L.

G21

Laader berg AS

C14

Libra International

A10

Maitreya Polymers & Speciality chemicals Pvt. Ltd.

G04

Manali Petrochemical Ltd.

B09

Marubeni India Pvt. Ltd.

G08

McLube Asia Pvt. Ltd.

G13

bASF Polyurethane India Ltd. A14, B01 F03, F04

baulé

bayer MaterialScience Pvt. Ltd. B06, C01 beamech Group

H05

beda Flow Systems Pvt. Ltd.

C11

bharat Enterprises

A01

bharat Seats Ltd.

E08

c.A.M.I. S.p.A.

H03 D02

chemie Products Pvt. Ltd.

D07, D08

chemtrend chemicals chemtura chemicals India Pvt. Ltd.

G24 – G26

coim India Pvt. Ltd.

F15

crain communications Ltd.

A06

Diamond Tools

D01

Dongguan ErS Machinery co., Ltd. H02a Dongguan Qianghui Foaming Machinery Technology

H28

A one-day conference on 10 March 2011 will give attendees the possibility to learn about the latest developments in PU technology.

More than 20 papers will be presented by industry experts covering all aspects from automotive to rigid foam, slabstock, CASE applications, EHS and fire safety (complete programme on www.pu-magazine.com or www.putechindia.com).

In addition, the Indian Polyurethane Association has invited Isopa to feature its Polyurethanes campaign at the trade show. Isopa will introduce the campaign and its approach to communicate the benefits of polyurethanes to the public and to policymakers.

Era Polymers Pvt. Ltd. (Spectrum Technologies)

18

huntsman International I Pvt. Ltd. A04, A05, A15, B02

C12

Dongguan U-long Machinery co., Ltd. & Dongguan chashan Zhenfeng Machinery Manufactory F07a

The organiser expects 3,500 trade visitors from all parts of India, Pakistan, Nepal, Sri Lanka, the Maldives, Thailand, Malaysia, Singapore, Indonesia, the Philippines, Bangladesh, the Middle East, Africa and other countries. Opening hours of PU TECH will be from 10:30 a.m. until 6:30 p.m. More than 125 companies will offer their newest products and services. Some of the exhibiting companies are introduced on the next pages.

C16

D03

A12, A13

Aquent Impex

E11

hennecke-Maruka Asia Pte Ltd.

hyma Foam Machinery

F04a

Amritchem

hebei yadong

E01

Meenakshi Polymers P Ltd. Milliken Asia

E16, F02

MM Traders

H17

Modern Enterprises

F08

Momentive Performance Materials India Pvt. Ltd.

C04, C05

Mondi

G14

Nanjing Dymatic

E21

Nantong healthcare Industries co. Ltd.

E12, E13 H13

Oerlikon Textile India Pvt. Ltd. Orjin Kimya A.S.

F10

Pcc rokita SA

G16

Polycraftpuf Machine Pvt. Ltd.

F09a, G01a E15

Dow chemical Intl. Pvt. Ltd.

B04, B05

Polymer Technology Group

Dut Korea

H31, H32

Polytec EMc Engineering Gmbh & co. KG

H20

Prime comfort Products

A11a

Prochem co. LLc

F05a

Ekosystem SrL

E03

Elitecore Machinery Manufacturing co., Ltd.

H30 F07

Evonik Degussa India Pvt. Ltd.

A16, B03

Expanded Polymer Systems Pvt. Ltd. / cannon

B08

Fecken-Kirfel Gmbh & co KG

C17

Flexipol Foams Pvt. Ltd.

C13

Fushun Jiahua

H17a

Graco India

A03

Gujarat Narmada Valley Fertilizers co. Ltd.

C03

Gusbi (Asialink Agencies Pvt. Ltd.) H04 hainan Zhongxin

G11

PU Magazine International

A09

PU TEch Eurasia

E02

Purinova Sp. z o.o.

G09

Quilt India

E09

r. P. Foam home Pvt. Ltd.

C10

recticel NV

G22, G23

rGP Moulds Pvt. Ltd.

D09

rim Polymers

A07

rishi Overseas

F11

royal Synthetics

H15

rubber board (Govt. of India)

E10

rudra blades & Edges Pvt. Ltd.

H19

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

10

D04, D05 5

H01a

ScI Tech books SD Korea co. Ltd.

E07

Stair

Shandong Dongda

E15a

Stair

Sheela Foam Pvt. Ltd.

B07, C02

Shree Malini Foams

E05, E06

Sojitz India Pvt. Ltd.

E17, E18

Somany foam Ltd.

A08

Springfeel Polyurethane

F14

Spuhl AG

C15

SrI Impex

G10

Stepan company

B10

Sun yang Global co., Ltd.

D06

Suzhou Xiangyuan

F18

Svenic

F09

Swagath Urethane

H01

Synthesia

A02

ConF regn.

Theme pavilion

Lounge Area

Lounge Area

12 x 6 = 72 sqm

HALL “C”

Internet Kiosk

Lift Fire escape lift Escape door

Internet Kiosk

Stair

H17 H19 H18 H18 a a H17

H16

H15

G13

G15

G14

H03 G16

H04 G17

aisle G

Toilets

H14

H13

H20

aisle H

H02 H01 H01 a a H02

G03

H05 G18

H06 G19

G20

F10

F11

H30

H28 H29 G21 G22

G23

HALL “B”

F12

aisle F

F01 E15

G25

Stair

Uflex Ltd.

G18

Stair

Ufoam Pvt. Ltd.

H02

Unekar Polymer Agency

H21

E01

E02

C06

G07

G08

G09

G10

G11

F17

F18

F19

F20

F21

F15

F02

F03

E16

E17

E03

F04

F04a

F05a

E18 aisle E

E04 E05

E06 E07

F05

F06

F07

F07a F08

E19

E20

E21

E22

aisle E

E09

E08

E10

E11

E13 E14 E15a

E12

C07

C08

C09

C10

C11

C12

C13

C14

C15

C16

F20

Escape door

C17

aisle C

aisle C

C01

C02

C03

aisle C

D10

C05

D09

C04

aisle D

B06

B07

aisle B

aisle B

B01

B02

B09

B08

B03

HALL “A”

Loading gate

aisle B

B04

B05

D05 aisle D

ENTRANCE FOYER

D08

D06

B10

Toilets

Hall Entry/ Exit

Lift

D07

Zhangjiagang Strength & Industrious Machinery co., Ltd. H18a

Zibo Dexin Lianbang chemical Industry co. Ltd.

Lift Fire escape lift Escape door

aisle E

Toilets

yantai Wanhua Polyurethane co., Ltd. E19, E20, F05, F06

E14

Service room

aisle F

G17

Zhejiang Sanmei chemical Ind. co. Ltd.

Loading gate

Lift

Voelkel Industrie Produkte Gmbh / Silicone concepts C06

F17

Lift

Stair

G01, G02

yang yu Foaming Machinery co. Ltd.

Lift

G26

aisle G

aisle F

aisle F

aisle E

F21

F01

Service room

Toilets

G03

Wintech Engineering

Fire escape

H31 H32 H33

G24

aisle G

G04

Stair

H22 H23 H24 H25 H26 aisle H

H27

F14 F09a F09

H21

aisle H

aisle G

G01a G01 G02

Techno PU.MA. S.r.L.

Vimal Intertrade Pvt. Ltd.

Tea/Coffee counter

aisle H

Taiwan PU corporation

Ureatac co., Ltd.

ConF regn.

Conference hall

G07

Saba Dinxperlo bV Saip SrL

14

D10 , H33

Conference hall

Saan Global

A01

A14

A15

aisle A

aisle A

A02

A03

A04

A05

A16

A17

A18 aisle A

A06

A07

A08

A09

Lift

D04

Lift

D03 D02 D01

A010 A011 A011a A012 A013

Escape door

Stair

Flexible Polyurethane Slabstock Foaming Machines

Hall A, booth C14

Visit the Inventor of Maxfoam™ at:

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

www.laaderberg.com 19

Raw materials and additives Air Products, hall A, stand C08, C09 Air Products offers PU additives, including amine catalysts, tin- and metal-based catalysts, silicone and non-silicone surfactants, e. g. for flexible moulded foams, flexible slabstock, construction, and shoe sole applications. For flexible moulded foam applications the company will present its Dabco series NE 300 blow catalyst, NE 210 balanced catalyst, NE 1070 gel catalyst, BA 100 blocking agent, CL 420 crosslinker, and DC6070 silicone surfactants for TDI and TM systems as well as DC2525 for MDI systems. These products bind chemically into Air Products supplies speciality additives for the PU foam matrix various applications while maintaining foam proper ties and when used in automotive applications, catalyst contribution to odour and emissions causing windshield fogging and vinyl staining are eliminated. New catalysts for fast demoulding include Dabco MP601 delayed action balanced catalyst and MP602 delayed action non-fugitive catalyst for improved skin cure.

Products of the Dabco series presented for flexible slabstock applications include RP204 balanced catalyst for ultra low to high foam density and DC5906 non-fugitive silicone surfactant. They reduce odour and can be used to produce products that meet Certi-PUR requirements. Dabco DC5950 and DC5986 flame retardant silicone surfactants enable to meet the requirements of BS5852 Crib 5 tests (DC5950) and CAL 117 tests (DC5986).

For construction applications, the company will highlight LK221 and LK443 non-silicone organic surfactants for rigid and microcellular PU formulations. Dabco PT series catalysts are amine catalysts for rigid spray foam, providing low odour. The LK series surfactants and Dabco PT series catalysts are used in rigid foams with low k-factors, high percentage of closed cells, high dimensional stability, adhesion strength, and smooth surface.

For appliance applications, Air Products will present Dabco BX405 and BX406 catalysts, that accelerate the demould time and improve adhesion. Products showcased for shoe sole applications include Dabco DC 3042 and DC 3043 surfactants, that provide fine, uniform cell size distribution, good surface quality, dimensional stability as well as enhanced flowability. Dabco XD102 catalyst improves flowability, KTM-60 and 1027 catalysts provide faster demould properties, and XD104 prolongs cream time and improves the surface quality with shining skins.

Air Products will present two papers at the conference, titled: “Building Quality Rigid Polyurethane Foam with Air Products Additives” and “The leading additives to support the further success of Polyurethane Industry”.

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Asia Polyurethane, hall B, stand E22 Asia Polyurethane (APU) will present its range of customised polyurethane solutions. The company also provides advice to enhance its customers’ production process. Development work has been done on blowing agent technologies to phase out HCFC141b, using such materials as HFC365, HFC245 and methyl formate. The new products that APU intends to show at the exhibition will involve PU systems that are compatible substitutes for all HCFC141b blown system. APU will showcase several environmentally friendly polyol-blended systems with zero-ODP, zero-GWP, and zero-VOC, that have proven to be alternatives to HCFC141b blown systems. APU offers these PU systems for integral skin, spray foam, pre-insulated pipes, and deep freezer applications.

BASF, hall A, stand A14, B01 Exhibiting under the theme “Polyurethane Solutions”, BASF will display innovative PU products in various segments including automotive, construction, appliance, bedding and furniture, and sports and leisure.

At PU TECH, BASF will highlight its ROM (Reactive Over Moulding) technology and PU skin technology for the automotive industry. In addition, the company will showcase its Elastotrack railway ballast binder for track stabilisation and Elastopave porous eco-pavement for enhanced exchange of air and water between surface and underground. For the construction sector, BASF will present its latest technology in PU spray foam PURE 1.1 polyurethane concept shoe for fire resistance and sound-damping insulation solutions for buildings. Also on show will be the eco-friendly, phthalate-free, 100 % polyurethane concept shoe PURE 1.1. One of its core materials is Elastollan Soft, which constitutes the lace system and front outsole.

Through its network of PU system houses, the company provides fast local support, from technical services and sales to production and marketing during the development of customised solutions.

Baulé, hall B, stand F03, F04 Baulé is a 50:50 joint venture between Bayer MaterialScience and Michel Baulé SA with headquarters in Romans, France. The company supplies cast PU system formulations and dispensing machinery.

Baulé says it offers the widest possible spectrum of castable PU systems based on TDI, MDI, quasi-MDI, quasi-NDI, NDI, and PPDI prepolymers with polyether, polyester, and polycarbonate polyols.

New H&S-friendly Baytec Max cast PU systems based on amine-

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

We see a better world

MDI BASED SOLUTIONS FROM

Visit us at PU TECH 2011 9-11 March 2011 India Expo Centre, New Delhi Booth number A4, A5, A15 & B02 www.huntsman.com/pu PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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crosslinked MDI prepolymers will be highlighted during the event. According to Baulé, these systems are easy to process with MOCA and are also available as MOCAfree versions. Further PU systems highlights include Baulé Compact 3M machine quasi-MDI prepolymer-based systems with mercury-free integrated catalyst in both ether and ester versions. These three-component systems allow multiple hardnesses (from 60 Shore A to 95 Shore A) with a good processability, longer pot-life, and shorter demoulding time.

On the machinery side, the company will present the three-component compact dispensing machine Compact 3M with output up to 10 kg/min. Baulé’s says its low pressure dispensing machines are suitable for all kinds of PU elastomer applications and their range meets almost any process parameter and manufacturing environment. All machines are designed to process almost any system available. The three-component compact machine series is especially adapted for the processing of quasi-MDI prepolymer-based systems with integrated catalyst.

Bharat Enterprises, hall A, stand A01 The Delhi-based chemical trading company Bharat Enterprises offers raw materials and technologies to the adhesive, rubber, and polyurethane industries. With its India-wide distribution network Bharat represents many overseas companies in India. At the exhibition the company will showcase polyurethanes for adhesives (TPUs) from Merquinsa Mercados, Spain; bonding agents (adhesives) for PU to metal/plastic applications from Chemical Innovations Ltd., UK; mould release agents from Huron Technologies, Inc., USA; polyester polyols, systems, and polymeric polyesters from Synthesia, Spain; PU related machines from Tec Mac Srl, Italy; cutting and dispensing machines from Edge Sweets, USA; and castable polyurethanes from NUI, South Africa.

Era Polymers, hall B, stand F07 Under the motto “Excellence in polyurethane chemistry”, the Australian company Era Polymers will be showcasing its diverse range of PU prepolymers at PU TECH 2011. The company’s product portfolio includes spray polyurethane and polyureas, rigid and flexible foam systems, rubber binders, coatings as well as machinery. Era Polymers manufactures over 700 grades of PU prepolymers including simple to process single component 1K and 2K systems as well as new

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three-component MDI polyether and polyester systems. These threecomponent systems are ideal for manufacturers using plural component machines. Compared to traditional two-component systems that offer a specific hardness, these quasi systems are more flexible as varying hardnesses can be achieved.

Evonik, hall A, stand A16, B03 Evonik Industries’ business line Polyurethane Additives is a global supplier of auxiliaries for PU foam manufacturing. The company offers a complete range of additives, including Tegostab silicone stabilisers, Tegoamin amine catalysts, Kosmos metal catalysts, Gorapur release agents, Tegocolor pigments and Ortegol speciality additives.

During the exhibition Evonik will present its most recent product innovations: For flexible foam Tegostab B 8160, a new medium active stabiliser with improved processing latitude for standard ether foams, will be highlighted. Also for flexible foam production Ortegol G will be presented. It is an effective crosslinker, tailor-made for foams containing high filler loadings, for box- and low density foaming to reduce foam defects, like splits.

For rigid foam manufacturing Evonik offers a full range of surfactants for all types of formulations and processing conditions. Two new products will be introduced during the exhibition. Tegostab B 8491 is designed to improve the surface quality and ensure system stability in hydrocarbon blown systems. Tegostab B 8522 is a versatile siloxane providing very good foam quality in continuous and discontinuous foaming processes using hydrocarbons or HCFCs as blowing agents.

Furthermore, Evonik will introduce Tegostab B 8742 LF 2 for automotive moulded foams that meet latest VOC requirements. According to the company, this product has been proven to reduce transmissivity of vibrations through HR TDI or TM 20 seating foam. For the production of microcellular PU materials with an increased conductivity and hence improved antistatic properties Ortegol AST 8 will be recommended.

Evonik also provides Gorapur release agents through its affiliate Evonik Gorapur GmbH from Wittenburg, Germany, to the Indian market, offering products for the HR-moulded (automotive) market, as well as for the shoe sole industry, and other microcellular PU applications.

Gujarat Narmada Valley Fertilizers, hall A, stand C03 Gujarat Narmada Valley Fertilizers (GNFC), a leading chemical and fertiliser manufacturer in India, will highlight its role as a raw material supplier to the polyurethanes industry. GNFC says it is the largest producer of methanol, acetic acid, formic acid, aniline, and TDI in India.

Besides these, GNFC also manufactures nitric acid and ammonium nitrate. According to the company, it is the only TDI manufacturer in India with a capacity of 16,000 t/y. In addition to this, a new 50,000 t/y TDI plant is currently under construction in Dahej, Gujarat, which is scheduled for completion by December 2011. GNFC’s existing TDI plant is based on technology from Chematur Engineering AB, Swe-

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

den. The new TDI plant will employ the same technology. GNFC says the present demand for TDI in India is estimated at 35,000 t/y and has a double digit growth rate. In addition, the company is exploring possibilities for setting up new manufacturing facilities for other PU raw materials.

Huntsman, hall A, stand A4, A5, A15, B02 Huntsman Polyurethanes operates an established network of sites across India. At the trade show, its full range of PU products and services will be presented. In addition, the company intends to announce the expansion of its local manufacturing assets during the show. By offering raw materials and technical support, Huntsman says it is helping to increase the adoption of PU throughout India by working with some of India's most dynamic product manufacturers.

By 2015, the country is expected to emerge as the second largest PU market in the Asia Pacific rim. An expanding middle class, increased urbanisation and significant infrastructure development projects are driving local demand for MDI for use in the production of cars, footwear, and furniture as well as construction related items such as insulation systems and coatings. At the show, Huntsman will showcase its local capabilities for these markets.

Furthermore, the company will present three papers at the conference: “Future trends in foam pad development for car seat design”, “Economic blowing agents for India in the post 141B era”, and “Flooring systems for humid conditions”.

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Strong protection Solkane® 365mfc is your ideal choice when the highest fire safety classes are specified. Enhance this even further with IXOL®: Solvay’s own range of reactive flame retardant polyols.

Kuwait Polyurethane Industry (KPI) is a manufacturer of systems for rigid PU foams in the middle east. The company’s product offering includes customer specific rigid PU systems based on 141b, 365/227 blend, and pentanes for applications such as: continuous and discontinuous sandwich panels, spray foam, pour-in-place and pipe insulation, refrigeration, high density blocks as well as water heaters.

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PCC, hall B, stand G16

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

011 H 2 re,

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Kuwait Polyurethane Industry, hall B, stand G21

Solvay Fluor GmbH Postfach 220 · 30002 Hannover Germany Phone + 49 511 857-2444 Fax + 49 511 857-2166 foamingagents@solvay.com www.solvay - fluor.com

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PCC SE together with its subsidiaries PCC Rokita SA and ProdexSystem Sp. z o.o. will exhibit at a joint stand at PU TECH 2011.

PCC Rokita SA is a manufacturer of polyether polyols with a production plant in Brzeg Dolny, Poland. The company will highlight its range of polyether polyols for use in the production of quality HR and viscoelastic foams. According to the company, the nameplate polyol production capacity in Brzeg Dolny will be expanded from 70 kt/y to 100 kt/y by the fourth quarter of 2011.

Furthermore, PCC will highlight its newly acquired Polish system house Prodex-System Sp. z o.o. located near Warsaw that specialises in insulation and CASE applications. In addition, PCC announced it is seeking potential partners in India to create business alliances.

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Solvay Fluor A Group active in Chemistry The use of Solkane®365mfc and of blends containing Solkane®365mfc might fall within the scope of U.S. patent no. 5,496,866. The following must be noted regarding the USA (until March 5, 2013): (1) Solkane®365mfc cannot be used in the USA, by itself or in a blend, as a blowing agent to foam a plastic based on an isocyanate to form plastic foam compositions; (2) Solkane®365mfc and blends containing Solkane®365mfc must not be made, used, offered for sale, or sold in the USA, or imported into the USA, for such blowing uses; and (3) closed cell plastic foam compositions prepared by foaming a plastic material based on isocyanate in the presence of a propellant comprising Solkane®365mfc and/or a blend containing Solkane®365mfc, cannot be made, used, offered for sale, or sold, within the USA, or imported into the USA. To do so can result in a claim of patent infringement under U.S. patent no. 5,496,866. Solvay will not sell Solkane® 365mfc or blends containing Solkane®365mfc to any purchaser intending to use the product accordingly. For addional information and details please visit our webside: www.solvay-fluor.com.

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Purinova, hall B, stand G09 The Polish company Purinova from Bydgoszcz produces polyester polyols and PU systems and also offers taylor-made solutions. More than 70 % of the company’s total production is exported to Europe and Asia. At the trade show, Purinova will spotlight its polyester polyols based on dicarboxylic acid mixture, which are said to be unique in the world and are manufactured with a patented production technology. Further highlights will be its PU systems for shoe soles and rigid PU systems (both based on own patented polyesters).

