Thermoplastic specialist R&P POLYPLASTIC

ThERMoPLaSTIC SPECIaLIST

R&P POLYPLASTIC specialises in the production of thermoplastic compound materials for processing by pressure, blow and extrusion moulding. The company is the absolute industry leader in Russia, boasting a more than 40 per cent share of the Russian market of composite polymer materials for technical purposes. Mikhail Katsevman, the company’s director for science and development, speaks about the current product range, competitive advantages and plans for further expansion.

The history of R&P POLYPLASTIC reflects the development of Russia’s plastics industry. Founded in 1991, the company has evolved into a major player supplying its products to a wide range of industries. Mikhail Katsevman describes the latest development: “In the last two to three years our company has notably increased production efficiency. We managed to reduce the amount of waste and reach a fundamentally new level of customer cooperation. A good example is R&P POLYPLASTIC’s successful access to the European market.”

Solid base

R&P POLYPLASTIC consists of the head office, two production sites and an R&D centre with trial production. The industrial sites are located in the Russian regions: one production plant is situated in the ‘auto capital’ Togliatti (Samara region), geographically aiming at one of the company’s main customers, Renault-Nissan-Avtovas; the other, larger plant is located in Engels (Saratov region), housing 13 production lines of the world-renowned equipment producers Berstorf, Coperion, ICMA and BUSS. “By the end of 2017, we are planning to launch two additional extrusion lines allowing us to increase production capacity to 115000 tonnes a year,” says Mr Katsevman.

He further highlights the aspects that make the company stand out. “Quite recently, our cooperation with PSMA Rus (a joint venture of the PSA Group and Mitsubishi Motors Corporation) became truly global. Our company was included in the PMR 2017 international list. This means that we can supply our compounds to all production plants of this international car manufacturer around the globe. What differentiates us from European competitors is our list of products based on the principle ‘as good as necessary’, and a top-class research and technology division supporting the customer while homologation of new types of materials is taking place. One of the basic guiding principles of R&P POLYPLASTIC for many years has been ‘tailor-made materials’. This refers to a customer-focused attitude and providing maximum comfort to the client,” he confirms.

Focus on development

The company’s core business is the production of thermoplastic compound materials, which are widely used for a large number of applications. The major customers of R&P POLYPLASTIC are automotive producers, large domestic appliance makers and manufacturers of construction materials, both interior and exterior. “We have a wide range of materials, more than 250 product names primarily based on Polypropylene (Armlen) and Polyamide (Armamid). There is also quite a high demand in Russia for our products based on PA66, HDPE, PBT and POM, under the brand names Technamid, Armobond, Torlen, Technoter, Technoset and others. We also have new developments based on polyphenylene sulfide — a material adapted to high temperatures which is used in the energy industry,” explains Mr Katsevman.

He further remarks that the current trend is focused on compounds based on high-temperature matrixes, including the use of high modulus and so-called ‘long fibres’ (LFT), in order to achieve a unique range of characteristics. These materials are increasingly used in electronics, electric engineering, automotive and other high-tech industries as an alternative to metals. “We also expand the use of recycled polymers and biodegradable compounds. We are actively working in these directions. Our R&D specialists have developed a relevant compound product range, while a separate group of developers is working with recycled polymers. The latter analyse the market, conduct experiments, develop formulations and create quality requirements for future industrial applications.”

Today, the most promising sector for R&P POLYPLASTIC is automotive – each vehicle contains more than 10 per cent thermoplastic compounds and the rate is constantly growing. However, the company strives to accommodate the needs of clients from all sectors alike; for example, when one of its clients, Whirlpool, asked it to work out an individual solution to develop a washing machine drum for its latest model, the company’s specialists developed a material to make the sides of the drum thinner while maintaining the same strength properties. This enabled it increase the drum’s efficiency by up to 30 per cent and the spin cycle speed by up to 1500 rpm without changing its dimensions. In 2014, the company received the JEC International Award for this achievement.

Going stronger

“Our enterprise has been successfully delivering its mission for more than a quarter of a century, with great support from our suppliers,” says Mikhail Katsevman. “We have been working with some of our suppliers for decades. When it comes to Polypropylene and Polyamide, our basic matrices, we are working with local producers such as Sibur, Lukoil, Nizsnekamskneftehim and Kuibishevazot. I would like to point out that we strive to build long-term relations with all our suppliers.”

He confirms that the company is well on track for future growth. R&P POLYPLASTIC is looking forward to the opening of Zapsibneftehim (owned by the Sibur Group), one of the largest modern petrochemical complexes in Russia with a PP copolymer production unit with a 500,000-tonne capacity. “The installation of this unit will give our company a competitive advantage and not only in Russia,” he claims.

After achieving a leading position on the local market, the company is seeking new areas for development; to this end, an expansion strategy called ‘Export Boost’ has been developed, based on its programme of external development. The current focus is on boosting business in central Europe, where most of its potential customers are located. “We will take the extensive path based on the principle of mergers and acquisitions,” says Mikhail Katsevman. “Our company is ready to cooperate in any form including purchasing new production plants.”

He concludes: “Last year R&P POLYPLASTIC had its 25th anniversary. Remarkably, our company was registered on the day of the collapse of the Soviet Union and the foundation of a new Russia. And believe me, a quarter century’s development of a company that is 100 per cent private through such a difficult period is worth a lot.” n