Taiwan PU Corporation, hall B, stand F21 Taiwan PU Corporation (TPUCO) is a manufacturer of polyurethane materials and finished products since 1986. The company develops, manufactures, and markets thermoplastic polyurethane, TPU adhesives (granules, powder, and hot melts), PU casting prepolymers, doming casting polyurethane, PU adhesives and hot melts, one- and two-component adhesives, water-based adhesives, millable urethane, and MOCA hardener additives. It also offers tailor-made products according to customer requirements. Its polyurethane finished products offering includes: pneumatic and spiral tubes, air hoses, rods, pipes, sheets and films, belts, printing squeegees, and forklift and friction wheels. TPUCO operates production facilities in China and Taiwan.

Voelkel Industrial Products, hall A, stand C06 VIP – Voelkel Industrial Products LLC from Munich, Germany, will be highlighting polyurea coating systems for various applications. The company operates a new production site in Dubai and its polyurea coating systems are now also available from a specialised distribution and applicator network throughout India. Its Polyurea Quick Spray can be applied to concrete, metal, plastics or foam by simply using a double carVIP polyurea coating systems provide good tridge with mixer adhesion on concrete, foam, metal, and plastics. tips and a pneumatic gun which also make it a mobile system. Pure Polyurea creates a highly resistant, durable coating to almost any surface, says VIP. Polyurea coatings are VOC-free and offer very fast gel-times. They have good mechanical properties and are highly resistant to chemicals and to impacts.

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Yantai Wanhua Polyurethanes, hall B, stand E19, E20, F5, F6 At PU TECH 2011, Yantai Wanhua Polyurethanes Co., Ltd., Asia Pacific’s largest MDI producer, will present itself as a raw material supplier to the Indian and global markets. With the start up of its new plant last December in Ningbo, China, the total capacity of the Yantai and Ningbo MDI plants has reached 800 kt/y. In addition, the company is building a new integrated park involving MDI and polyol plants in Yantai Bajiao.

Under the motto “Your trustworthy partner for PU solutions”, Wanhua will highlight its progress in PU rigid/flexible foam and specialities and in providing ideal PU solutions, especially in the automotive, furniture, and CASE sectors. According to Wanhua, the company is also the biggest TPU supplier in China and new TPU products will be presented at the stand including halogen-free TPUs, hot melts, and super soft varieties. 

Machinery and ancillary equipment Alba Powerspack Tooling India, hall B, stand F19 Alba Powerspack Tooling India Pvt. Ltd. (APT) is a joint venture between Alba Tooling & Engineering GmbH, Austria, and Spack Automotives Ltd., India. The company was established in 2009 and operates a fully integrated aluminium moulds manufacturing facility for PU seat cushions. APT says it offers the full spectrum of PU mould manufacturing, such as the designing and modelling of pads, master models and foundry patterns, CNC machining and spark erosion as well as delivering finished checked pads along with the moulds.

APT’s offering includes the manufacturing of aluminium moulds for complete vehicle PU seat cushions, headrests, armrests, and two wheelers seat cushions. The company also produces mould carriers to customer specifications, complete back foam tooling for vehicle interiors, instrument panels, door trims, and roof headliners as well as pour-in-place moulds for headrests and armrests. During the trade show, APT will display a car seat cushion mould, a two wheeler seat cushion mould, and a “PIP” headrest mould with carrier.

Albrecht Bäumer, hall A, stand C12 The German company Albrecht Bäumer GmbH & Co. KG supplies machines and equipment in the fields of cutting, converting, and transport of PU foam and similar materials. As inventor of the long splitting system for converting foam blocks with lengths of up to 120 m into paper thin foils, the company delivered the first looper in 1957. In the last 50 years, the technology of this installation has been continuously improved. More than 250 machines of this type have

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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been sold all over the world, 12 machines in 2010 alone. By utilising servo technology for the belt drive motors, it is now possible to exchange a roll without having to stop the machine completely. The roll can be exchanged at a machine velocity of 0.5 m/min. Due to the constant continuation of the cutting process unwanted marks in the foam or inaccurate cutting results are avoided. After the new roll has been wound, the machine continues to cut with the selected production speed.

According to Albrecht Bäumer, its Looper is the only machine in the market equipped with this technology. In addition, the new option “all-automatic change of cutting The Albrecht Bäumer Looper thickness“ ensures an accurate cutting result from the start of the cutting process on, according to the pre-selected cutting thickness without producing any waste. This fully automatic system is realised by additional servo motors.

Furthermore, the company can provide after-sales service for the Looper by remote diagnosis using a VPN connection via internet.

Fecken-Kirfel, hall A, stand C17 Fecken-Kirfel is a manufacturer of cutting machines for flexible and rigid foams, rubber, cork, and similar materials. The familiy-owned company offers custom-designed machines with quality “Made in Germany”. At the PU TECH 2011, Fecken-Kirfel will be presenting its wide product range from machine classics to recent developments such as the new horizontal CNC contour cutting centre C 68/69 with oscillating knife. Also its established and continually improved carousel cutters and profiling machines will be highlighted.

This year Fecken-Kirfel will spotlight its new development: the “Loop” cutting line H 32 LF. It integrates a fully automatic bandknife splitting machine into a loop conveyor system for the production of roll goods.

The solid cast-iron frame is designed to take buns of flexible PU foams of up to 60 m length. According Fecken-Kirfel “Loop” cutting line H 32 LF to customer requirements the conveyor can either be built with idler rollers, with multi-stripe belts or even with a combination of both. The machine

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can be equipped with a cross cutter, side trimmers, and an ergonomic wind up devise at the ground floor by side of the machine. The “Loop” can also be custom-designed with further Fecken-Kirfel options.

Hennecke, hall A, stand C16 At PU TECH 2011 Hennecke GmbH will present itself with one of the largest ranges of polyurethane processing equipment on offer. Under the motto “PUR Fascination”, the German machine and plant manufacturer intends to convince customers on the emergent subcontinent especially by its long-standing experience and problem-solving competence. According to Hennecke, a variety of products on display will illustrate the specific unique selling points of its equipment. Apart from presenting high-tech applications and the new developments in processing technology, the company will also showcase traditional PU core technologies.

Since 2009, the German corporate headquarters is supported by a branch office in Hyderabad. Hennecke says it has already brought on stream a considerable Hennecke Topline HK number of HK metering machine machines and various slabstock production lines in India. In spite of this, there is still a great demand for processing technology in the Indian PU industry. This is demonstrated, for example, by a recent order intake in the area of discontinuous and continuous slabstock lines as well as HK metering machines of the Topline and QFoam type, says the company.

KraussMaffei, hall A, stand A17 KraussMaffei will exhibit its new EcoStar polyurethane mixing and metering machines at the trade show. Especially small and mediumsized PU processors in the automotive and construction industries can profit from the attractive price/performance ratio, says KraussMaffei. The basic version of the new series includes volume flow meters, MKE-3B mixing heads, axial piston pumps, and a Siemens control system. The volume flow meters make it possible to visualise the current machine situation, thereby simplifying process control. Altering process parameters for a product change is now faster. The result is a more stable and reliable process plus more flexibility for product changes and a lower reject rate. EcoStar machines have double-walled component tanks equipped with agitators

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

to ensure precise temperature control. The MKE-3B mixing heads with their T-impingement pattern ensure good mixing and laminar, s p l a s h - f re e d i s charge. Capable of The new KraussMaffei a fast succession EcoStar of shots and a wide discharge range, the mixing heads are suitable for f o a m d i s c h a rg e into both closed and open moulds.

Another feature of EcoStar machines is the use of KM axial piston pumps. Their long service life and rugged engineering make these low-maintenance pumps.

The basic EcoStar version can be optionally upgraded with additional function packs, including closed loop control, transfer mixing heads, different-sized outriggers, and plate heat exchangers. KraussMaffei continues to offer the proven RimStar series for special applications with demanding temperature control and automation requirements.

Laader Berg, hall A, stand C14 The family-owned company Laader Berg from Ålesund, Norway, is launching a new and improved edition of its Multimax machine, which provides the option to choose between high and low pressure production. The new edition can also easily be changed between the Liquid Lay Down and the Maxfoam alternative. The new Multimax was developed in order to produce foam in a broad range of qualities and to be able to fulfil the standards needed in the actual markets. Laader Berg says these achievements have been made possible through long and close relations with its customers all over the world.

According to the The new edition of the Laader Berg Multimax company, the new machine can be used for high and low pressure Multimax combines production. its 50 years of experience in producing continuous foaming machines.

It is designed to offer high ease of use and to produce consistent foam quality.

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The new edition is said to improve the yield, reduce the pinholes, and produce finer cell structured foam, all in an easy run operation. This is regardless of different qualities and F.l.t.r.: Gunnar Berntsen (Laader Berg), Satishchandra Mehta, Roshankumar Sanghavi, different foam seg- and Deepak Mehta (Tirupati), Malvin Berg and ments, says Laader Per Henning Vågen (Laader Berg) Berg. In addition, Multimax is offered for a competitive price.

Tirupati, an Indian foam producer, has just invested in a new Multimax machine to be installed at its new factory.

Tirupati, a long term customer of Laader Berg, will use the machine to produce a wide range of quality foams for the growing and competitive Indian market.

OMS Group, hall B, stand G15 Impianti OMS S.p.A, a manufacturer of foaming machines and turn-key plants for the PU industry, will highlight its continuous lines for the production of flexible foam panels at PU TECH 2011. According to the company, its lines are capable to reach a productivity of 60 m/min and include flexible face decoilers, panels trimming, stacking, and packing. Furthermore, OMS will present its discontinuous plants for the production of rigid foam blocks with solid fillers for the automotive sector (headliners) and special foams. In addition, it will present a continuous plant equipped with multi- OMS continuous line for the production of panels component metering streams (up to 20) for the production of panels with high technology content. At the trade show, OMS will display product samples as well as technical documentation.

Polytec EMC, hall B, stand H20 Polytec EMC, a manufacturers of low pressure dispensing machines, will participate as an exhibitor in PU TECH 2011 for the first time. The company manufactures two- and multi-component metering, mixing, and dispensing machines for liquid-reactive chemicals since more than 25 years. For the processing of PU, adhesives, sealants, PU hot cast

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elastomers, epoxy resins, silicones or foams Polytec EMC designs and builds customised solutions for nearly every requirement. Its portfolio includes the small laboratory and prototyping machine DG-10 for cold castable materials, the two- or three-component machines DG-107, DG-108, DG-105, and DG-103 for Polytec low pressure hot-casting applicadispensing machine tions as well as the fully automated and fully controlled multicomponent series DG-200. At the show, Polytec EMC will introduce its new DG-130 and DG150 series for the first time. Both machine series are designed as two- or three-component machines for all MDI/TDI/Mboca systems. Optional equipment like colour dosing, degassing, agitators or automatic refilling is also available.

Saip, hall A, stand D04, D05 The Italian company Saip will present its EL series elastomer casting machines, which were designed and developed to process prepolymer systems based on MDI. Saip says its EL series low pressure machines easily meet any production requirement thanks to their sturdy construction and simplicity of use.

The EL series low pressure maSaip EL series elastomer chines are available in a wide casting machine range of models with outputs ranging from 8 – 20 kg/min and working temperatures up to 80 °C. According to the company, the most important advantages include an attractive price/performance ratio, low energy consumption, and easy maintenance.

Secmer, hall B, stand F03, F04 The French company Secmer, part of the Baulé group (see p. 20), will introduce its new low pressure dispensing range of machinery designed for use in polyurethane CASE applications, foams, potting and encapsulation of low temperature processing resins. Features of the new machines include: recirculation for all components, pressure control, dynamical mixing, precision gear pumps, and cleaning of the mixing system with a cleaning rinsing line. All Secmer machines feature a programmable logic controller combined with a touch screen panel.

The Multicast series offers heavy duty, low pressure, low temperature

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

dispensing machinery that can cope with between two and four components with an output of 5 g/min to 300 kg/min. The machine can process any cast resin or foam whatever the viscosity, says Secmer.

The Dosamix series of two-compoDosamix two-component low pressure dispensing nent low pressure machine dispensing machinery is ideal for lab tests and can generate an output of 5 – 500 g/min of material. The machine can cast resins or foams that are processed at room temperature.

Wintech Engineering, hall B, stand F01 Australian CNC foam cutting machinery manufacturer, Wintech Engineering, will be exhibiting its range of blade, abrasive wire, and hot 185x130_E_PU_MON:Layout 1

26.01.2011

18:15 Uhr

wire contour cutting machines at the trade show. Its oscillating blade contour cutting machines use a narrow (3 mm) sharp blade oscillating with a stroke of 46 mm at 50 – 60 cycles per second and produce fast, dust-free cutting of a wide range of flexible foams. The design ensures speed, accuracy, and clamp-less cutting for high productivity, says the company.

The oscillating blade allows for tighter shape cutting and complete circle cutting in one pass. These machines can even spiral cut a block into one continuous sheet and also provide sheet and contour cutting capability.

Wintech Fastwire abrasive wire contour cutting machines are available in a range of sizes and use an abrasive cutting wire moving at nearly 300 km/h to cut almost any type of rigid or semi-rigid foam.

The company exports these machines all over the world. Recent sales have been to Russia, Algeria, South Africa, France, Iran, and China.

For cutting EPS foam, hot wire cutting options are available. Wintech provides machine installation, on-site operator training, and after sales service in over 25 countries.

Furthermore, the company will presents its Hotwire and Compuset contour cutting machines as well as its Compuline automatic cutting line machine for cutting EPS foam. 

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Pur(e) Fascination...

Whichever way you look at it, by choosing Hennecke's plant and machinery technology you are laying the foundation for superior product quality and efficient raw material utilisation. You won't regret your decision to opt for innovative technology that has great economic and ecological benefits and can be used for countless applications and fascinating PU-based products.

>> Metering machines

>> Sandwich panel lines

>> Moulded foam lines

>> Refrigeration equipment lines

>> PUR-CSM spray technology

>> 360˚ Service

>> Slabstock lines

>> 100% know-how for all your ideas!

PU Tech 2011, India 09.03. - 11.03.2011, Stand C16

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

www.hennecke.com

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Finished products

Recticel, hall B, stand G22, G23

Arvind International, hall B, stand H14 The Indian company Arvind International Ltd. from Bagru near Jaipur is a producer of all kinds and classes of PU foam, rubberised coir, rebonded foam and its products as well as mattresses, pillows, and home comfort products marketed under the Arvind brand. The company operates four plants. At PU TECH 2011, it will display die-cut foam components and FR foam.

Jumax Foam, hall B, stand E04 Jumax Foam Pvt. Ltd. is a manufacturer of flexible polyether foam, flexible moulded foam, and rebonded foam. Its clients include companies in the automotive, footwear, and home furnishing industries.

Jumax says it only manufactures 100 % pure foam without fillers. Its rebonded foam plant recycles over 1,200 t of foam scrap every year.

Its offering to the footwear industry includes flexible polyether foam with high load bearing properties or for lamination, anti-UV foam with non-yellowing properties, and rebonded foam with small chip size.

Jumax products for the automotive industry include flexible moulded headrests, flexible polyether foam for lamination with anti-fogging and FR properties as well as rebonded foam components.

Wanhua acquires full control of BorsodChem Wanhua Industrial Group has acquired full control over the Hungarian isocyanate producer BorsodChem by exercising a call option which it was granted as part of BorsodChem’s financial restructuring in June 2010. Wanhua purchased all the shares held by funds advised by Permira and Vienna Capital Partners, the company’s previous majority owners. As part of the restructuring last year, Wanhua provided BorsodChem with new funds of EUR 140 million, which the company currently uses to complete the construction of the new TDI-2 plant and the new nitric acid plant. The long-term development

30

of BorsodChem is now secured

by Wanhua, which is financially backed by a syndicate led by the Bank of China.

“The integration of BorsodChem into the Wanhua Group creates the third largest isocyanate producer in the world by turning both companies from two regional players into one global company.

I am convinced of the future benefits of our partnership sharing industry know-how and driving genuine synergies,” said Jason Ding, Chief Executive Officer of Wanhua Industrial Group. “Wanhua will leverage BorsodChem on its path towards globalisation.

W ithin the Wanhua Group,

Recticel will be showing its technical solutions in flexible PU foams for different markets such as automotive, sports, healthcare, acoustics, and consumer goods. The company offers a broad range of PU foams for industrial and domestic applications, e. g. insulation, acoustics and shock absorption, high-tech formulations to produce ceramic filters in iron and aluminium casting industries as well as painting, shoe, healthcare, and lingerie applications. The Belgian group has over 100 establishments in more than 20 countries.

Sheela Foam, hall A, stand B07, C02 Sheela Foam Pvt. Ltd. is a leading flexible PU foam manufacturer in India with presence in all four major regions of the country. At the trade show, the company will showcase its foams for special applications, moulded car seat foams, and comfort products. Sheela will also present its new glow foam, heat sensitive foam, and special applications of flexible PU foam in industrial products. In addition, it will inform about its group company Sheela Woodbridge Urethanes (P) Ltd., which supplies the seat foam for the Tata Nano, and it will discuss the restructuring of its Australian subsidiary Joyce Foam. Sheela Foam will present a paper at the conference, titled “Formulation and characterization of silica-based hybrid flexible polyurethane foam”. 

BorsodChem will be responsible for Wanhua’s European operation. We aim to expand BorsodChem and make it the most competitive isocyanate producer in Europe,” added Ding.

“Wanhua has acquired a successfully re-engineered company with efficient production technologies and committed employees. The strategic cooperation with Wanhua will make BorsodChem an even stronger partner to the European customer base of the group. In addition, it creates an access for BorsodChem to the Asian markets. With these excellent future perspectives BorsodChem will remain one of the largest employers in Hungary,” said Wolfgang Büchele, Chairman and CEO of BorsodChem.

“By developing a world-class management team with crisis

and restructuring experience and implementing a successful reengineering programme, Permira has achieved that now BorsodChem is a lot stronger and much more competitive than four years ago. We are convinced that the new owner will continue along the growth strategy that Permira and VCP initiated,“ said Christian Neuss, Partner at Permira.

“This transaction is highly significant for Central Europe and will pave the way for further investments by Chinese companies in the region. Having been invested in and committed to BorsodChem for more than a decade, we would be pleased if we could continue to be involved in the company under Wanhua’s stewardship,” said Heinrich Pecina, Senior Partner of VCP. 

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Chinaplas 2011 celebrating its 25th edition chinaplas 2011, the 25th international exhibition on the plastics and rubber industries, will be held from 17 – 20 May 2011 in the largest exhibition hall in Asia, the china Import and Export Fair Pazhou complex, Guangzhou, china. According to the organiser, the event is the largest plastics and rubber exhibition in Asia and one of the most influential exhibitions of its kind in the world. The exhibition will cover a total area of more than 160,000 m2. The event is expected to attract more than 2,200 exhibitors from 35 countries and regions and will feature 11 pavilions hosted by Austria, canada, France, Germany, India, Italy, Japan, UK, USA, china, and Taiwan. The organisers expect about 80,000 visitors, 18 % of whom are overseas visitors from more than 130 countries and regions.

The year 2011 marks the 25th edition of Chinaplas. In the past two decades, the exhibition experienced many ups and downs, including the Asian financial crisis in 1998, the “9.11” incident in the USA in 2001, the SARS outbreak in 2003, and the global financial crisis in 2008. However, by virtue of perseverance, the organiser says to have overcome these challenges. To celebrate the 25th edition of Chinaplas, a series of concurrent events will be organised during the exhibition period.

In early times, Chinaplas was a platform to provide learning opportunities for Chinese enterprises. When recalling the first edition of Chinaplas, Stanley Chu, Chairman of Adsale Exhibition Services said, “There were only several thousand square metres of exhibition space and a hundred exhibitors which were all overseas companies. There weren’t any China-made products and technologies at the fairground in the first edition.

However, thanks to the growth of the plastics and rubber industries after China launched its open door policy, Chinaplas has become one of the top three international plastics and rubber fairs in the world and is now ranking first in Asia. Having grown with the plastics and rubber industries, Chinaplas has witnessed a strong development in the past two decades.”

Following the overwhelming response for “Green Forum”, a concurrent activity of the last edition, Chinaplas will organise a “Chinaplas 2011 – Eco-friendly Plastics Conference” this year. The government officials from the mainland and Hong Kong, the environmental experts and leading enterprises from related industries will get together to share their insights on “green” plastics and machinery. Experts will give lectures on production technology, market supply chain, practical application of low-carbon plastics, successful case studies as well as breakthrough achievements in research.

Chinaplas 2011 is organised by Adsale Exhibition Services Ltd., hosted by the China Foreign Trade Guangzhou Exhibition General Corporation and co-organised by the China Foreign Trade Cen-

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

tre (Group), China National Light Industry Council – China Plastics Processing Industry Association, China Plastic Machine Industry Association, Guangdong Plastics Industry Association, Messe Düsseldorf China Ltd., Shanghai Society of Plastics Industry and Beijing Yazhan Exhibition Services Ltd. In addition, the event is supported by the China Rubber Industry Association as well as various other plastics and rubber associations in China and abroad.

First introduced in 1983, Chinaplas is China’s only plastics and rubber trade show approved

by UFI – The Global Association of the Exhibition Industry. Chinaplas has been exclusively sponsored by the European Plastics and Rubber Machinery Manufacturers Association (EUROMAP) in China for the 22nd time.  Since China’s reform and open door policy, all kinds of businesses have been thriving for the past three decades. As one of the important pillar industries of its economy, the plastics industry has continuously maintained high-speed development for the past 30 years. Its average annual growth rate is over 10 %, which is higher than the total growth rate of the national economy. According to statistics provided by Adsale, more than 20,000 plastic processing companies realised an industrial output value of CNY 499.72 billion between January and May 2010 in China. The output value of new products accounted for 4.38 % with a year-on-year growth of 32.48 % and a sales-output ratio of 97.97 %. In addition, the export delivery value reached CNY 79.049 billion with a year-on-year growth of 25.77 %, and the proportion of exports among sales rose to 16.15 %. The Chinese rubber industry also experienced a steady growth in 2010. Statistics show that the industrial output value from January to November 2010 was CNY 229.23 billion, with a year-on-year growth of 22.1 %. The sales income was CNY 228.02 billion, with a year-on-year growth rate of 24.3 %.

The export delivery value was CNY 60.6 billion and its year-on-year growth rate was 35.6 %.

31

Sonderhoff with new activities in India, Israel, and Australia The rising demand for service and support in the plastic and rubber industry markets is the reason for Sonderhoff, a leading system supplier of FIPFG (Formed In Place Foam Gasket) technology, to extend its activities to further growing countries for all relevant applications, like automotive, electronics, enclosures, filters, lighting, and packaging.

Sonderhoff already has several subsidiaries and representatives all over the world, e. g. in Europe, China, North and South America, and Africa to maintain and improve its competitive position worldwide.

Now the company presents its new partners and representatives in India, Israel, and Australia.

In India, Sonderhoff cooperates with Magal LVD India Pvt Ltd. Magal with its 30 employees was founded in 1992 by M. K. Narasinga Rao and has branches in Chennai, Pune, and Delhi. Over the years, Magal has represented many large overseas manufacturers in India and successfully built a respectable clientele based on principles of technological proficiency and conscientious customer service. Today, Magal has firmly established itself as a one source company for supply, service, and consultancy of engineering in India. The group’s capabilities is evident from its long list of customers, across various industry sectors like automotive, machine tools, and material handling.

Technology X Materials Ltd. will be the new partner for Sonderhoff in Israel. TXM positions itself as highly focused, technical oriented distributor of adhesives, sealants, Sonderhoff multi- component dosing and mixing system

Sonderhoff mixing head MK 600

and dispensing equipment for industrial applications in Israel. TXM was established as trading company in 2008 and its management, engineers, and sales team have over 20 years experience to provide customers with quality industrial products and to deliver first class solutions and service. TXM offers a wide range of products like material and machines of Sonderhoff to industrial users.

The goal of TXM is to become its customer’s first choice when it comes to solutions concerning adhesives or sealants, encapsulation and dispensing equipment for industrial applications in Israel.

The third new Sonderhoff partner comes from Australia. Amtronics is a service company that also provides sales of machines and products to increase the customer’s productivity. The company with its branches in Sydney and Auckland covers almost all machines in the sheet metal industry as well as

32

machines in other industries. Amtronics builds custom made automation and robotics applications and handles all the machinery safety applications ensuring maximum operation with its safety integration into the customer’s machinery. Amtronics’ core business as service provider allows to deliver skilled engineers with a wide range of technical expertise to support Sonderhoff machinery and applications. The new Australian representative handles everything from machine and application recommendations to installation, after sales support, and maintenance. Amtronics can also help to integrate the Sonderhoff machines into existing automation lines.

Because of their technical expertises and insights, Sonderhoff is convinced that Magal, TXM, and Amtronics are the best partners for the company to succeed in the Indian, the Israeli, and the Australian plastic and rubber markets. The systematically acquired knowledge, more than 1,000 formulations, and the innovative power of the Sonderhoff group of companies ensures customer orientation, tailor-made products, and solutions in line with market conditions. Its polymer two-compoment products for gasketing, glueing, and potting as well as for foam moulding are dispensed on site and in a wide range of products – across all levels, using diverse materials and in varied geometries by using contour robots in freely programmable geometry – CNC-controlled.

Sonderhoff combines its chemical and technical competence with creative services.

This includes supporting customers from the production of individual prototypes to taking over series production as well as consultancy and training. 

Peter Fischer, Marketing Director p.fischer@sonderhoff.com carsten broich, Marketing Manager c.broich@sonderhoff.com Sonderhoff holding Gmbh, cologne, Germany

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

The global PU industry returns to growth in 2010, but challenges remain In contrast to 2009, most PU markets demonstrated better than expected growth in demand for PU raw materials. Care should be taken when comparing years, because several markets experienced sharp changes in demand patterns. In total, global production is estimated to have exceeded 2008 levels by the end of 2010 reaching an estimated 15.8 million t, although production in NAFTA, Europe, Middle East and Africa did not fully recover.

All major regions experienced positive growth in PU production during 2010 (tab. 1). This is no surprise since markets fell sharply during 2009 and any slight growth will be reported as positive. Growth in Europe, North America and China benefited from various stimulus packages during 2009 and 2010, as these are more or less finished, growth in 2011 is expected to be slower. European recovery remains a two speed affair but energy efficiency and legislation is helping to drive demand for MDI in North America and China. South American economies remain buoyant, especially Brazil, where consumer demand is growing fast and much hope rests upon the Soccer World Cup and Olympic Games Global automotive production is expected to have grown 8 % during 2010, according to initial data from the German association of the automobile industry VDA (Verband der Automobilindustrie). The association also forecasts further growth of 8 % for 2011.

“The worldwide demand for passenger cars is continuing to rise. People’s desire to own their own automobile is obviously a crosscultural and multi-continental phenomenon,” Matthias Wissmann, VDA President announced at a recent press conference in Berlin. He also anticipates that the focus of the world’s automotive market will continue to shift. “China’s proportion of the global

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

automotive market will have climbed from 10 % to 19 % between 2008 to 2011, while the USA and Western Europe will each lose 3 %,” he suggested (tab. 2).

Global indicators are positive The combined wisdom of various economists suggest that the global economy will continue to grow at an average of 4.0 % over the next two years. Historically, demand for PU products and chemicals has grown at rates higher than GDP, so perhaps the future is starting to look more optimistic, although countries such as India still need per capita GDP to increase significantly before PU demand reaches equivalent levels to developed markets (tab. 3).

NAFTA optimistic for 2011 2009 had the worst beginning to a year ever, but the impact of stimulus programmes and the resulting economic recovery helped the PU industry to regain some lost ground.

During the first nine months of 2010, some MDI suppliers reported growth in US sales as high as 25 % compared to 2009. Demand has been driven by dramatic recovery in the automotive industry and demand for insulation materials. US automotive sales were up 

by 11 % in 2010 compared to the previous year and automotive sellers and manufacturers have been re-stocking inventory levels.

This recovery led to an increase of 63 % in production during H1 2010 vs. H1 2009.

H1 2009 reported 3.6 million builds compared to H1 2010 of 5.9 million. H2 2009 and H2 2010 builds are of a similar number of 5 million and 5.5 million respectively. However, when making this comparison it should not be forgotten that the “cash for clunkers” stimulus package did not kick in until H2 2009, so such dramatic growth will not be repeated.

“Although demand for MDI was down during Q4 2010, after three quarters of growth, the outlook for 2011 is one of stabilisation.

2011 should see some further growth in demand but not as much as in 2010. Hopefully by 2012, demand will be back to or close to 2008 levels,” suggested Jerry MacCleary, Senior Vice President, Polyurethanes North America Marketing and Business Development, Bayer MaterialScience LLC. “Growth in 2011 for MDI could be 10 % and then stabilising to 5 – 6 % by 2012.”

MDI growth in the region for 2011 is expected to be double digit, given the impact of legislation, including CARB 2. The effect of the new Ashrae 90.1 building code should also stimulate demand for more PIR panels and spray foam for wall insulation in the commercial market, once more normal market conditions are established. “We remain optimistic about the effect of CARB 2 on demand since MDI binders allow better process optimisation and faster production than conventional UF resins for OSB,” stated Mark Bradley, General Manager, Yantai Wanhua

Tab. 1: Estimated PU production by region, 2008 – 2011 (forecast) (t) (% AAGr)

Region

2008

2009

% AAGR

2010

2008/09 NAFTA South America

% AAGR

2011 (f)

2009/10

% AAGR 2010/11 (f)

2,922,000

2,500,000

-14.4 %

2,630,000

5.2 %

2,750,000

4.6 %

558,000

604,000

8.2 %

660,000

9.3 %

702,000

6.4 %

china

4,235,000

4,600,000

8.6 %

5,250,000

14.1 %

5,732,000

9.2 %

EMEA

5,557,000

4,915,000

-11.6 %

5,300,000

7.8 %

5,487,000

3.5 %

1,800,000

1,670,000

-7.2 %

1,960,000

17.4 %

2,063,000

5.3 %

15,072,000 14,289,000

-5.2 %

15,800,000

10.6 %

16,734,000

5.9 %

Asia Pacific Total

Source: PU Magazine & industry estimates

33

America Co. “In Canada the OSB and automotive industries are recovering and in Mexico there is also stronger recovery than expected.”

US housing starts remain low The number of private housing starts in the US decreased by 5 % during 2010 to a total of 560,000. The level of activity in the US is expected to remain well below the 1 million mark until 2012. Residential housing starts are still 18 months away from normal levels and the commercial construction markets have bottomed out due to lack of available financing and oversupply. However, there is some growth in the installation of wall and roofing PU and PIR insulation in the retrofitting of commercial buildings as the building envelope concept is being adopted.

Mexico did not show such a strong reaction to the economic recession, and customer behaviour has not been as extreme as in the US. Mexico and Canada have both performed better than the US but are still not back to 2008 production levels. The Canadian residential market is showing signs of recovery with new housing starts of 150,000 reported for 2010. This trend is reflected in an improving OSB industry, although production remains low compared to the 2007 levels.

US flexible foam faces difficulties As far as the US flexible foam industry is concerned the demand for new furniture is low and demand is still being met by imported goods. While mattresses are mainly produced here, there are some imports entering the market. Bedding sales are improving slowly but furniture production remains a severe problem. Sales of new mattresses have shown some recovery over 2009 both in terms of units and USD value. Recent reports from the International Sleep Products Association (ISPA) suggest that production of mattresses will have increased by 5.5 % during 2010 and that a similar growth in

34

ergy. These out of the box applications drive innovation and use PU’s exceptional properties allowing the material to be used to find solutions to difficult problems,” said Christoph Gahn, Vice President, Urethane Chemicals NAFTA, BASF.

sales value will also be achieved. The forecast for 2011 is for a 5.7 % rise in USD sales and a 3.5 % rise in units.

“Experience shows that mattress sales are influenced strongly by trends in the national economy, especially by changes in consumers’ disposable income, sales of new and existing homes, and changes in consumers’ wealth,” said ISPA President Ryan Trainer.

“So far this year, the industry is performing significantly better than it did at this time in 2009, but we’re not out of the woods yet.

Unemployment remains high, consumer confidence fell in June, and many consumers and businesses are anxious about when and how quickly the economy will improve.”

South America – a land of opportunities MDI sales to South America are reported to have grown by 25 % during 2010 due to record production of new vehicles, appliances, foundry binder and the start of an insulation industry. In addition, demographic changes will create a huge growth in demand for new homes and consumer goods.

Brazil is now self-sufficient in energy, is rich in natural resources and is enjoying a period of political stability.

According to Statistics Canada, sales of mattresses and upholstered furniture were reported to have also bounced back sharply during H1 2010 by 16 % and 4.2 % respectively, suggesting that the industry is starting to make a recovery.

Brazil expects to attract more than USD 35 billion of domestic and foreign in-

In contrast to the flexible foam sector, the CASE sector continues to provide opportunities for growth. Low VOC, solvent-free and “bio” products for both industrial and household use have experienced positive growth throughout 2010. “The CASE sector is likely to drive innovation in the PU industry in North America and other developed global markets because most foam applications in automotive, construction, and appliances are mature. Examples include the new Airbus A380 that is “glued together”, oil and gas pipeline coatings, and solar en

Tab. 2: Global automotive sales trends in major  markets (January – November 2010) Region

Change (Jan. – Nov. 2009)

Units

EU27 + EFTA russia*

12,736,100

-5.1 %

1,706,300

27.6 %

USA*

10.414,600

11.1 %

Japan

3,972,600

10.3 %

brazil*

2,967,700

8.7 %

India

2,193,100

31.5 %

china

10,169,600

36.6 %

*light passenger vehicles only Source: VDA

Tab. 3: Economic indicators for PU major markets, 2010 – 2012

Major markets

GDP in USD trillion

Population in millions

GDP/capita in USD

Growth in output (% AAGR)

2010

2010

2010

2010

2011

2012

china

5.72

1,343

4,260

10.1

8.9

9.0

India

1.52

1,214

1,253

8.4

8.2

8.4

brazil

1.97

195

10,094

7.6

4.5

5.2

Mexico

1.02

111

9,207

5.0

3.4

3.5

russia

1.48

140

10,522

3.9

3.7

3.9

USA

14.16

308

46,000

2.6

2.2

2.8

Japan

5.02

127

32,000

2.7

1.1

1.4

EuroZone

16.21

501

32,900

1.7

2.3

2.9

World

62.03

6,890

9,020

4.5

4.0

4.4

Source: Global Insight & UN

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Europe, Middle East & Africa – three tier market

vestments in the run up to the Soccer World Cup in 2014 and a further USD 10 billion for the Olympic Games in 2016. For theses events an estimated 20,000 new hotels will be built, requiring at least 4 – 5 million new mattresses!

“EMEA is definitely a three tier economy,” believes Steven English, Business Director Dow Polyurethanes. “The Middle East and Africa are small but growing the fastest.

Some countries in Northern Europe have seen positive growth in demand for PU raw materials, some even achieving double digits, Russia has come back strongly and is expected to continue this trend as oil and gas prices increase. Meanwhile, the debt laden economies of Southern Europe remain mainly depressed.”

Production of furniture in Brazil declined in 2009 due to the effects of the global economic crisis but also due to increasing penetration of Asian made goods. Demand has been stimulated by a reduction in sales taxes and increased consumer purchasing power.

Overall, production of furniture will recover to grow by 3 – 4 % in 2011, according to CSIL, Milan. Government financing policies have also stimulated the housing market, enabling the growing middle class population to buy a home. A policy called “My house, my life” offers subsidies for first time house buyers.

“While industries such as furniture and automotive were hit hardest by the recent crisis, there was only limited impact on insulation products. One example has been the strong growth in demand for insulation boards,”

2009

2010

Growth 2009 – 2010 (% AAGR)

USA

365,000

335,000

-8.2 %

Mexico

55,000

56,000

1.8 %

canada

38,000

40,000

5.3 %

Total North America

458,000

431,000

-5.9 %

South America

320,000

365,000

14.1 %

West & East Europe

1,100,000 1,150,000

Market

Africa Middle East, inc. Turkey Total EMEA India, Pakistan, Sri Lanka, Bangladesh

4.5 %

220,000

260,000

18.2 %

180,000

220,000

22.2 %

1,500,000 1,630,000

100,000

11.1 %

880,000

920,000

4.5 %

Australia & New Zealand

28,000

26,000

-7.1 %

South Korea

30,000

31,500

5.0 %

Japan

44,000

46,000

4.5 %

Vietnam

14,000

17,000

21.4 %

Malaysia

14,000

16,000

14.3 %

China

Singapore

5,000

5,000

0.0 %

Philippines

25,000

27,000

8.0 %

Taiwan

35,000

38,000

8.6 %

Indonesia

40,000

44,000

10.0 %

Others

10,000

12,000

20.0 %

Total Southeast Asia & Australasia

245,000

262,500

7.1 %

Global total

3,493,00 3,708,500

Source: PU Magazine International

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

6.2 %

During the next few years, government budget cuts across both Southern and Northern European countries are expected to impact the level of subsidies for insulation and construction projects. However, at the end of 2010, the European rigid foam industry association, PU Europe, was successful in persuading the European Parliament to adopt its initiative report on the future EU energy efficiency strategy, which will be tabled by the Commission in March 2011. The report calls on the EU to set a binding energy efficiency target of at least 20 % by 2020. Enforcement is considered necessary since at the current rate of improvement only 9 % savings will be achieved by 2020. The report provides overwhelming evidence of the economic, social and environmental benefits of investments in energy efficiency. It suggests that meeting the 20 % energy savings target could create up to one million new jobs and reduce energy costs by up to EUR 1,000 per household.

Flexible foam production patchy

8.7 %

90,000

said Frank Grunert, Head of Marketing for EMEA and LATAM regions, Bayer Material­ Science. “Since buildings emit over 40 % of greenhouse gas emissions, many countries in Europe have stiffened their regulations regarding energy savings and this has led to a strong interest in rigid PU foam.”

The automotive market declined 25 – 35 % in 2009 but has almost recovered to 2008 levels of production during 2010. There is still concern about whether this is sustainable because new purchase incentives have pulled Tab. 5: refrigerator and freezer production in  china, 2005 – 2010

 Tab. 4: Estimated global production of PU flexible slabstock, 2009 – 2010 (t)

Year

Fridges (in million units)

Freezers (in million units)

2005

31

6

2006

35

7

2007

41

10

2008

43

11

2009

60

13

2010

70

15

Source: chEAA

35

through demand faster than normal. Due incentives, sales of smaller and medium sized cars have increased most, while sales of luxury models have benefited from exports. Unfortunately, production of smaller, more efficient models means less PU per vehicle.

As far as flexible foam slabstock is concerned, the EMEA region is definitely a three tier market. The size and growth of some of the “emerging markets” of the Middle East suggest that they no longer deserve this label. For example, the Turkish market has grown enormously during the past ten years.

There are now 25 foamers who produced approximately 85 kt in 2010, bouncing back from the 30 – 40 % decline in slabstock production experienced in 2009.

There has been some growth in the bedding markets where foam mattresses have further increased their market share. Foam mattresses are expected to have achieved a 50 % share of the German market in 2010. Foam mattresses, especially viscoelastic (VE) mattresses, were given favourable reports from Stiftung Warentest during September 2010. This may have spurred on the sudden increased sales in H2 2010.

There is growing demand for flexible foam in Eastern Europe for both bedding and upholstered furniture. Production in Poland continues to grow as the new Ikea-owned plants, Dendro and Komforti, ramp up production.

Total capacity in Poland is now estimated to be 130 – 140 kt/y. In 2011 a new foamer also plans to start up production in the south of the country, adding further capacity.

In Russia, Foamline was hit hard during 2009, but they are reported to have invested in new projects and equipment in preparation for the upturn in demand for higher quality foams that started during 2010. Markets outside Russia have also performed well during 2010. Plama Pur in Slovenia have invested in a new polyether slabstock plant in Bosnia and upgraded equipment in Slovenia.

Interfoam in Ukraine has also been upgrading its lines in order to offer higher quality foams to a recovering market.

36

Demand for MDI from the European flexible slabstock market continues to increase as more producers of VE foams use MDI-based formulations to meet mattress manufacturer specifications.

have also lost out due to the strength of the EUR vs. the USD and a weak housing market. Table 4 illustrates the growth trends in the global flexible slabstock production including Africa and the Middle East.

In Southern Europe, upholstered furniture production in Spain and Portugal has declined 30 % during 2010, but sales of mattresses have held up a bit better. Italy continues to struggle with overcapacity and a loss of export sales. Italian producers, including Natuzzi, are also suffering from low cost copies being exported into the US. Italians

“Within the EMEA region, the MDI market is expected to grow by 15 – 20 % during 2010, while the TDI market may have grown by 7 – 10 % during the same period.

For the whole year of 2010, we expect demand for MDI and TDI to have reached levels higher than those of 2008,” suggested Grunert.

Indian PU production

t

Flexible slabstock

90,000

Flexible moulded foam

48,000

rigid foam

37,000

Shoe sole resin

21,500

cASE

12,000

TPU Tab. 6: Estimated PU production in India, 2010

2,500

 Total

211,000

Source: PUIA

NAFTA

South EMEA America

APAC

China

Total

MDI

840

115

1,450

800

1,170

4,375

TDI

195

140

540

170

490

1,535

Aliphatic NcOs Polyester polyols (aromatic) Polyester polyols (aliphatic)

50

5

55

22

85

217

185

15

195

8

25

428

90

30

190

175

500

985

750

265

2,100

360

1,675

5,150

17

20

110

75

140

362

503 Tab. 7:  Additives Estimated demand for PU Total 2,630 raw materials by region, Source: PU Magazine Intermational 2010 (t)

70

660

350

1,165

2,748

660

5,300

1,960

5,250 15,800

APAC

China

Polyether polyols Speciality polyols (acrylic, PhTF, graft)

NAFTA

Total

MDI

925

121

1,535

830

1,280

4,691

TDI

185

148

555

178

540

1,606

50

5

57

23

87

222

200

16

205

12

30

463

Aliphatic NcOs Polyester polyols (aromatic) Polyester polyols (aliphatic) Polyether polyols Speciality polyols (acrylic, PhTF, graft) Tab. 8: Forecast demand for PU raw materials by region, 2011 (t)

South EMEA America

 Additives Total

85

32

185

180

600

1,082

780

285

2,175

380

1,845

5,465

17

21

105

80

150

373

1,200

2,832

508

74

670

380

2,750

702

5,487

2,063

5,732 16,734

Source: PU Magazine Intermational

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Africa – underestimated Opportunities in Africa are often underestimated or ignored due to business barriers.

An estimated 260 kt of flexible slabstock was produced in 2010 to meet growing demands for greater comfort. Nigeria is the largest manufacturer, producing an estimated 90 kt in 2010. Here mattresses are typically 40 – 45 cm deep and used for general living and sleeping. Generally low density, low quality foam is used, requiring replacement after only 2 – 3 years leading to a growing disposal problem as old mattresses are simply abandoned. Elsewhere, the African market is developing due to in-

vestments by major groups such as Tuff Foam of Uganda, Mouka and Vitafoam of Nigeria, outside of their domestic markets.

Refrigerator production is also developing, mainly in North Africa with several new plants recently installed by local manufacturers in Egypt, Algeria and Tunisia. North Africa continues to offer a low cost, off-shore, production base to European manufacturers of PU products, including auto components and furniture. Interest in insulation is developing, several Spanish spray foam contractors, whose domestic market has almost disappeared are finding business here, insulating upmarket residential buildings.

MDI capacity by manufaturer

2010

2011

2015

2020

bASF

1,170

1,170

1,570

1,570

bayer MaterialScience

1,340

1,340

1,755

2,245

huntsman

970

970

1,170

1,170

Dow chemical

695

695

695

695

yantai Wanhua

500

800

1,000

2,000

NPU

400

400

400

400

borsodchem

160

160

200

200

Mitsui & co.

60

60

60

60

Kumho Mitsui Total

130

130

130

130

5,485

5,785

7,040

8,530

Source: Industry sources

TDI capacity by producer

2010

2011

2015

2020

bASF

560

560

560

560

bayer MaterialScience

415

665

850

850

Mitsui

240

240

240

240

Dow

65

65

65

65

Perstorp

125

125

125

125

KPX Fine chemical

100

100

100

100

borsodchem

200

200

200

200

Zachem

75

75

75

75

Nanya

30

30

30

30

Dc Korea

50

50

50

50

blue Star

130

130

130

130

Gansu yinguang

100

100

100

100

beijing Jinhua

50

50

50

50

rio Tecero

25

25

25

25

NPU

25

25

25

25

cangzhou Dahua

80

100

180

180

Gujurat Namadur Fertiliserco.

17

50

50

50

yantai Wanhua

0

0

300

300

2,287

2,590

3,155

3,155

Total Source: Industry sources

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

 Tab. 9: Global MDI capacity, 2010 – 2020 (kt)

China – still heading for overcapacity?

China is now the world’s largest single manufacturer of both products and raw materials, producing 5,25 million t of PU products and operating raw material plants with 5.5 million t of capacity (TDI, MDI, AA, PPG, BDO). Tables 7, 8, 9 and 10 illustrate the tremendous growth in raw material capacity slated for the country over the next 5 – 10 years and table 1 shows the growth in total production since 2008. China is fast approaching self-sufficiency in terms of raw materials, although supply/demand projections suggest that overcapacity could become an issue starting from 2012.

High-end applications in transport and communications as well as exports and development of the industrial markets are expected to absorb much of the capacity.

Flexible slabstock production remains difficult to estimate, but based upon TDI demand, production is estimated to have exceeded 900 kt in 2010. There is scope for quality improvements not only for furniture and mattresses but also for medical applications, footwear, and toys.

The rapid evolution in industry development might suggest that sectors, such as flexible foam and appliance, are becoming mature in terms of product development.

But no, some manufacturers are looking to produce highly technical foams for medical applications and appliance manufacturers are using state-of-the-art technology to produce more efficient models. Production of domestic refrigerators continues to expand due to government incentives (tab. 5).

CASE has overcapacity

 Tab. 10: TDI capacity by manufacturer, 2010 – 2020 (kt)

Some parts of the Chinese PU industry continue to suffer from overcapacity, mainly in the production of synthetic leather and shoe sole resins, spandex fibres, and TPUs. There are an estimated 20 shoe sole resin manufacturers and 20 synthetic leather manufacturers. In the next 2 – 3 years a further

37

545 kt of synthetic leather resin capacity is anticipated. TPU production capacity is reported to be 300 kt, while production in 2010 was only 170 kt. Spandex production is also highly competitive, more than 30 manufacturers have a total capacity of 360 kt, producing 220 kt in 2010. Yet despite declining prices, production capacity is forecast to reach 450 kt within the next five years.

TDI demand in 2010 reached 490 kt of which only 50 kt were imported. The use of TDI in wood coatings is a major market, found nowhere else in the world to the same level, coating manufacturers are looking at waterborne coatings as government regulations regarding VOC emission are enforced. Total coatings production reached 5 million t alone in the first half of 2010, mainly around the Pearl river delta, where the furniture industry is concentrated. Waterborne coatings may eventually take as much as 50 % of this market over the next five years as environmental pressure forces producers to use more acceptable products.

After a slight hiccup in early 2009, production of flexible slabstock has continued to expand, spurred on by an average 15 % growth in furniture production. Capacity has increased as more manufacturers have made the transition from box foamer to a continuous line. Overall, domestic demand has been booming with furniture manufacturers focusing more on developing the domestic market through larger supply networks.

Statistics from the China National Furniture Association suggest that domestic sales grew by 30 % in 2010, although a survey by CSIL amongst 35 leading manufacturers produced a growth of 10 – 20 %.

Insulation hits a problem In 2009, China was the world second largest market for spray polyurethane foam (SPF), where along with rigid slabstock, pour-inplace foams, and panels it is used for insulation of new and existing buildings. Several highly publicised fires have forced the gov-

38

ernment to introduce tougher regulations which are difficult for SPF to meet, especially the open cell water blown foams. Japan has also introduced tougher flammability tests. Open and closed cell SPF continues to be used in the OEM and agricultural markets, insulation of water heaters, temporary industrial buildings, and pipelines.

Asia Pacific – back on track After an average decline of 7 % in PU production, the Asia Pacific region is back on its track of growth. The Indian PU market continues to grow, reaching an estimated 211 kt of products in 2010 (tab. 6) and is forecast to grow more or less continuously at 12 – 15 % per year for the foreseeable future. Growth of 4 – 5 % is forecast by the Korean PU industry for 2011 and even Japan had a sudden burst of growth in Q4 2010 as manufacturers of consumer goods anticipated strong sales resulting from year-end bonuses and 10 % growth in car sales.

Raw materials – 2011 a more expensive year “2011 will see higher raw material prices,” stated English. Based upon Q1 2011 contract prices for PU precursors, such as propylene oxide and benzene, the days of relatively low cost materials will disappear during 2011. “Isocyanate and polyol manufacturers will be unable to absorb these double digit price rises,” he continued. Benzene and PO prices are escalating fast due to increasing demand for non-chemical uses and general growth in demand for plastics from global growth. PO prices for January were 12 % up on the previous month, and crude oil prices have also moved up due to stronger demands from heating and transportation.

“All along the value chain prices are increasing,” he concluded.

“Further down the supply chain these price rises may stall growth in PU insulation. As a result of higher raw material costs, PU may become less competitive than alternative products,” anticipates Herman Motmans,

Global Marketing Director, Dow Poly­ urethanes. “The price of styrene will also make EPS more expensive and higher energy prices will affect production of rockwool, but PU may be perceived as more costly.”

On a global basis demand for MDI is expected to grow by double digits given the impact of CARB 2 legislation affecting production of OSB (orientated strand board) and MDF (medium density fibreboard) for use in furniture and construction. The need for greater energy saving and carbon dioxide reduction measures will also boost demand. Demand for MDI in China alone grew by 200 kt in 2010.

US and West European markets experienced some weakness in demand for TDI during 2010, but this disappeared during Q4. Both TDI and MDI were tight during 2010 as plants shut down for maintenance or repair.

Manufacturers anticipate a more balanced supply/demand scenario for 2011.

Tables 7 and 8 provide estimates for raw material consumption and demand for 2010 and forecasts for 2011.

Global capacity reaches new levels From tables 9 and 10 it can be seen that the global capacity for MDI and TDI starts to increase dramatically from 2013 onwards due entirely to new plants slated for China.

These figures assume that the increases listed below prove a reality and that Huntsman may also enter the Chinese market with another world-scale plant within the next five years. Plans announced for possible plants in the Middle East have also been excluded, but should not be ruled out.

Yantai Wanhua started up their Ningbo 2 plant on 22 December 2010 to give the company a capacity of 800 kt, making it the fifth largest producer worldwide and the largest in China. A further 600 kt will be added by 2014, creating a net addition of 400 kt. Yantai Wanhua has also suggested that it may even consider investing in fur-

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

ther capacity to reach 2 million t by the end of the decade.

No new capacity is due on stream in China until 2014, not even BASF Chongqing will start up before 2014. Therefore, the global MDI market is expected to remain tight during 2012/2013. BorsodChem, partly owned

by Yantai Industrial Group, hopes to start up its TDI plant during 2011, adding some 160 kt of capacity. Table 10 provides TDI capacity changes announced by manufacturers.

For BMS, the PU business has replaced growth through capital investment with innovation and cost control. In 2008/2009 BMS mothballed MDI/TDI plants until the demand recovered, most of these plants are now operational again. The use of system houses to supply product to market has also been useful in maintaining the loading of the supply chain. “BMS in 2:53:20 now leaner as a result of CPS11PUint'l.pdf 1/31/11 PM

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

the economic challenges, it has reduced inventories and instilled a low cost culture into the business,” concluded MacCleary.

“BMS intends to consolidate its production in Europe and to expand isocyanate production through the build-up of a gas phase TDI plant in Dormagen of 300 kt and expand MDI production at this site to 400 kt over the next 3 – 4 years, depending upon market development,” confirmed Grunert.

Also in December Bayer announced that it wishes to increase its capacities in Shanghai for raw materials for the production of polyurethane rigid foam, which is used, for example, to save energy throughout the cool chain as an insulant. To this end, it plans to build a new MDI plant with an annual production capacity of 500 kt. At the same time, the company also intends to expand the capacity of its present MDI production facility from 350 kt to 500 kt/y. During H1 2011,

BMS should start-up commercial production of TDI at its 350 kt plant here.

The only other new capacity that may start this year is an additional 33 kt of TDI at Gujarat Narmada Valley Fertilizers Co. Ltd. in India.

No further news has been posted by BASF as to the start-up date of their proposed 400 kt plant in Chongqing. The site has been levelled but approvals to commence construction had not been received by Q4 2010.

“Overall PU demand should continue to grow above GDP due to the demand for insulation where the material is a premium performance material. PU is always at the forefront of innovation and is used in applications because it is a polyaddition reaction with no side products and requires only simple equipment to process,” stated Gahn, optimistically. 

39

German efficiency generates growth Germany, the world’s fifth largest economy and Europe’s largest, has benefitted during 2010 from its highly skilled workforce and national obsession with quality and efficiency.

The country has successfully exported machinery, vehicles, chemicals, and household equipment to achieve one of the highest GDP growth rates in Western Europe. Export markets in China and other Asian economies were the first to recover from the global economic recession, providing excellent export opportunities for German products. Helped by the weakened Euro, the economy started to rebound from Q2 2010 by increasing exports to markets outside of the Eurozone.

Overall, German GDP growth is expected to reach at least 3.4 % for 2010, economists forecast this to slow to 2.0 – 1.8 % in 2011.

Apart from exports, household and government spending has helped to boost growth in demand for polyurethane products. Higher than expected demand for building materials from the construction sector was reported from Q2 2010 onwards, due to a period of “catch up” following the harsh winter. Sales of domestic appliances and vehicles were also stimulated by demand for more efficient and durable goods. The German consumer continues to make purchasing decisions based upon quality and performance. More efficient vehicles and appliances have experienced increased sales and mattresses with approvals from Stiftung Warentest and Blauer Engel have attracted consumer’s attention.

2009, to reach an estimated 733,000 t.

Although data presented in table 2 shows that production has not recovered to 2008 levels, the German PU industry produced a solid performance based upon improved efficiency and product development to meet consumer needs. Overall, the German PU market has performed better than the European average, at levels more or less in line with that of GDP growth, with the automotive industry recovering fastest reporting exports up by 27 % and production up by 12 % compared to 2009.

Auto production to set new records in 2011?

PU volumes produced for the German automotive sector have been quite good during 2010 reaching an estimated 73,000 t of moulded foam. Some foamers anticipate that the PU volume per vehicle will decline over the next few years due to the demand for

PU production in Germany grew by an estimated 4.1 % during 2010 compared to

40

“The German automotive industry has emerged from the crisis faster than expected (tab. 3). In 2011 we already anticipate new record levels again in passenger car exports and in domestic production. The domestic market is on course for normalisation, and new registrations will rise to 3.1 million units in the coming year. Production capacities are again being well used, and the level of orders is now far in excess of the average over recent years,” stressed Matthias Wissmann, President of the German Association of the Automotive Industry (VDA), at the association’s annual press conference in Berlin.

In 2010 the global automotive market is expanding by 8 % to nearly 60 million passenger cars and thus already exceeds the level before the crisis. Further growth of 8 % is expected in 2011, up to 64.5 million passenger cars. “The world-wide demand for passenger cars is continuing to rise. People’s desire to own their own automobile is obvi-

Use of GDP (adjusted for price) [1]

2008

2009

2010

2011

Annual changes in %

Table 1 provides data and forecasts for the German economy in terms of key economic indicators. While exports grew, so did imports of goods and services during 2010, demonstrating a return in consumer spending.

PU production shows solid growth

smaller, lighter, more efficient models. However, foamers report continued interest from automotive companies in durable, low VOC foams for seating as well as foams with a bio-content.

GDP

1.0

­4.7

3.4

1.8

Private consumption [2]

0.7

­0.2

0.1

1.1

State spending

2.3

2.9

2.4

0.5

capitalinvestment

2.5

­10.1

6.4

3.9

Equipment

3.5

­22.6

10.0

7.0

buildings

1.2

­1.5

4.2

1.6

Domestic demand

1.2

­1.9

2.4

1.3

Export

2.5

­14.3

15.0

8.0

Import

3.3

­9.4

14.0

7.7

Private consumption [2]

1.7

0.1

2.1

1.3

GDP

1.0

1.4

0.7

1.2

Employment (domestic)

1.4

0.0

0.3

0.6

consumer price index

2.6

0.4

1.1

1.3

Price change

Tab. 1: Key indicators for the german economy 2009 – 2011 (%) (Source: Press release bundeswirtschafts­ ministerium from 21. October 2010)



Absolute value in Mio. Employment (inland)

40.3

40.3

40.4

40.6

Unemployment (bA)

3.3

3.4

3.2

2.9

[1] Until 2009 preliminary results of the Statistischen bundesamtes (24. August 2010).

[2] Including voluntary organisations

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

ously a cross-cultural and multi-continental phenomenon. The German manufacturers in particular are benefiting from this development,” Wissmann underlined.

efforts German automakers were able to reduce carbon dioxide emissions by 5.7 % to an average of 157.2 g/km.

Capacity utilisation throughout the German automotive industry, which had shrunk to 62 % in the second quarter of 2009, revived in the last quarter of 2010 reaching nearly 85 %. The figure at the passenger car manufacturers is over 87 %. And the suppliers are also keeping busy, with capacity utilisation of over 81 %.

Domestic appliance demand grows despite recession

“The prospects constitute good reason for realistic optimism. Incoming orders from Germany have risen continually and with increasing speed since September. Domestic orders are now at 532,000, which is around 100,000 units higher than the average level from recent years,” Wissmann explained.

The German automotive industry has always known that research and innovation are the keys to a successful future. Implementation of the government’s “Kurzarbeit” policy has helped the industry to retain skilled workers.

In total this sector of the economy accounts for more than 36 % of all R&D spending by German industry, spending more than EUR 20 billion in 2009. As a result of the R&D Tab. 2: 

In spite of the economic downturn, sales of domestic appliances, including refrigerators and freezers have benefited from near zero inflation, and government financial stimulus packages for the economy and industry. The highest value growth in major appliances was for refrigeration and home laundry appliances. Within small appliances, small cooking appliances and personal care appliances witnessed the strongest growth. The refrigeration sector which is very important to the PU market remained relatively stable. According to the Statistisches Bundesamt there are 47 million refrigerators and 23 million freezers in German households.

Fridges and freezers are only produced at two locations in Germany. Liebherr produces in Ochsenhausen their own brand and Miele while BSH GmbH in Giengen produces the main brands Bosch, Siemens and special brands like Gaggenau, Neff, Thermador, Constructa, Viva and Ufesa.

Estimated and forecast German PU production 2008 – 2011 (t) (Source: PU Magazine International and industry estimates) 2009/2010 2010/2011 (% change) (% change)

PU production (t)

2008

2009

2010

2011(F)

Flexible slabstock

146,000

115,000

120,000

122,000

4.3 %

1.7 %

79,000

65,000

73,000

77,000

12.3 %

5.5 %

Flexible moulded auto Flexible moulded non auto

35,000

30,000

32,000

31,000

6.7 %

­3.1 %

Total rigid foam

260,000

210,000

225,000

230,000

7.1 %

2.2 %

rigid foam construction

120,000

90,000

100,500

112,000

11.7 %

11.4 %

rigid foam refrigeration

16,000

14,500

15,000

15,000

3.4 %

0.0 %

rigid foam other uses

28,000

26,000

28,000

28,000

7.7 %

0.0 %

Total rigid foam

164,000

130,500

143,500

155,000

10.0 %

8.0 %

coatings

148,000

130,000

134,500

142,000

3.5 %

5.6 %

Adhesives & Sealants Elastomers binders Total CASE* Total production

The most important contribution to the German refrigeration industry’s growth has been the introduction of new, energy efficient appliances. The A+ and A++ energy-class appliances have encouraged consumers to replace their old units. The A++ rated appliance can reduce energy consumption by 40 – 50 % compared with class A. For example a new freezer model rated A++ for energy efficiency under the EU scheme, is reported to have low running costs compared to other freezer models at less than EUR 25 per year!

Furniture depressed but bedding grows Production of flexible slabstock foam in Germany started slowly during 2010, due to declining sales of PU mattresses and furniture during Q1 2010 vs Q1 2009. Sales started to improve in Q2 so that overall, sales were down by 3.5 % for H1 compared to H1 2009. From the start of Q3, until the end of the year production of foam and mattresses unexpectedly increased in some cases by 8 – 10 % (fig. 1). Demand for raw materials, especially MDI increased by double digits, due to the growing trend for mattress companies to specify MDI based viscoelastic foams. Sales of technical foams, especially for medical applications have also been buoyant creating an overall 4.3 % increase in production compared to 2009.

Consumer preference in Germany continues to favour PU foam mattresses. Preliminary industry statistics, suggest that they have achieved a 49 % market share of the German market. Latex mattresses are reported to have lost market share while more PU foam is being used in hybrid mattresses as the Tab. 3: 

65,000

53,000

55,250

57,000

4.2 %

3.2 %

195,000

140,000

130,000

128,000

­7.1 %

­1.5 %

Vehicle type

Auto production in Germany 2008 – 2011 (units) 2008

2009

2010*

2011*

46,000

41,000

45,000

48,000

9.8 %

6.7 %

cars

454,000

364,000

364,750

375,000

0.2 %

2.8 %

Trucks

513,700

245,334

333,000

372,000

buses

10,038

7,786

7,000

7,200

878,000

704,500

733,250

760,000

*For the cASE data, particularly for coatings, it is important to note that significant amounts of solvents and other additives contribute to the total tonnage

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

4.1 %

3.6 %

Total

5,532,030 4,964,523 5,540,000 5,780,000

6,045,730 5,209,857 5,880,000 6,159,200

*Forecast; Source: VDA

41

mattress topper. PU full foam mattresses and especially viscoelastic mattresses were given favourable reports from Stiftung Warentest during September. German consumers take a close interest in technical consumer reports and this may have been an important factor in stimulating sales.

Upholstered furniture production in Germany continues to decline with recovery not expected. Here too the cyclical nature of both, furniture and mattresses production is clearly illustrated (Fig. 2).

Technology stimulates sales The Western European flexible foam market is relatively mature so developments are increasing focused on product differentiation and offering specific solutions down the value chain. Therefore, it is not surprising that the German mattress market has seen the installation of equipment to manufacture single shot moulded foam mattresses. This technology is in use in other parts of the world, but is new to the German market. Both Breckle, located in Nordheim and Dunlopillo in Hanau now have the capability to manufacture a complete mattress core in a single moulding process.

The mattresses, weighing up to 20 kg each, are made using closed mould injection and open-mould processing. These mattresses Fig. 1: 

are reported to be selling well at the premium end of the market. Certification of these mattresses by Stiftung Warentest, Oekotex, LGA and Blauer Engel have helped to increase demand for these products.

double digit rates since September. Some European manufacturers of insulated panels are reported to have been supplying products into the market at below cost simply to maintain production volumes, prices and margins starting to improve by Q4. The unexpected demand for PU construction products caught raw material suppliers with low inventories and caused manufacturers to experience difficulties in obtaining MDI during the summer. MDI supplies are now more or less in balance, allowing both raw material and insulation manufacturers to rebuild stocks during the quieter winter months.

Although production of flexible foam has increased slightly this year, due almost exclusively to growth in mattress sales, exports of foam blocks to Poland have declined. German manufacturers, close to the Polish border have traditionally exported foam to the country’s furniture manufacturers. However, since the two Ikea owned plants have started operation, the market is virtually self sufficient. Total flexible annual foam capacity is estimated to be around 140 kt and will increase further during 2011 when a new flexible foamer commissions a plant in Southern Poland.

Figure 3 is an indicator of building permits granted for structural engineering work requiring a permit in Germany during the first nine months of 2010. The upward trend is evident but levels have not yet reached those experienced at the peak of 2008 and 2007.

There is also concern that budget cuts will hit programme such as insulation and energy efficiency during 2011, thus stalling demand for retrofitting the existing building stock.

Construction benefits from government spending Many parts of the PU industry were hit hard by the recession but there was only a limited impact on insulation applications. Production of insulation boards continued to grow strongly during 2009 and again in 2010. After a slow start to the year, due mainly to the weather, demand for insulated panels in Germany and its near neighbours has grown at Fig. 2: 

Mattress production in Germany 2002 – 2010 by type (units) (Source: Statistisches bundesamt) Forecast

1,600,000

Legislation may sustain growth At the end of 2010 the European Parliament adopted an own initiative report on the future EU energy efficiency strategy to be tabled by the Commission in March 2011. The report

Upholstered furniture production in Germany 2002 – 2010 by type (units) (Source: Statistisches bundesamt) 900,000 800,000

1,400,000

700,000

1,200,000

600,000 Units

Units

1,000,000 800,000

400,000

600,000

300,000

400,000

200,000 100,000

200,000 0

0 Q 1

Q 4

2002

Q 3

2003

Q 2

2004

Q 1

Q 4

2005

Innerspring mattresses Latex mattresses

42

500,000

Q 3

2006

Q 2

2007

Q 1

Q 4

2008

Q 3

2009

PU soft foam mattresses Other mattresses

Q 2

2010

Q 1

Q 4

2002

Q 3

2003

Q 2

2004

Q 1

2005

Q 4

Q 3

2006

Q 2

2007

Q 1

Q 4

2008

Q 3

2009

Q 2

2010

Upholstered chairs with wooden frame Other upholstered seating furniture with wooden frame

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

calls on the EU to set a binding energy efficiency target of at least 20 % by 2020.

Enforcement is considered necessary since at the current rate of improvement only 9 % savings will be achieved by 2020. The report provides overwhelming evidence of the economic, social and environmental benefits of investments in energy efficiency. It suggests that meeting the 20 % energy savings target could create up to one million new jobs and reduce energy costs by up to EUR 1,000 per household across the EU.

Raw materials TDI was very tight during most of 2010, although supplies loosened during Q4 and some purchasers reported falling prices (currently 1,95 – 2,05 EUR/kg). Supplies have been restricted due to plants being idled while demand has remained surprisingly strong, especially during the second half of the year. BorsodChem may commission its TDI plant in 2011 which might stabilise the markets. Bayer MaterialScience intends to

6.8 6.6 6.4 6.2 6.0 5.8 5.6 5.4 5.2 5.0 4.8 4.6 4.4 4.2 4.0 3.8 2005

2006

2007

2008

2009

2010

Source: Deutsche Bundesbank



 Abb. 3: building permints 2005 – 2010 (EUr billion per month)

build up a state-of-the-art world-scale plant for TDI in Dormagen with an annual capacity of 300,000 t but not before 2014 and to terminate TDI production in Brunsbüttel. At that site, the annual production capacity for MDI shall be expanded to 400,000 t.

MDI was also tight during middle of the year due to a force majeure at BorsodChem and the fact that some suppliers struggled to ramp up production to meet the sudden upturn in demand for construction products following the long hard winter that delayed a lot of building work. As far as 2011 is concerned the supply/demand situation should be a little better because there should not be the sudden boom in demand that was experienced during the middle of the year. Growth rates should be more evenly spread over the year. Unfortunately, raw material prices are expected to increase during 2011 (currently 1,95 – 2,05 EUR/ kg) as contract prices for benzene and propylene oxide have already been settled at much higher levels than in 2010 and raw material manufacturer will look to pass these prices onto the PU processor during 2011. New MDI capacity is planned to come on stream until 2013. In addition, Stepan will continue to expand its polyester polyol capacity a Wessling, Germany, by the end of 2010 to meet demand from the insulation industry.

Tab. 4: Estimated raw material demand in Germany 2008 – 2011 (t) (% change) 2008

2009

2010

2011 (F)

PMDI

191 000

145 000

167 000

182 000

15,2 %

9,0 %

MMDI

80 000

65 000

54 000

50 000

­16,9 %

­7,4 %

TDI

70 000

53 000

55 000

52 000

3,8 %

­5,5 %

Aliphatic isocyanates

17 000

12 500

14 250

13 000

14,0 %

­8,8 % 5,3 %

Raw material (t)

Polyether polyols incl. graft polyols

2009/2010 2010/2011 (% Change) (% Change)

260 000

216 000

225 000

237 000

4,2 %

Polyester polyols

85 000

65 000

75 000

80 000

15,4 %

6,7 %

Other polyols

30 000

25 000

18 000

16 000

­28,0 %

­11,1 %

Additives incl. water

145 000

123 000

125 000

130 000

1,6 %

4,0 %

Total

878 000

704 500

733 250

760 000

4,1 %

3,6 %

Source: PU Magazine International & industry estimates

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Trends in the flexible and rigid foam markets are reflected in table 4, with demand for TDI declining due to a small decline in demand from the automotive industry and product substitution of TDI for PMDI in flexible slabstock. Demand for MDI is expected to grow due to demand for more insulation but at a slower rate than during 2010. MMDI demand is expected to continue falling as many elastomeric materials – shoe sole resins, cast elastomers – are produced outside of Germany. 

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Pumping and measuring high-viscosity PU components The global consumption of polyurethane is currently about 15 million t/y. This makes PU one of the most frequently used polymer materials after the so-called standard plastics (polyolefins, PVc, polystyrene). Optimal production conditions have to be available so that the advantages provided by polyurethane materials come into their own. The product quality depends on the mixing process of the high-viscosity basic components and additives.

Kral pumps and flowmeters can make a decisive contribution here.

A crucial criterion of the polyurethane com­ ponent quality and the process stability is that the liquid components polyol and isocy­ anate are made available constantly and are metered with precision. This is particularly challenging for the polyol component. In spe­ cial applications polyols with a very high vis­ cosity are processed. Even under these conditions Kral screw pumps and flow­ meters operate with precision and reliably.

Meaning very good product quality and high plant availability, even when the materials used are highly viscous.

Use of screw pumps Large quantities of raw materials are often processed during the production of poly­ urethane products. Usually the raw materials are made available in very large tank farms that are unpressurised. In order to be proc­

the specifications even in the case of high raw material viscosities, since they operate with automatic suction and feed the metering pumps continuously and free of pulsations across a wide quantity range. Meaning that the transfer of vibrations to the plant or the pumped liquids is practically excluded.

In order not to damage long polymer chains gear pumps have to be operated at low rota­ tional speeds. A screw pump pumps the liquid product­conserving, quietly, with low pulsation and with high output density. Kral screw pumps do not have to be designed larger, they remain compact and inexpensive.

Hermetically-sealed magnetic coupling

Kral volumeter and electronics

essed further within the production plant, the raw materials have to be transported from the tank to the plant. Kral pumps are suited to transporting the raw materials. In plants with continuous production they serve as booster pumps for the reaction components polyol and isocyanate. Pump sets from Kral fulfill all

In special applications fillers are added to the polyol component. Fillers influence the phys­ ical properties such as, for example, the sturdiness and electrical conductivity of the polyurethane products. In order to avoid the risk of damage to the mechanical seals through abrasive fillers, the only solution is to do completely without pumps having a mechanical seal. Kral screw pumps with hermetically­sealed magnetic couplings are conceived so that they can be designed with hardened screws and screw casings for a wide variety of fillers. The lack of a mechan­ ical seal avoids heat reactions caused by friction at the rotary ring surfaces and leak­ ages can be avoided.

Flow measurement for polyurethanes

Kral pump with magnetic coupling

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In order to manufacture polyurethane prod­ ucts having different property characteristics, it must be possible to meter a wide range of components flexibly. To this purpose the out­ puts of the individual components are sup­ plied to the mixing head by means of speed­ controlled pumps. To ensure that all the reac­ tion partners are available in the stoichio­ metrically required quantities, the pump out­ puts are monitored and controlled perma­ nently through Kral precision flowmeters.

This guarantees exact adherence to the reci­ pes for quality polyurethane products. 

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Hennecke invests in customer centre for high-volume RTM applications Focus on lightweight construction Due to increasing requirements for efficiency and ecology, interest in lightweight solutions for the automotive industry continues to grow. The focus is especially on one process: resin Transfer Moulding (rTM). Thanks to investments in a new rTM centre, hennecke Gmbh now offers sufficient scope to its customers to manufacture, test, and develop parts until they are suitable for mass production. In the process, the company can provide technical aspects of the rTM technology that ensure suitability for mass production in terms of automation and cycle time.

pressure metering takes effect. This applies to mixheads for instance, which provide quality and reproducible results. Moreover, the use of the company’s patented constantpressure injector ensures homogeneous injection pressure – regardless of whether RTM raw material systems with or without filler are being processed.

In future, customers and raw material suppliers will have the opportunity to find out more about these advantages at Hennecke’s headquarters in Sankt Augustin, Germany. In addition to its equipment, the company will also provide the know-how of experienced process engineers.

Part manufactured in the hP-rTM process

Apart from new drive concepts, reduced vehicle weight is a major element to ensure more efficiency in future automobile manufacture. Lightweight construction in motor racing has long provided for improved performance and increasingly found its way into mass production. In the car body sector, automobile manufacturers meet these requirements by using fibre-reinforced structural components that are convincing both in terms of low weight and crash behaviour. As the manufacture of such high-tech parts in the classical RTM process is partly characterised by long process times, due to the amount of manual work involved, the industry is searching for manufacturing methods that are suitable for mass production and an adequate implementation of high volumes.

However, increased automation alone can only optimise cycle time to some degree.

The aim is to find a solution which reduces the specific curing times of parts.

By introducing the High-Pressure RTM (HPRTM) process, Hennecke GmbH has tackled this problem and pursued familiar paths in polyurethane processing technology in a new way. The focus of the HPRTM method is on a task that is well-known and tried and tested in polyurethane processing: the high-pressure injection of reactive mix into a mould within seconds. In combination with the appropriate raw material system, the HPRTM process provides for accelerated reaction and short curing times. In addition, Hennecke’s long-standing experience of high-

rTM centre

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

“We intend to assist our customers with the implementation of their ideas and plans already before they purchase a processing plant and support them in their investment decision-making process“, says Alois Schmid, Managing Director of Hennecke.

According to Jens Winiarz, Hennecke’s responsible Sales Manager for Composite Spray Moulding (CSM) and new technologies, “In our customer centre for CSM polyurethane spray technology, we have already tested successful raw material systems and develop PU-based sprayed products. The RTM centre will carry on this way.“  Hennecke manufactures machines, production lines, and systems for all polyurethane core technologies. The company’s product portfolio comprises highpressure metering machines, mixheads, elastomer, moulded foam, CSM, refrigerator, sandwich panel, slabstock, and recycling lines as well as mould carriers, tank farms, and peripheral units.

45

Cannon Viking – evolving and improving the world’s flexible PU foam industry cannon Viking was founded in 1956, as an engineering company, working closely with IcI to develop and supply equipment to handle, store and process polyurethane raw materials, at a time when the polymer was still new. In 1989 Viking became part of the cannon Group, a leader in polyurethane processing technologies. Viking brought block foaming technology to the Italian group as well as the capability to provide technology for bulk material handling to any cannon project.

were hit hard by the recession during 2009, with production declining by 30 – 40 % but they are also upgrading equipment to produce HR and VE foams, confident that the market is not only experiencing growth but is demanding better quality goods. Flexible foamers in Ukraine, Bosnia, Serbia, and Slovenia have also been active in expanding capacity and installing new cost-effective Cannon Viking technology to manufacture higher quality foams.

South America A prestigious contract for the design, supply and installation of a turnkey tank farm project for the new factory of CLC Corporation of Venezuela was won by Cannon Viking in addition to the supply of a Maxfoam Omega 800 plant.

Equipment includes state-of-the-art integrated process and temperature conditioning equipment, computer-controlled monitoring of tank levels, and a range of the latest safety features.

cannon Viking factory in Manchester, UK

All the staff at Cannon Viking have many years of industry experience. All the technical staff have more than 15 years service, creating a strong bond and family feel to the business. Throughout the recent crises the company has made no redundancies and maintained its expert staff. Its diverse customer base of 700 manufacturers across 120 countries, combined with a strong technology portfolio has allowed Cannon Viking to experience strong growth in spite of the challenges faced by some economies. The ability to supply solutions to suit every budget, whether it is for the smallest discontinuous plant to a fully integrated turnkey solution of high pressure foaming machine, tank farm and block storage area, allows the company to be an integral part of the development and the evolution of the polyurethane foam industry worldwide. Despite difficult trading conditions in many countries during 2010, business for Cannon Viking has remained strong worldwide and the company already has a healthy order book for 2011.

46

K 2010 exhibition Cannon Viking was a part of the strong Cannon Group presence in Düsseldorf and received over 50 enquiries worldwide for new equipment with particular interest in the latest enhancements to the highly successful Omega controls system.

Europe A notable trend during the past year has been the high level of investment in new equipment and upgrades among foamers in Eastern European countries. This trend suggests that foamers and consumers in the region are now able to play “catch-up” with those in the US and Western Europe. The new capacity in Poland has caused some leading foamers to lose volume but Cannon Viking has continued to install new equipment including at SunGarden’s plant in Poland and a turnkey plant for a brand new foamer in Southern Poland. Russian foamers

Africa The African market remains strong and is growing steadily, seemingly unaffected by the global recession. Population growth and rising living standards have led to a growth in demand for foam mattresses and upholstered furniture. This has created a steady demand for continuous slabstock lines – a clear sign that many nations are taking the first step in developing a PU industry. The manufacture of flexible foam blocks is alTechnical grade foams produced with the addition of the Liquid Laydown Module

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

ways seen as the precursor to market development, ensuring that Cannon Viking is always in at the ground level in new markets.

Growth has been fuelled by several factors such as: · box foamers upgrading, · the formation of several large foaming groups who are investing beyond their domestic markets, and · the replacement of old equipment.

For the past year Cannon Viking has been working in association with Snetor Chemie to sell and service equipment in the North and West African markets. The venture has already resulted in several new projects installing continuous flexible slabstock lines in the region. Snetor Chemie is a well established trader of PU and plastic raw materials and consumables throughout Africa with a staff of over 50, and offers excellent synergy with Cannon Viking’s product lines.

Snetor offers Cannon customers, local staff, spare parts, technical service as well as chemical supplies. Local staff are given extensive training by Cannon Viking, enabling them to offer technical service on the ground – a critical component of successful business in these markets. The combined businesses are now able to supply and service turnkey projects throughout Africa. This cooperation has led to substantial new business in several countries including the Ivory Coast and Senegal and a significant growth in enquiries for new machines throughout the continent.

Cannon Viking’s General Sales Manager, Jonathan Rayner, was recently invited to

address the PU Summit for Foamers in Nigeria where his presentation on the latest Cannon Viking developments was enthusiastically received by a large number of delegates.

A significant achievement in 2010 was the commissioning of the largest continuous slabstock line in Africa at Vitafoam, Johannesburg, where Cannon Viking installed a Maxfoam Elite 800 machine capable of manufacturing standard polyether, HR, VE, and FR grades of polyether foams. The foam will be produced predominantly for the furniture and bedding industry, but will undoubtedly change the economics of the flexible slabstock industry in Southern Africa.

Middle East Business in the Middle East continues to be good with three new orders being received during the last two months alone.

Cannon Viking have a long and successful association with the independent Obegi Chemicals Group whose extensive network of local companies provides regular close contact with technical and sales support to foamers throughout the region.

India During the past two years, Cannon Viking has refocused their efforts on this small but growing market of 100 foamers producing around 90 kt of foam. The company has reinforced its presence by establishing a sales office in New Dehli, run by Saurabh Prasad, who has many years of experience through posts at Chellarams in Nigeria

and Winmar in India. Cannon Viking will continue to work closely with its agent, Expanded Inc., Mumbai, to expand the client base but also to develop equipment to meet local needs. This strategy has already yielded success with the installation of state-ofthe-art equipment at Rudraksh Laminates. The Maxfoam Omega 400 plant can produce standard polyether foam and high quality, low pinhole, foams suitable for lamination. Springfeel Foams have also upgraded their equipment to expand the grades and quality of foams they can offer the market.

CarDio meets demands of established foamers The worldwide acceptance of the Montreal Protocol which sets out to eliminate all ozone depleting materials such as CFC’s has meant foamers continue to invest in this patented technology from Cannon Viking. The CarDio technology uses a gatebar to control foaming pressure through a slot. The advantage of this system is that it can be used to process foams that contain filled polyols and fillers such as calcium carbonate, standard pigments, and melamine, unlike competitive technologies which use a series of filters to manage pressure during the foaming process. CarDio technology can be fitted to existing machines and allows a standard continuous line to produce more sophisticated and higher quality foam products. CarDio has proven popular in developed markets such as the US, and is the next step in the evolution of foam production, allowing foamers to further differentiate their products in a cost-effective manner.

Liquid Laydown Module proves popular

cannon Viking Maxfoam Elite foam plant supplied to Vitafoam in Johannesburg, South Africa

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

South American demand for flexible slabstock is growing but also for more technical foams – this is particularly evident in Colombia and Brazil. In these two markets, Cannon Viking has a number of new projects to allow standard polyether foaming lines to manufacture VE, HR and FR foams. In particular, the company has been active in converting low pressure machines to higher pressure ma-

47

chines through the installation of their patented liquid laydown technology.

The Liquid Laydown Module (LLM) can be added to standard foaming equipment.

This allows better mixing and control of the nucleation air. This unit is fitted prior to the main continuous machine mixing and creates a homogeneous blend of air and activators which produces a better cell structure. Instead of using the Maxfoam trough process, this system involves the installation of an aluminium pour plate and attaching the existing mixer unit to a liquid laydown unit for direct foam pour prior to the Maxfoam fallplate. The system allows any gas bubbles to escape from the reacting foam prior to formation on the fallplate.

This creates a finer and more regular cell structure and fewer pin holes in the final foam. The foams are also of higher quality and higher density produced using this technology. Due to their suitability for textile lamination demand for these foams is growing fast in the emerging automotive component industries of Brazil, Colombia, and Turkey.

This liquid laydown technology allows foamers to upgrade their equipment to a level that is intermediate in performance between a conventional Maxfoam and a C-Max high pressure machine in a very cost-effective way.

Turnkey projects Since its earliest days Cannon Viking has offered customers bulk material handling equipment, firstly in the form of tank farms for bulk liquids, but now turnkey projects include their Omega foam plant control technology and block storage. This turnkey tech-

IAc Group from Krefeld, Germany, has chosen KraussMaffei as system supplier to equip the company’s new production plant in romania. The order, valued in the double-digit million range, includes supplying and assembling systems, machinery and moulds, developing, planning and design of product elements, together with a number of services.

48

Part of the synergy within the Cannon Group means that Viking also supplies the bulk storage and handling facilities for all turnkey packages whether it is for refrigeration or moulded foam. 

Liquid laydown in production with one of cannon Viking’s clients in Far East

IAC Group chooses KraussMaffei as system supplier for new plant in Romania

IAC Group will invest EUR 58 million to build a new greenfield manufacturing facility in Bals, Romania, in the southwest Oltenia region. The state-of-the-art facility will produce instrument panels, door panels, headliners, and various other interior trim components

nology was used at the new Vitafoam plant in South Africa, creating the first foamer in Africa to use bulk raw materials. The turnkey package has become popular with customers in the Middle East where the industry is developing so rapidly that the initial box foaming stage is skipped and foamers are buying and installing complete new continuous plants.

polyurethane technology. We’re sure that the collaboration between IAC and KraussMaffei on this project will be characterised by mutual trust and successful outcomes – possibly extending beyond the scope of the project,” commented Maurits Willaert, Vice President Operations at IAC Europe, while the contract was being officially signed in Munich.

to support Ford Motor Company’s production of two new passenger cars (B-Max) at its plant in Craiova, Romania.

“We’re delighted with the trust that IAC has demonstrated by placing this major order with us. We see it as further confirmation of our industry-leading competence as a supplier of technologies, processes, and solutions,” explained Dr. Karlheinz Bourdon, head of Injection Moulding Machinery at KraussMaffei Technologies GmbH.

“KraussMaffei impressed us with their outstanding expertise in injection moulding and

As sole contract partner for plastics technology, KraussMaffei will be supplying the

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

new IAC production plant with 28 injection moulding machines (500 – 3,200 t clamping force, plus automation), systems for polyurethane foaming and punching, and the required tooling. The company will also support the development, planning, and design of product elements and provide a number of services.

“The fact that IAC has chosen KraussMaffei as system supplier for the new plant is more than simply a confirmation of our Technology3 approach to delivering application-specific process solutions;” added Bourdon. “The order also highlights our expertise in machine quality and our ability to deliver integrated production concepts.”

“At an early stage, we worked with IAC to analyse the planned process sequences and now, in the implementation phase of the production plant, we’re in a position to coordinate machine technologies, process sequences, and materials for optimal outcomes”, explained Frank Peters, head of Reaction Process Machinery at KraussMaffei Technologies GmbH.

“Our highly effective project management is based on seamless coordination of technology and know-how from our plants in Munich, Viersen, and Harderberg to supply the injection and reaction machinery and systems, together with customised automation solutions. KraussMaffei pursues a One-Face-to-the-Customer philosophy with very positive and advantageous results.

Although products and services are sourced from across the whole KraussMaffei Group, the customer has just one knowledgeable and reliable contact person to deal with,” emphasised Willaert. Peters pointed out that, “Moulds and tooling make up a substantial share of this order; this reflects the huge expertise of the responsible division, Automotive Component Systems (ACS) in Viersen and Harderberg (Germany) and also indicates that the recently completed doubling of the production area of our plant in Harderberg was a good strategic move”.

IAC is the first automotive supplier to set up a greenfield facility in Romania to support Ford’s operations in Craiova. IAC intends to

F.l.t.r.: Maurits Willaert (IAc), Dr. Karlheinz bourdon (KraussMaffei), Marc Flegler (IAc), Frank Peters (KraussMaffei)

employ about 400 personnel at the Bals facility with an output of 300.000 interior parts when fully operational.

“I am very proud to announce this key investment for IAC in Romania,” said Jens Höhnel, IAC Group President and CEO of Europe. “This strategic expansion allows IAC to support one of its important global customers, Ford Motor Company, as it continues to expand globally. Furthermore, it strategically positions IAC to support other automotive customers in the region.”

The Romanian government supported this investment project with state aid worth EUR 17 million. This state aid will be granted in various installments and will add to the EUR 58 million IAC plans to invest in Romania. This investment will have a multiplying effect by developing other related industries in Romania.

“We hope the IAC Group investment in Bals will become, in time, an important factor for the economic development of the southwest Region of Romania,” stated the Romanian Minister of Public Finance, Gheorghe Ialomitianu. “Many new jobs will be created and state-of-the-art technologies will be transferred to our country. This is a major contribution to the development of our automotive industry. At the same time, with IAC’s support and the overall contribution of the Ford project, we expect to see major investments in human resource training, as well as research and development programmes in partnership with regional universities.”

The 15,000 m2 facility that IAC will establish in Romania will be a manufacturing centre of competence for IAC. In this capacity, the company will work with regional universities and technical schools to jointly develop curriculum and training programmes to help educate the workforce and develop commercial and technical talent for the region. 

www.pu-magazine.com PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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B. W. Naber, G. Behrendt*

Recycling flexible foam PUR – part 1 The important class of materials, flexible foams based on polyurethane (referred to here as PUr-FF) is now an indispensable part of our lives. Mattresses, car seats, and upholstered furniture are the largest volume applications for these substances. The PUr-FF are classified according to their chemical composition and manufacturing technologies. Used PUr-FF streams (post consumer materials) are analysed for quantity, composition and quality, and assessed for their suitability for recycling. For a variety of reasons outlined here recycling used PUr-FF does not appear ecologically and economically sensible. Disposal with thermal energy recovery remains the only viable option for these waste streams. Various material and feedstock recycling methods are presented in a second part of this paper.

1. Introduction

2. PUR-FF types

Although polyurethane foams (PUR-FF) are one of the older classes of products in polyurethane chemistry, they have been continuously developed and adapted to the needs of different users and applications.

The first block foamed PUR-FFs based on toluene diisocyanate (TDI) and polyester polyol (PESOL) came on the market under the name Moltopren (Bayer) in the first half of the 1950s. These products from the early days of PUR-FF are no longer comparable with today’s high tech products, even if nothing or very little has changed in the basic chemical principles. Rapid development in the field of polyether polyols (PETOL), additives and catalysts, and the use of diphenyl methane diisocyanate (MDI) have opened up completely new application opportunities for PUR-FF. How common these products are today, is shown in the following summary of PUR-FF applications in Germany (tab. 1).

2.1 Classified according to base raw material

* Dipl.-chem. bernhard W. Naber, bernhardwnaber@aol.com Industrieberatung Naber, Schwarzheide, Germany Prof. Dr. Dr. h. c. Gerhard behrendt, University of Applied Sciences Wildau, Germany

50

• from the facility to give the PETOL molecule a particular structure. This is achieved by copolymerising EO and PO. In this way the PETOL can be given a block structure, i. e. in the chain sections are found to consist exclusively of EO or PO. Otherwise, EO and PO are randomly distributed in the chain. Parameters such as hydrophilicity, reactivity and, within limits, the price can be influenced by the EO content.

• from the facility of grafting olefinic monomers such as styrene, acrylonitrile and others, on to the PETOL chain. The resulting graft polyols or “polymeric polyols” give the PUR-FF higher compression modulus at lower density.

• from the possibility of using different PETOLs in a wide variety of mixtures to control certain specific foam properties.

2.1.1.2 Polyester polyols (PESOL)

2.1.1

Classified according to polyol

2.1.1.1 Polyether polyols (PETOL) Today the overwhelming majority of PUR-FFs are based on PETOL. This type polyol is currently produced on a scale of several million tonnes. They are products of a ring opening, usually anionic, polymerisation reaction of ethylene oxide (EO) and/or propylene oxide (PO).

The range of different PETOLs comes about: • from the possibility of using different starter molecules that determine the functionality, f, or the number of OH groups in each polyol molecule. Glycerol (f = 3) and trimethylol propane (f = 3) are used preferably for FF polyols, but other starter molecules are also known giving the PETOL a functionality f = 2 (water) and f = 4.

• from selecting different molecular weights, which are usually in the range of 3,000 to 6,000 g/mol. Various end properties such as ultimate elongation, compressive strength etc. of the final PUR-FF can be influenced by the molecular weight. Technological parameters, the catalysts used (anionic or metal coordinated) and in particular the product viscosity govern the PETOL molecular weight.

Nowadays the use of PESOL in the production of PUR-FF is quite low, when compared with the use of PETOL. This is because of the price as well as technical reasons (viscosity) and the fact that, despite stabilisation, PESOL-based PUR-FFs are more sensitive to hydrolysis than PETOL foams.

They are, however, irreplaceable in certain applications (such as flame retardant coatings). PESOLs are prepared by condensation (esterification) of dicarboxylic acids with diols. Adipic acid is by far the commonest dicarboxylic acid used. Occasionally PESOLs are found containing sebacic acid or terephthalic acid. The PESOL functionality is usually f = 2, rarely f = 3. The variety of PESOLs comes from: • molecular weight selection, which is normally between 2,000 and 3,500 g/mol.

In practice the molecular weight can not 

Tab. 1: PUr-FF applications in Germany 2008

block flexible foam (mattresses) Moulded foam (automobile industry) Moulded foam (nonautomobile industry)

2009

146 kt 115 kt

2010 (estimated) 120 kt

79 kt

65 kt

73 kt

35 kt

30 kt

32 kt

Source: PU Magazine

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

be taken much higher, because viscosity climbs rapidly with increasing molecular weight, there are side reactions and condensation times are long.

• the variety of diols used.Typically, ethylene glycol (MEG), diethylene glycol (DEG), triethylene glycol (TEG), 1,4-butanediol (B14, BDO) and/or neopentyl glycol (NPG) are used. Usually mixtures of two or even three glycols are used to reduce the PESOL's melting point • the possibility of mixing different PESOLs, in order to obtain particular foam properties.

2.1.1.3 Other There have been extensive studies of the production of PUR-FF polyols based on renewable raw materials. The polyols so developed have been able to find application on the basis of their prices and the physical and mechanical properties of the PUR-FF made with them in mixtures with standard polyols up to a certain level.

2.1.2

Classification according to isocyanate

2.1.2.1 Toluene diisocyanate (TDI) TDI is the oldest diisocyanate commercially available for large-scale foam production. It is inexpensive to produce and available in large quantities in the market. TDI is a waterclear, low viscous liquid with a sweet, acrid smell. It’s use is growing continually more restricted because of its toxic properties.

However, there are a large number of applications in the production of PUR-FF, in which TDI is indispensible.

In particular applications where it is helpful to use a prepolymer TDI is the isocyanate of choice (prepolymers are reaction products of polyol with a part quantity of the total isocyanate).

2.1.2.2 Diphenylmethane diisocyanate (MDI), polymeric MDI (pMDI) MDI, particularly pMDI, has replaced TDI in many cases. The reasons are

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

• the low vapour pressure, which considerably simplifies the technical handling • the commercial availability of light coloured qualities with various properties, • a viscosity of >200 mPas, which simplifies metering.

2.1.2.3 Other Isocyanates were also tested in the course of investigations into PUR component materials based on renewable raw materials. Any technical application is currently possible only to a very limited extent based on their price and the properties obtained with the resulting PUR-FF. In principle it is possible to manufacture “green” PUR-FF based on renewable raw materials, both polyol and isocyanate. The use of cycloaliphatic or aliphatic diisocyanates to improve the UV stability is only of marginal interest.

2.2 Classification according to technologies Only two technologies are widely practiced in the production of PUR-FF, block foaming and mould foaming. The third possibility, of foaming PUR-FF at the point of use (“pour-inplace”), is less widespread and not significant to the consideration of PUR-FF recyclability.

2.2.1

Foaming in the mould

2.2.1.1 Cold moulding In this method, the reactive mixture, consisting of component A (a mixture of polyols, catalysts, blowing agents and additives) and component B (isocyanate in the form of a prepolymer and pMDI or TDI) is introduced into a mould. The mixture can be introduced into either the open or the closed mould. The mould temperature is between 30 and 60 °C, depending on the formulation and the part geometry. The reactive mixture expands in the mould, hardens and is removed as a moulded part.

Highly reactive polyols with a high primary OH group content are employed here. Polymeric polyol formulations are usual and widespread.

2.2.1.2 Hot moulding A mixture of polyols, water, additives and isocyanate is introduced into a mould. The mould temperature is > 50 °C. After foaming and filling the mould cavity, the mould temperature is increased and the moulded part is thermally hardened in the mould. The polyols are usually products with a high proportion of secondary OH groups. TDI is a widespread and commonly used isocyanate. Alternately heating and cooling the mould means the hot forming process is energy intensive. It does, however, yield very high quality mouldings.

2.2.2

Block foams

The classic production of PUR-FF in block is a continuous process with high productivity.

The blocks are produced up to 220 cm wide, 110 cm high and can be any length. The reactive mixture of polyol, water, additives, blowing agents and isocyanate is only produced in the mixing head and spread on to a belt covered with paper strips (lost mould).

The expanding block is transported through a heating tunnel. Modern block foam systems have output rates of up to 500 kg/min.

This nevertheless represents > 15 m3/min of foam at a density of 30 kg/m3! Automated recipe changes only take seconds. The recipe changes affect the isocyanate (hardness, elastic behaviour), bulk density or possibly colour and cell structure. The blocks are cut to the desired length and, in most cases, finished by mechanical processing (cutting, punching, milling, peeling). The resulting significant quantity of waste (offcuts) can be an important raw material source for different types of recycling processes.

A combination of carbon dioxide, which is formed by the reaction of water with isocyanate with the formation of urea, and low boiling organic liquids is used as the blowing agent. Consequently block foams always contain mainly urea groups. This is important for chemical recycling processes (see part 2). Newer or alternative block foam processes use liquid carbon dioxide as a blowing agent, resulting in PUR block-FF with specific properties.The CO2 process was compulsory

51

in Michigan, as the use of methylene chloride (CH2Cl2) is prohibited!

3. Requirements for recycling Certain minimum requirements must be met to make a recycling process economically and environmentally viable. Recycling at whatever price is by any account the wrong way. There are waste streams that, despite their high value content, can not for various reasons be usefully recycled.

An analysis of the preconditions for recycling, not only for plastic, shows which basic requirements must be met: • Sufficiently large streams: The products being considered for recycling must be present or obtainable in sufficient quantities to make the building and operation of a recycling plant economically attractive. Here the minimum size of the stream depends on the manufacturing cost and the value of the recycled material. The higher its’ value, the smaller the minimum raw material stream required. It should be noted that even with significant quantities of a relatively valuable waste stream, recycling does not make sense if the raw material being considered occurs in many places in small quantities (logistics costs).

• Sufficiently uniform streams: The stream of reusable material to be recycled must flow at a more or less uniform rate. If the annual raw material requirement is delivered once or twice annually to a recycling plant, the costs involved for storage, capital and labour mean that such a delivery model is viable only for extremely high quality materials.

Precious metals may fall into this category, plastics, certainly do not.

• Sufficiently pure streams (in the sense of chemically pure and homogeneous): Particularly for PUR, this aspect should not be ignored. PURs with similar properties can have completely different chemical composition and structure, which, in the worst case, leads to incompatibility.

It is particularly inconvenient if, for example, PUR-FF is mixed with a latex-based soft foam or thermoplastic material. This

52

requirement is not as stringent for physical recycling processes as for chemical processes. The demand for chemical purity is particularly important for PUR-FFs, as these include a variety of, sometimes, incompatible additives.

• Sufficiently clean streams (in the sense of uncontaminated): Any recycling process can only tolerate mechanical impurities (commonly called dirt) up to a certain extent. The requirement for clean raw materials is especially vital for PUR-FF, which has a very large internal surface area. Contaminated feed materials can lead to significant problems in the preliminary stages of the actual recycling process.

This is especially true for PUR-FF from the post-consumer sector. Contamination with: - microorganisms in mattresses and cushions (fungi and spores, bacteria, mites), - pollen in upholstered furniture and car seats, - sand in the seat cushions of construction and agricultural machinery, - petroleum oils in car seats and work mats, - water in any quantity and in all types of material and volumes, causes practically unsolvable problems and fatal disorders.

These are just a few examples of real sources of problems found in the study of PUR-FF recyclability.

Before any debate about purifying at high temperatures in a chemical recycling process or the production of flocked composites it should be borne in mind that prior to the actual recycling process, the PUR-FF must, among other things, be transported, loaded, sorted and, comminuted. These are necessary and unavoidable processes carried out by people, which cannot, or can only to a small extent, be transferred onto machines. Also, during the thermal recycling process, strong, unpleasant smelling degradation products are formed.

4. Raw materials sources for PUR-FF recycling As mentioned in the introduction, PUR-FF essentially finds application in four main areas.

Each of these raw material sources has specific properties that must be considered if the recycling project based on them is not to end in disaster.

4.1 Mattresses (bedding) A wide range of different products of varying technical complexity from a variety of different manufacturers is understood under the term “mattress”. They range from simple foam mats sawn from a PUR-FF-block, up to products built up from different FFs (not only PUR-FF!) with built-in inserts in the form of metal springs, textile pockets and/or PET fibres. The product name “ether foam” or “polyether” says nothing about the actual composition of the PUR-FF. 3.55 million PUR mattresses were produced in 2009 in Germany (Source: PU Magazine).

In nearly all cases, the mattresses are covered with textiles, predominantly regenerated cellulose, PET, PA or cotton. These textiles must be removed and disposed of or sent to their own recycling process, as they disrupt any recycling process. Separating metallic components (springs) from PUR-FF is uncomplicated, once the composite item has been broken up. This step is quite costly, however, because it is technologically complex. Separating PUR-FF from foam not based on PUR, is complicated. If chemical processes are envisaged for the recycling, the 100 % removal of these foreign foams is a precondition for success!

The risk of microbiological contamination is very high especially in mattresses. It can not be excluded that mattresses from hospitals and similar institutions are among those delivered to the recycling plant. And by whom, when, where, and how which mattress has been used, is usually not traceable. This, in the authors‘ opinion, is the real problem in mattress recycling. Infestation with house dust mites causes a strong allergenic potential in handling used mattresses because of the mite faeces. Also, it is rarely possible to ascertain the manufacturer, the production period, and consequently information about the PUR formulation used. The problem is theoretically soluble by analytical methods,

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

but this course is not practical, because it is too expensive and time consuming (such a process was abandoned by the Ford Motor Co. after trying for two years). Further comments on this problem area can be found in section 2 – adequately clean streams.

In summary, it is clear that PUR-FF from used mattresses can really only be disposed of by thermal treatment, which is to say, energy recovery through incineration. That this, however, is only feasible under certain rules and restrictions, is set out in part 2. Waste from mattress production is much easier for recycling to handle, when only a limited number of formulations and systems are used and these can be recycled separately.

4.2 Car seats (automotive) Only PUR-FF from cars will be considered here, which, depending on the category, can contain up to 25 kg PUR-FF. These products are located almost exclusively in the seat upholstery. Surprisingly, this raw material stream is rarely suitable as a feed stock or material for recycling. This has many reasons: The upholstery in a car seat is built up from different PUR-FF systems or from combinations of very different foams. For example, other, higher requirements are set for making the foam for the driver‘s seat than the cushion for the back seat. These different requirements can not be met in every case, simply by adjusting the NCO index by alterung the mix ratio A : B. Very often systems with very different formulations are used. Modern car seats are usually “two hardness seats” in which the seat and the seat sides, although from the same polyurethane system, are foamed with different NCO indices. As this technology is a “wet on wet” foaming, the two foam parts can not be cleanly separated.

Car seats are made from cold-formed, hotformed and block foams. Which PUR-FF type is used, can have very different reasons, which may change in the course of time, as a result of model changes and for other reasons. As PUR-FF can be from cars up to 20 years old, it is not possible to obtain a uniform, or even an almost uniform, chemical fraction.

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

PUR-FFs are completely open-cell products.

Alternating loading and relaxing gives a pumping effect, by which dirt is transported into the interior of the cushion by the incoming and outgoing air. In studies, pollen, mineral dusts, (choliform) bacteria, skin flakes, and oil etc. have been found, so the hygiene concerns listed for mattresses are applicable to car seat upholstery as well.

disposal by thermal incineration with energy recovery. This method offers no technical, ecological and economic problems, when combined with initial shredding and incinerating of the SLF. Production residues and offcuts of PUR-FF are clean and pure and therefore much more amenable to recycling.

Car seats are usually covered with textiles, leather or artificial leather. These covers can be relatively easily separated from the foam if the covers have not been directly backfoamed. In the latter case, a separation is possible only with considerable effort. Steel springs, cables, motors and other functional parts are often installed in the upholstery of car seats, and have sometimes been foamed in. As, in all cases, these have to be removed, the costs of separation increase, usually logically with the class of cars to be dismantled.

What was stated for mattresses and upholstered car seats applies completely to recycling PUR-FF from upholstered furniture.

Quite different PUR-FF-types, some more than 30 years old, mixed with latex foam, PET fibres, horse hair, seaweed and other upholstery materials demand a lot of effort in sorting. Different PUR-FF types and recipes, foam surrounded (wood) parts and the necessity to remove covers made from the widest variety of fabrics, already give an indication of the technical, organisational and logistic problems of recycling PUR-FF from upholstered furniture.

According to PRAVDA (Projektgruppe Altauto-Verwertung der deutschen Automobilindustrie, German Automobile Industry Project Group for Scrap Car Exploitation), the removal and extraction of the foam upholstery cost 0,80 DM per seat in 1993. These dismantling costs have to be added to the logistic and disposal costs. If the car is shredded the PUR-FF finds its’ way naturally into the shredder light fraction (SLF). It is impossible to separate a pure, useful PUR-FF fraction from the SLF. Contamination with automotive fluids which, despite completely draining the car, are present at least as traces, can be detected in the flexible foam and allow this to be classified only as hazardous waste.

Any attempt to create a (marketable) product from the SLF in any way is a waste of money and resources. Car seat upholstery has been and is not only manufactured from PUR-FF. Cushioning is known made from horse hair, PET fibres, latex foam, cellulose foam, polypropylene foam, and others. Whichever method is selected for recycling PUR-FF from car seats these materials must be 100 % without fail removed. So which useful recycling methods are left? The only method is

4.3 Upholstered furniture

It can easily be seen that the same hygiene concerns indicated under mattresses and car seats apply to upholstered furniture. There is another particular problem with upholstered furniture. As part of global trade flows PUR-FF foams (semi-finished products), moulded parts and finished upholstered furniture are shipped around the world. Because they have to comply with relevant national registrations and standards, these products often contain additives, especially flame retardants, which are not permitted in all countries. The age of some of the resulting PUR-FFs suggests foams will turn up, which have been compounded with ingredients, whose use is now banned internationally. These include certain phosphorus- and/or halogen-containing chemicals, particularly polybrominated biphenyls and diphenyl ethers.

Here too, the answer to the question about a viable recycling concept can only be combustion with energy recovery.

4.4 Packaging This segment is the smallest area of application of PUR-FF. However, it should be dealt

53

with here as packaging from this material can be found in every home, office, or other type of workplace. PUR-FF (reusable) packaging has proved itself for packing certain goods. The controllable resilience of these materials makes it possible to protect perfectly delicate goods such as precision engineering and optical instruments, measuring instruments and standard tools as well as watches, jewelry and gift items. For this, PUR-FF slabs are furnished with cavities which surround and retain the items to be protected and guard them against bumps and knocks. Disposable packaging made of PUR-FF is rare. It has already been almost completely substituted by EPS packaging elements.

In nearly all cases PUR-FF packages are intended for a longer life, which can range from several weeks to many years. Customised very low density PUR block foams and their blends of are usually used here.

Moulded foams are quite rare. In many

4.5 Other sources

cases, individual pouches are covered in textile, leather or artificial leather for various reasons. Flocked surfaces are also common.

PUR-FFs have found wide usage in technology, housing and leisure thanks to their excellent and precisely adjustable properties.

In nearly every case where, adjustable elasticity, insulation from vibration and shock, good comfort and low weight are required, PUR-FF can fulfil it. These are naturally the smaller applications with many different parts in very small numbers, which are still widely distributed, similarly to the packaging described above. Examples include tractor and machine seats, sport and gymnastic mats, toys, clothing and carpet backing.

Seat upholstery on planes and public transport (bus, train, tram) is almost non-recyclable, since it can not be cleanly and economically removed and collected. They contain in every case a very high proportion of organic and inorganic flame retardants, which interfere with any recycling process. They are usually thermally disposed of. 

Recycling these packaging foams is nearly impossible. The reasons for this are to be found in the unclear origins of the flexible foam, in the necessity of having to free small parts from coatings and covers and simple contamination, which can range from dust to oil. Further, the very low density leads to high volumes, which drive up logistic costs.

Microbiological contamination is unlikely. A bigger problem, however, is posed by the wide and diffuse distribution of relatively small parts in our technical and private environment. Centralised or decentralised collection of PUR-FF packaging is simply not feasible. They are therefore almost entirely disposed of as a domestic type commercial waste and sent to incineration. In the German dual system (DSD) bins, they are rubbish.

compared to the same period in 2009. Russia stays on third place in the list of the most important destinations for German plastics and rubber machines after China (EUR 357 million) and the USA (EUR 258 million).

As a consequence of the global economic crisis, in 2009 the worldwide exports to Russia only reached a value of EUR 321 million.

Compared to the previous year, this is a drastic decline in shipments of 49.2 %.

Russia as market for plastics and rubber machinery On the occasion of Interplastica, that took place from 25 – 28 January 2011 in Moscow, Russia, the Plastics and Rubber Machinery Association within the German Machinery and Plant Manufacturing Association (VDMA) has published the current

figures on the German and international export shipments of plastic and rubber machinery to Russia.

According to the report, German exports to Russia during the period January to October 2010 only reached a value of EUR World exports of plastics and rubber machines to russia 76.6 million, which is 2008 Million EUR 2009 Million EUR 2009/2008 (%) a decline in shipGermany 234.3 135.6 -42.1 ments of 20.7 % Italy

133.0

50.0

-62.4

china

58.3

25.4

-56.4

romania

2.6

12.4

383.8

Austria

20.3

12.3

-39.4

France

14.2

11.9

-16.2

Germany remains number one of the most important suppliers of plastics and rubber machines to Russia with a share of 42.2 % of the total export, followed by Italy (15.6 %), and China (7.9 %).

German exports of plastics and rubber machines to russia Million EUR

Change over previous year (%)

Share in world exports to Russia (%)

2004

162.9

57.1

38.9

republic of Korea

14.8

9.5

-35.9

2005

180.0

10.5

41.7

Switzerland

13.3

8.6

-35.4

2006

218.4

21.3

39.5

Finland

34.0

8.1

-76.1

2007

242.1

10.9

35.1

The Netherlands

27.4

7.8

-71.7

2008

234.3

-3.2

37.1

632.3

321.2

-49.2

2009

135.6

-42.1

42.2

Total

54

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

I. Sendijarevic, J. G. Harris, S. Hoffmann, S. Heric, N. Lathia, V. Sendijarevic*

Polyether polyols from scrap polyurethanes – for use in rigid and flexible foams Infichem Polymers, LLc has developed a new range of polyols called InfiGreen polyether polyols produced with over 60 % of the feedstock coming from scrap polyurethane foams.

These polyols have over 20 % of the aromatic content originating from urethane and urea linkages. both rigid and high resilience (hr) polyurethane foams have been prepared with these novel polyols. Flexible foams have been prepared with 5 % and 10 % of the total polyol content based upon InfiGreen 320 by simple replacement of conventional polyether polyol and without any adjustment in the formulation. Free-rise and moulded flexible foams based on InfiGreen 320 exhibited resilience characteristics expected of hr foams.

Although most of the foam properties were affected by the introduction of the new polyols, almost all properties, including wet compression set, were in the range of values specified for automotive seating foams. rigid PU foams prepared with InfiGreen 420 as the sole polyol using a mixture of water and hFc-245fa as blowing agents exhibited comparable properties to the reference foam prepared with a conventional polyether polyol. The thermal conductivity of the foam based on InfiGreen 420 was in the range of values reported for foams with the same density range prepared with similar levels of hFc-245fa using 100 % conventional polyols. In addition, rigid foams containing these recycled polyols exhibited lower burning rates than the reference foam.

1. Introduction It is well known that chemolysis processes, such as glycolysis, hydrolysis, and aminolysis, can be used for depolymerisation and recycling of polyurethane scrap. The major difference between glycolysis, hydrolysis, and aminolysis is in the type of reactants utilised for depolymerisation and in the composition of the final products. The advantage of the

hofer and Weigand [1]. A more recent review of chemical recycling of polyurethanes including glycolysis (fig. 1) was published by Behrendt and Naber [2]. Most of the chemolysis products described are for use in polyurethanes without any modification or with only minimum modification. Practically all chemolysis processes, including glycolysis, result in amine formation which greatly affects the reactivity of these products with isocyanates. Due to the high reactivity and extremely broad molecular weight distribution, only limited amounts of glycolysis products could be used in a mixture with virgin polyols to prepare polyurethanes with useful properties. Thus far, application of glycolysis products has mostly been limited to some rigid foam applications [2].

glycolysis process is that it can be carried out at atmospheric pressure at temperatures of around 200 °C. Glycolysis products contain original polyols, urethane/urea-containing polyols (short chain hydroxyl oligomers), and residual glycolytic agents (reactants).

InfiChem Polymers has developed a proprietary two-stage process for manufacturing of different types of polyether polyols from scrap flexible foams. InfiGreen polyols offering a range of reactivities have been developed to meet processing and property requirements of various PU products including flexible and rigid foam applications. The viscosity of these polyols is comparable to conventional polyols and due to the aromatic content being greater than 20 %, these polyols also have enhanced flame resistance.

InfiChem has also developed polyols compatible with blowing agents such as HFC-245fa.

There are numerous patents describing the chemolysis technologies. In 2001, a comprehensive review of polyurethane chemolysis processes, and more specifically glycolysis of polyurethanes, was published by Rass-

In the experimental testing, both rigid foams and high resilience (HR) flexible foams were prepared with InfiGreen polyols. Water blown rigid polyurethane foams were prepared using InfiGreen polyol as the sole polyol and in a

* Ibrahim Sendijarevic Process for recycling of polyurethane foam

isendijarevic@infichempolymers.com Jordan G. harris, Stephen hoffmann Infichem Polymers, LLc, Sterling heights, MI, USA

Polyurethane foam

Senad heric, Nirali Lathia, Vahid Sendijarevic Troy Polymers, Inc., Troy, MI, USA

Diethylene glycol

Published with kind permission of cPI, center for the

Propoxylation reactor #2 Glycolysis reactor #1

Polyol initiator

Propylene oxide

Polyol

Polyurethanes Industry, Washington, Dc, USA Paper, Polyurethanes 2010 Technical conference, 11 – 13 October 2010, houston, TX, USA, cPI, center for the Polyurethanes Industry

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Fig. 1: Glycolysis of scrap polyurethane foam



55

50/50 mixture with a conventional sucrosebased polyol. Rigid PU foams based on 100 % InfiGreen polyol were also prepared using a mixture of HFC-245fa and water as a blowing agent. High resilience flexible foams were prepared with 5 % and 10 % of the total polyols comprising of InfiGreen polyol.

Designation

Supplier

Polyols

These novel polyols, developed with over 60 % of the feedstock coming from scrap polyurethane foam, are “raising the bar” regarding what it means to be a truly “green” product. These products create a carbon dioxide reduction of over 2.2 kg per kg of petroleum polyol. The main product applications for these polyols include: automotive seat foam, energy absorbing foams, NVH applications such as carpet foam, and interior foams using both flexible and rigid polyurethane foams.

Poly G 85-29

Ethylene oxide caped polyether triol (Eq. wt. = 2157)

Arch

Jeffol G 31-28

Ethylene oxide caped polyether triol (Eq. wt. = 1901.7)

huntsman

InfiGreen 320

Aromatic polyether polyol (Eq. wt = 170.5)

Infichem

InfiGreen 320WPA2

Aromatic polyether polyol (Eq. wt = 170.5)

Infichem

Lumulse POE 26

Ethoxylated glycerol; Eq. Wt = 416.2

Lambent

Jeffol SG-360

Sucrose/glycerin-based polyol (Eq. wt. = 156)

huntsman

InfiGreenTM 420

Aromatic polyether polyol (Eq. wt = 137.2 )

Infichem

Tegostab b 4690

Polyether/silicone oil mix

Evonik

Dabco Dc193

Polysiloxane

Air Products

cell opener

Goldschmidt

99 % Diethanol amine (Eq. Wt. = 35.04)

Aldrich

33 % Triethylene diamine in dipropylene glycol

Air Products

Surfactants

Cell opener Ortogel 501 Crosslinkers DEOA Catalysts Dabco 33 LV

2. Experimental data

Niax A1

bis (2-dimethylaminoethyl) ether

Momentive

DMEA

Dimethylethanolamine

Air Products

1,1,1,3,3-pentafluropropane (hFc-245fa)

honeywell

Blowing agent

2.1 Raw materials

Enovate 3000

A list of raw materials used in the preparation of flexible and rigid foams is shown in table 1. All materials were used as received from suppliers. 

Type

Isocyanates Mondur MrS-2

2,4’-rich diphenylmethane diisocyanate (F = 2.2; Eq. wt. = 129.9) bayer

rubinate M

Polymeric MDI (F= 2.7; Eq. wt = 134.6)



huntsman

Tab. 1: Materials used in preparation of flexible and rigid polyurethane foams

Tab. 2: Methods used for testing flexible and rigid foams



Tab. 3: reactivity of InfiGreen polyols in flexible polyurethane foam formulation Reference HR foam

10 % Infichem 320

10 % Infichem 320WPA2

Mixing time

7

7

7

cream time

7

7

7

Gel time

39

36

41

Flexible foams core density, kg/m3

ASTM D 3574, test A

resilience (ball rebound), %

ASTM D 3574, test h

Tear resistance, N/m

ASTM D 3574, test F

Dry compression set (50 % deflection), % loss

ASTM D 3574, test D (ct calculation)

Wet compression set (50 % deflection), % loss

ASTM D 3574, test D, L (ct calculation)

cFD (25 %, 50 %, and 65 % deflection), kPa

ASTM D 3574, test c

Tensile strength, kPa

ASTM D 3574, test E

Elongation, %

ASTM D 3574, test E

Rigid foams

Reaction profile (s)

Off-gassing time cure time @ 80 °c

65

59

72

10 min

10 min

10 min

Foam properties Density (kg/m3)

2.5 ± 0.1

2.3 ± 0.1

2.4 ± 0.1

resilience (%)

63.9 ± 0.7

52.9 ± 0.7

52.5 ± 0.7

87

core density, pcf

ASTM D 1622-03

Formulations

compressive strength, psi

ASTM D 1621-00

Poly-G 85-29

97

87

compressive strain @ yield, %

ASTM D 1621-00

InfiGreen 320

-

10

-

Friability, mass loss

ASTM c 421-00

InfiGreen 320WPA2

-

-

10

burning rate in a horizontal position, mm/min

ASTM D 635-03

Lumulse PEO

3

3

3

Aging test @ 70 °c and ambient humidity, volume and mass change, %

ASTM D 2126-99

Water

Aging test @ -30 °c and ambient humidity, volume and mass change, %

3.6

3.6

3.6

Tegostab b4690

1

1

1

ASTM D 2126-99

DEOA

1

1

1

Water absorption, mass and volume change, %

ASTM D 2842-01

Dabco 33LV

0.8

0.8

0.8

K-factor, btu.in/h.ft.h. °F

ASTM c 518-02

Niax A1

0.1

0.1

0.1

56

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

2.2 Preparation and testing of flexible foams

case of free-rise foams, the polyol and isocyanate components were mixed for 7 s.

Afterwards, the mixture was transferred into a cake box, prior to the cream time. Foaming profile, including cream time, gel time,

All flexible foams were prepared using a standard laboratory high-torque mixer. In the 

Tab. 4: chrysler standards for cellular, moulded, hr polyurethane foam for seating Type I

core density, kg/m3, Min

Type II

Type III

Type IV

48

40

32

56

Indentation force deflection (IFD), N

Per engineering drawing with tolerance

Load indentation (bolster hardness), N (Dual firmness/dual density parts only)

Per engineering drawing with tolerance

hysteresis loss, % loss, max

23

25

30

35

Tear resistance, N/m, Min

500

450

450

450

Wet compression set, % loss, max (% of original thickness)

12

15

20

25

Wet age cFD change (50 %), %, Max (±)

20

20

20

20

constant force pounding - height loss, %, Max - IFD loss, (40 % deflection), %, Max

3 15

4 15

4 20

6 25

Staining, delta E change

Difference of 20 or less

Fogging, min

70, Oily droplets, crystals, or opaque film may be cause for rejection

burn rate, mm/minute, max

100

Tab. 5: Formulation, reaction profiles and properties of free-rise flexible foams for hr moulded foam applications  suitable for chrysler seating foam (*chrysler material standard) Reference

InfiGreen 320 5%

InfiGreen 320 10 %

InfiGreen 320

0

5

10

Jeffol G 31-28

97

92

87

Lumulse POE (26)

3

3

3

3.6

3.6

3.6

Water Tegostab b4690

1

1

1

DEOA

1

1

1

DabcO 33LV

0.8

0.8

0.8

Niax A1

0.1

0.1

0.1

Mondur MrS-2

58.2

61.15

64.27

90

90

90

7

7

7

NcO Index

Type IV *requirements

Reaction profile (s) Mixing time cream time

14

12

8

Gel time

45

50

40

rise time curing time @ 80 °c

80

60

60

10 min

10 min

10 min

35 ± 2

38 ± 2

34 ± 1

resilience (%)

58 ± 1

56 ± 1

52 ± 1

Tensile strength @ break (kPa)

99 ± 20

87 ± 3

98 ± 7

Elongation @ break (%)

133 ± 14

90 ± 9

92 ± 7

cFD @ 25 % compression (kPa)

1.5 ± 0.1

1.9 ± 0.3

2.7 ± 0.3

cFD @ 50 % compression (kPa)

2.6 ± 0.2

3.2 ± 0.6

4.6 ± 0.6

cFD @ 65 % compression (kPa)

4.7 ± 0.4

5.8 ± 1.3

8.3 ± 1.1

Tear strength (N/m)

332 ± 32

322 ± 53

307 ± 26

Dry compression set, ct (%)

3.7 ± 1.4

3.8 ± 0.6

7.2 ± 1.1

Wet compression set, ct (%)

12

19

23

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

In the case of moulded foams (15 x 20 x 5 cm), after mixing the polyol and isocyanate components the mixture was transferred into an aluminium mould preheated at 46 °C before the cream time. Afterwards, the mould was placed in an air-circulating oven preheated at 46 °C for 6 min to complete the cure.

All foams were cut and tested after aging at room conditions for at least one week. A list of measured properties and test methods is shown in table 2.

2.3 Preparation and testing of rigid foams All rigid foams were prepared using a standard laboratory high-torque mixer. The polyol component and isocyanate component were mixed for 10 seconds. Afterwards, the mixture was transferred into an open cake box before the cream time and let free-rise.

Foaming profile, including cream time, gel time, rise time, and tack-free time was measured on all foams. Like in the case of flexible foams, all rigid foams were cut and tested after aging at room conditions for at least one week A list of measured properties and test methods is shown in table 2.

3. Results and discussion

Foam properties Density (kg/m3)

and rise time was measured on all free-rise foams. After the rise time, the foams were immediately placed in an air-circulating oven preheated at 80 °C for 10 min to complete the cure.

> 32

> 450 < 25

3.1 Results for HR flexible foam InfiChem Polymers has developed two types of polyol: InfiGreen 320 and InfiGreen 320WPA2 with the potential to be used in both HR and conventional flexible foams as well as in rigid foam applications. Both polyols have practically the same range of hydroxyl values (320 – 340 mg KOH/g) and viscosities. The major difference between 320 and 320WPA2 grades is their reactivity.

57

InfiGreen 320WPA2 was found to be slightly less reactive than InfiGreen 320 when measured in a flexible PU foam formulation based on Mondur MRS-2 and Poly G 85-29 polyol.

Flexible foams prepared with 10 % of the conventional polyol replaced with the novel polyols exhibited resilience higher than 50 %, which is a characteristic of HR foams. The results are shown below in table 3.

In most flexible foams a proper foaming profile is critical for open-cell structure formation. Therefore, it is desirable that the introduction of any new polyol into the foam formulation does not affect the foaming profile.

This is why polyols with self-catalytic properties are not necessarily desirable in these applications.

Because InfiGreen 320 was available earlier than InfiGreen 320WPA2, the 320 grade was used for full evaluation of flexible foams targeting properties of HR moulded foam (tab. 4) [3]. Foams based on InfiGreen 320 were prepared using Jeffol G 31-28 as a base polyol, which is ethylene oxide capped polyether triol with equivalent weight of approximately 1,900. Mondur MRS-2 (2,4’-rich MDI) was used as an isocyanate at Isocyanate Index 90. Lumulse POE 26, ethoxylated glycerol, was used as a cell-opening polyol. The density and tensile strength of free-rise foams prepared with 5 % and 10 % InfiGreen 320 based on total polyols was similar to that of the reference foam prepared with Jeffol G 31-28 as the sole polyol.

The resilience, elongation at break and tear strength slightly decreased due to the introduction of InfiGreen 320. Compression force deflection, CFD, at 25 %, 50 %, and 65 % deflection increased by the introduction of InfiGreen 320 into the formulation. Dry compression set and wet compression set also increased by introduction of InfiGreen 320 (tab. 5). However, all free-rise foams, including the reference and those prepared with 5 % and 10 % InfiGreen 320 met the wet compression set requirements (tab. 4 and 5) specified by Chrysler Material Standard for seating foam application [3]. In the case of moulded foams, most of the trends were similar to those observed in the free-rise foams (tab. 5 and 6).

58

Reference

InfiGreen 320 5%

InfiGreen 320 10 %

InfiGreen 320

0

5

10

Jeffol G 31-28

97

92

87

Lumulse POE (26) Water

3

3

3

3.6

3.6

3.6

Tegostan b4690

1

1

1

DEOA

1

1

1

Dabco 33LV

0.6

0.6

0.6

Niax A1

0.1

0.1

0.1

57.93

61.11

64.25

90

90

90

Mondur MrS-2 NcO Index

Type IV *requirement

Reaction profile Mixing time (s) Mould release time @ 46 °c

7

7

7

6 min

6 min

6 min

Foam properties Density (kg/m3)

53 ± 1

48 ± 1

45 ± 1

resilience (%)

54 ± 1

52 ± 1

47 ± 1 130 ± 10

Tensile strength @ break (kPa)

128 ± 3

152 ± 8

Elongation @ break (% )

94 ± 0.2

106 ± 11

88 ± 11

cFD @ 25 % compression (kPa)

4.5 ± 0.4

4.0 ± 0.2

4.4 ± 0.2

cFD @ 50 % compression (kPa)

8.0 ± 0.7

7.4 ± 0.6

8.5 ± 0.3

cFD @ 65 % compression (kPa)

15.3 ± 0.9

14.4 ± 1.3

16.3 ± 0.9

683 ± 8

668 ± 80

617 ± 26

Dry compression set, ct (%)

11.0 ± 0.4

9.0 ± 0.1

12.0 ± 0.4

Wet compression set, ct (%)

16

18

19

Tear strength (N/m)

>40

>450 <20



Tab. 6: Formulation, reaction profiles and properties of moulded foams targeting automotive seating foam applications



Tab. 7: Formulations and reaction profiles of free-rise rigid foams Reference

Foams based on InfiGreen 420

InfiGreen 420

0

50

100

100

Jeffol SG-360

100

50

0

0

Water

4.5

4.5

4.5

3.0

Dabco 33LV

1.8

1.0

0.5

0.5

Dabco Dc193

2.0

2.0

2.0

2.0

Niax A1

0

0

0.13

0.13

Enovate 3000

0

0

0

10

rubinate M

171.9

177.3

183.2

158.5

NcO index

110

110

110

110

Reaction profile Mixing time (s)

10

10

10

10

cream time (s)

24

14

13

14

Gel time (s)

83

65

45

50

rise time (s)

123

90

71

105

Tack free time (s)

135

118

9

90

Density (pcf)

2.0 ± 0.1

1.8 ± 0.1

2.0 ± 0.1

2.1 ± 0.1

compressive strength (psi)

19.5 ± 1.1

19.1 ± 1.5

17.1 ± 0.9

16.8 ± 3.2

compressive strain @ yield (%)

5.4 ± 0.5

4.8 ± 0.7

4.6 ± 0.2

4.6 ± 0.1

Friability, mass loss (%)

< 1.0

1.3 ± 0.1

1.1 ± 0.2

< 581.0

burning rates (mm/min)

366 ± 54

312 ± 66

269 ± 52

203 ± 29

Foam properties

K factor (btu.in/h.ft.f. °F)

0.148

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

All moulded foams, reference and those prepared with 5 % and 10 % InfiGreen 320 met the tear strength and wet compression set requirements for automotive seating foam as specified by Chrysler (tab. 4 and 6).

HFC-245fa. Water-blown rigid PU foams were prepared by replacing the conventional polyols with 50 % and 100 % InfiGreen 420 respectively. Water-blown foams based on sucrose/glycerol-based polyether polyol, were prepared as reference. Rigid foams were also prepared with InfiGreen 420 as the sole polyol using a mixture of water and HFC245fa as a blowing agent.

The following tables illustrate the suitability of HR moulded foams made with 5 % and 10 % of the polyol content replaced with the novel InfiChem polyols, compared to a standard foam made with 100 % conventional polyols to meet type IV and III seat automotive foam requirements.

The reactivity of InfiGreen 420 is significantly higher in comparison to Jeffol SG 360.

The cream time, gel time and tack-free time of formulations based on InfiGreen 420 were faster at lower concentrations of Dabco 33 LV catalyst in comparison to the reference formulation based on the sucrose/glycerol polyol as the sole polyol.

3.2 Results for rigid foam InfiChem Polymers has developed three types of polyols for rigid foam applications; InfiGreen 410, InfiGreen 420,and InfiGreen 420WPA2. InfiGreen 410 and InfiGreen 420 are characterised by their enhanced catalytic properties. InfiGreen 420WPA2 is less reactive than InfiGreen 410 and InfiGreen 420. InfiGreen 420WPA2 was specifically designed to match the reactivity of conventional polyether polyols. Both InfiGreen 420 and InfiGreen 420WPA2 have good compatibility with physical blowing agents such as 

Compressive strength properties, friability, water absorption, and dimensional stability at -30 °C and 70 °C of foams based on InfiGreen 420 was comparable to the reference foam. All foams exhibited good dimensional stability in aging tests, however, the burning rate of foams based on InfiGreen 420 was significantly lower in comparison to the reference foams. Enhanced resistance to burning

Tab. 8: Properties of free-rise rigid foams

Designation

Reference

Foams based on InfiGreen 420

InfiGreen 420

0

50

100

100

Enovate 3000 (pbw)

0

0

0

10

Foam Properties Density (pcf)

2.0 ± 0.1

1.8 ± 0.1

2.0 ± 0.1

2.1 ± 0.1

compressive strength (psi)

19.5 ± 1.1

19.1 ± 1.5

17.1 ±0.9

16.8 ± 3.2

compressive strain @ yield (%)

5.4 ± 0.5

4.8 ± 0.7

4.6 ± 0.2

4.6 ± 0.1

Friability, mass loss (%)

< 1.0

1.3 ± 0.1

1.1 ± 0.2

< 1.0

burning rate (mm/min)

366 ± 54

312 ± 66

269 ± 52

203 ± 29

-

-

-

0.148

K factor btu.in/h.ft.h. °F

Mass and volume change with aging and water immersion tests Mass %

Vol. %

Mass %

Vol. %

Mass %

Vol. %

Mass %

Vol. %

Aging test @ -30 °c - after 24 h

0.48

-0.02

0.39

-0.48

0.43

0.1

-0.68

-0.22

- after 1 week

0.85

0.98

0.61

0.71

0.57

0.62

-0.32

0.10

- after 2 weeks

0.80

0.45

0.60

-0.27

0.54

0.10

-0.15

0.44

Aging test @ 70 °c - after 24 h

-1.60

0.48

-0,76

0,70

-0.79

0.53

-0.75

0.72

- after 1 week

-1.49

-0.33

-0.72

0.64

-0.83

0.42

-1.35

0.96

- after 2 weeks

-1.63

0.23

-0.49

1.09

-0.69

1.55

-0.64

1.32

of polyols recycled via glycolysis from scrap flexible foams was previously reported [4].

Thermal conductivity was measured on the foam prepared with InfiGreen 420 as the sole polyol using a mixture of water and HFC245fa as a blowing agent. The resulting Kfactor of 0.148 was in the range reported for foams with the same density range prepared with similar levels of HFC-245fa [5].

4. Commercial applications for InfiGreen 320 The success of foams containing InfiGreen 320 in meeting the Chrysler material standards for automotive seat foams has recently led to its incorporation in commercially manufactured polyurethane foam for automotive seating.

Magna Seating is one of the first manufacturers to recognise the benefits of the new InfiGreen polyol technology. This ground-breaking innovation has already achieved its first commercial automotive application in the seats of the all-new 2011 Jeep Grand Cherokee (fig. 2). The seat cushions are manufactured at Magna Seating’s new Highland Park, Michigan, US, facility.

The use of recycled polyols reduces the need for petroleum-based raw materials in the foam manufacturing process, thereby improving the overall carbon footprint of seat foam production. When replacing 1 kg of petroleum-based polyols, carbon dioxide emissions are cut by 2 kg. Additionally, the ability to use scrap foam redirects this material from landfills and reduces overall waste.

The closed-loop recycling process does not compete with food-source raw materials Fig. 2: 

InfiGreen 320 polyol incorporated by Magna in seat cushions for 2011 Jeep Grand cherokee

Water absorption @ 25 °C Immersion for 4 days

199

1.04

201

0.35

177

1.21

198

0.08

Immersion for 1 week

230

-1.60

229

1.37

192

1.78

224

-1.26

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

59

since the scrap foam used as a raw material comes from old automotive seat cushions.

As a result of implementing the commercial application of these novel polyols, Magna Seating, an operating unit of Magna International Inc., has received an Innovation Award in the environmental category from the Society of Plastics Engineers (SPE) Automotive Division.

In addition, the InfiGreen rigid polyols will be used in rigid automotive applications starting in 2012.

5. Conclusions 5.1 Flexible foams Flexible foams were prepared with 5 % and 10 % InfiGreen 320, based on total polyols, by simple replacement of conventional polyether polyol for flexible foams, without any adjustment in the formulation. Free-rise and moulded flexible foams based on InfiGreen 320 exhibited resilience characteristic for HR foams. Most of the foam properties were affected by introduction of InfiGreen 320.

Bookshop

However, almost all properties, including wet compression set were in the range of values specified for automotive seating foams.

[2]

5.2 Rigid foams [3]

Rigid PU foams prepared with InfiGreen 420 as the sole polyol using water and a mixture of water and HFC-245fa as blowing agents exhibited comparable properties to the reference foam. The thermal conductivity of the foam based on InfiGreen 420 as the sole polyol prepared with HFC-245fa as a blowing agent was in the range of values reported for foams with the same density range prepared with similar levels of HFC-245fa.

Foams based on recycled polyols exhibited lower burning rate than the reference foam which indicated enhanced resistance to burning of InfiGreen 420.

[4]

[5]

6. References [1] Rasshofer, W. and Weigand, E., “Automotive Polyurethanes--Advances in Plastics Recycling,” Volume 2, (2001), Technomic Publishing Co., Inc., Lan-

caster, Pa. 17604, USA, pp. 66 – 129.

Behrendt, G. and Naber, B. W., “The Chemical Recycling of Polyurethanes (Review),” 2009, Journal of the University of Chemical Technology and Metallurgy, 44, 1, 3 – 23.

Chrysler Material Standard: MS-DC649<S>: “Cellular, Molded Polyurethane, High Resilient (HR) Type, Seat Application,” Date Published: 2008-07-01 Sendijarevic, V., Sendijarevic, I., Mayne, K., Winslow, R. W., Duranceau, C. M., Simon, N. L., and Wheeler, C. S., “Recycling of Polyurethane Foams Recovered from Shredder Residue via Glycolysis Process into Polyurethanes,” Proceedings of SAE 2006 World Congress, April 3 – 6, 2006, Detroit, Michigan, Paper No. 2006-011579.

Bogdan, M. and Hoerter, J. M., “Enovate 3000 Blowing Agent Blend Technology for the Global Polyurethane.

Spray Foam Industry”, Proceedings of the API Polyurethane Conference, October 1 – 3, 2003, Orlando, Florida.

www.gupta-verlag.de

ALL ABOUT POLYURETHANES Since the first Polyurethanes book was published in 1987, and reprinted with updates in 1990, the world of polyurethanes has changed dramatically. This edition has been completely re-structured, re-written and enlarged by approximately 50 %. It provides a greater focus on the whole range of components used to produce polyurethanes, a more detailed analysis of environmental issues and extended views on the application of polyurethanes.

As with the previous editions, this book provides a comprehensive survey of these remarkable materials, again presented in a readable manner, and continues to provide both an easilyunderstood introduction for those with limited knowledge of chemistry as well as detailed coverage for the more chemically-minded.

David Randall, Steve Lee The Polyurethanes Book John Wiley & Sons, Ltd., 3. Edition, 2003 494 pages, Hardcover, ISBN 978-0-47085041-1 EUR 239,00

ain!

le ag b a l i a v A

Dr. Gupta Verlag · P. O. Box 10 41 25 · 40852 Ratingen/Germany · Tel. +49 2102 9345-0 · Fax +49 2102 9345-20 · info@gupta-verlag.de · www.gupta-verlag.de

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PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Vehicle underbody structure with lightweight PU composite Mazda Design Americas participated in the “L.A. Auto Show 2010 Design challenge” with an underbody design concept for reducing a vehicle’s weight to less than 1,000 lbs. For Mazda’s MX-0 concept, the lightweighting capabilities of bayer MaterialScience LLc’s materials provided an avenue for designing tomorrow’s fuel-efficient vehicles with alternative materials technology commercially available today.

panel weight of 100 lbs compared with the MX-5’s 665 lbs, according to Mazda specifications.

Elsewhere, the MX-0 concept utilises automotive glazing that could be produced using BMS Makrolon polycarbonate to replace heavy glass, reducing the glazing mass by up to 50 %. The concept vehicle also uses Baytec polyurethane for the wheels and incorporates Baydur STR for structural components. Ultimately, the MX-0 would weigh in at an airy 999 lbs.

In 2009 the average light vehicle weighed 4,108 lbs, according to federal statistics.

BMS offers innovative options that help provide significant weight savings, part integration, aesthetics, design freedom and performance enhancements using engineering thermoplastics and polyurethane composite technologies such as:

The MX-0 underbody design features bMS lightweighting materials

“While the Design Challenge focused on a vehicle that would be available in 2020, Mazda designers set their sights on a lightweight vehicle that, among other things, could be mass produced using materials technologies that exist today,” said Bruce Benda, Vice President, Automotive Marketing, Bayer MaterialScience LLC (BMS).

used for the safety cell, subframes, body panels, and interior surfaces. Mazda determined that manufacturing of this structure could be automated using BMS’s Baypreg F polyurethane composite sandwich. Use of this material could lead to a safety cell/body

· The adoption of lightweight polymers to replace traditional materials such as glass and steel in exterior applications, including window glazing and body panel components. · Polycarbonate and polyurethane roof modules that reduce weight and lower the vehicle centre of gravity. · Underbody applications that assist with battery location and sound reduction along with providing the potential for significant parts reduction/consolidation.



As a benchmark, Mazda used the featherweight MX-5 Miata, which tipped the scales at a little more than 2,000 lbs (race specifications). The company then carried out a systematic process of weight reduction and consolidation. Major weight savings were achieved by using unique design methods and materials in key areas.

Specifically, a bonded two-piece monocoque structure, similar to a Formula One car, is

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

Mazda’s new design concept reduces a vehicle’s weight to less than 1,000 lbs

61

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RAMPF Dosiertechnik GmbH & Co. KG RĂśmerallee 14 D-78658 Zimmern o.R. T +49 (0) 741 2902 - 0 F +49 (0) 741 2902 - 2100 E info@rampf-dosiertechnik.de www.rampf-dosiertechnik.de

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High pressure metering and mixing machines 46 avenue des Allobroges - BP 116 26 103 ROMANS sur ISERE - France

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polyurethane@secmer.com www.secmer.com

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Graco Ohio Inc. 8400 Port Jackson Ave NW North Canton, Ohio 44720 USA Phone: +1 800 367 4767 gusmer-decker@graco.com www.gusmer-decker.com

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PU processing machinery, plants & moulds

PU processing machinery, plants & moulds

Polyurethane Evolution Impianti OMS SpA Via Sabbionetta, 4 · 20050 Verano Brianza (MB) · Italy Tel.: +39-0362-9831 · Fax: +39-0362-983217 Internet: www.omsgroup.it Email: impianti.oms@omsgroup.it

Plant construction Screw pumps

KRAL AG, Bildgasse 40 Industrie Nord, 6890 Lustenau, Austria Tel.: +43 / 5577 / 8 66 44-0 Fax: +43 / 5577 / 8 84 33 www.kral.at, E-Mail: info@kral.at

Storage tank systems · Blending stations · System houses · Reactors and process technology for prepolymers and synthetic polyols H & S Anlagentechnik GmbH Sandstraße 19, 27232 Sulingen, Germany Phone +49 4271 1011 · Fax +49 4271 2576 E-mail: info@hs-anlagentechnik.de www.hs-anlagentechnik.de

Transfer gear pumps

PURe Competence Engineering Tooling Tool Carriers Rotary Tables Overhead Conveyors Mix-/Metering Machines Spray/Mix Heads Service

www.frimo.com

CASTING, SPRAYING, BONDING, FOAMING

FRIMO Lotte GmbH Phone: +49 (0) 5404 886 - 0 info.lotte@frimo.com

Hennecke GmbH Birlinghovener Str. 30 53754 Sankt Augustin, Germany Tel: +49-2241-339-0 Fax: +49-2241-339204 E-mail: hennecke@hennecke.com Internet: www.hennecke.com

High precision dosing and metering pumps Customer specific sub-systems Beinlich Pumpen GmbH Gewerbestr. 29 58285 Gevelsberg / Germany POLYTEC EMC ENGINEERING GmbH & Co KG Kiesstrasse 12 A-4614 Marchtrenk / AUSTRIA Tel.: +43-(0) 72 43 - 53 9 52 Fax: +43-(0) 72 43 - 53 4 51- 405 e-mail: office@polytec-emc.com www.polytec-industrial.com

SAIP S.R.L. Via Bressanella, 13 22044 Romanò di Inverigo (C0) Italy infosaip@saipequipment.it · www.saipequipment.it Tel. +39 031 605762 · Fax +39 031 606934

Phone +49 (0) 23 32 / 55 86 - 0 Fax +49 (0) 23 32 / 55 86 31 www.beinlich-pumps.com info@beinlich-pumps.com

THE FOUNDATION FOR SUCCESS STORAGE TANKS PRODUCT HANDLING PROCESSING FACILITIES DISCHARGING UNITS PROCESS AUTOMATION RENEWABLE ENERGIES

Kracht GmbH Gewerbestrasse 20 58791 Werdohl, Germany fon: +49 (0)2392/935 0 fax: +49 (0)2392/935 209 mail: info@kracht.eu web: www.kracht.eu

Hans-Jürgen Keil Anlagenbau GmbH & Co. KG Zum Welplager Moor 8 49163 Bohmte-Hunteburg, Germany Tel.: +49 5475 9200-0 Fax: +49 5475 9200-190 Wwww.keil-anlagenbau.de

tank-farms mixing/blending technology resign plants heating and cooling plants dosing systems engineering

Tank farm, IBC-Station High pressure dosing machine Plant construction

PURPLAN GmbH Penter Straße 28 | 49134 Wallenhorst Telefon +49 (0) 54 07 81 77-0 www.purplan.de | GERMANY

Industrie-System-Technik Woitzel Wickingweg 23a D-49479 Ibbenbüren Tel: 05451 - 45 081 Fax: 05451 - 970 347 E-Mail: ist@woitzel.com

PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

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Publication information & contacts

Testing

Services

End products

Flow meter Dr. Joop Koster Kracht GmbH Gewerbestrasse 20 58791 Werdohl, Germany fon: +49 (0)2392/935 0 fax: +49 (0)2392/935 209 mail: info@kracht.eu web: www.kracht.eu

KRAL AG, Bildgasse 40 Industrie Nord, 6890 Lustenau, Austria Tel.: +43 / 5577 / 8 66 44-0 Fax: +43 / 5577 / 8 84 33 www.kral.at, E-Mail: info@kral.at

Chemin Chantemerle, 26 CH-1260 Nyon Tel. fix/fax + 41-22-3617960 Tel. mob. + 41-79-2020035 jkoster@iprolink.ch

Flexible Foam Production & Cutting FORMSÜNGER VE YATAK SAN. VE TİC. A.Ş.

1.Organize Sanayi Bölgesi 8.Cad. No:60 38071 Kayseri – TURKEY Tel : + 90 352 322 10 20 - Fax: + 90 352 322 01 26 info@formsunger.com.tr - www.formsunger.com.tr

Elastomers, polyurethanes, TPE – development, testing, failure analysis

Contract gasketing •

Contact: Dr Markus Grass +49 (0) 62 01 80 51 23 markus.grass@freudenberg.de

High precision flow measurement VSE Volumentechnik GmbH Hönnestr. 49 58809 Neuenrade / Germany Phone +49 (0) 23 94 / 6 16 30 Fax +49 (0) 23 94 / 6 16 33 www.vse-flow.com info@vse-flow.com

Testing, calculation, analysis, development, consultancy, sampling

•

Failure analysis Contact: Dr Kurt Marchetti +49 (0) 62 01 80 50 28 kurt.marchetti@freudenberg.de

Freudenberg Forschungsdienste KG 69465 Weinheim / Germany www.forschungsdienste.de

Sonderhoff Services GmbH Mathias-Brüggen-Str. 126-128 50829 Köln·Germany Tel +49 221 956526-0·Fax +49 221 956526-39 info@sonderhoff.com·www.sonderhoff.com

Publication information & contacts Publisher Dr. Heinz B. P. Gupta

Advertisement Tel. +49 2102 9345-14

Address Dr. Gupta Verlag Am Stadion 3b, 40878 Ratingen, Germany VAT No. DE 157894980

Subscription Tel. +49 2102 9345-12

Postal address P. O. Box 10 41 25, 40852 Ratingen, Germany Tel. Fax

+49 2102 9345-0 +49 2102 9345-20

E-mail info@gupta-verlag.de Internet http://www.pu-magazine.com Editors Dipl.-Chem. Frank A. Gupta (Editor-in-Chief) Angela Austin Jiri Drobny Paul Farkas Dr. Heinz B. P. Gupta Dipl.-Biol. Markus Linden Dr. Stephanie Waschbüsch Editorial secretary Tel. +49 2102 9345-0

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PU MAGAZINE – VOL. 8, NO. 1 – FEbrUAry/MArch 2011

”You’re so cool.“ Perfect insulation of fridges is what keeps stuff inside them cool and fresh and lasting. Perfect insulation makes fridges more efficient and environmentally friendly – and saves the consumers money. Developing additives to continuously improve the insulation properties of refrigerators and freezers is our goal.

That’s how we support you innovating systems and formulations that meet the ultimate goal: climate conservation. We help you to shape our future fridges, as we understand products’ and people’s needs.

Do you speak foam? We do.

Evonik Goldschmidt GmbH Essen, Germany phone +49 201 173-2229 fax +49 201 173-1991 polyurethane@evonik.com www.evonik.com/polyurethane-additives