Sustainable comfort solutions Recticel Group

susTAInABLE CoMfoRT soLuTIons

Belgian Recticel Group, a specialist in the manufacture and transformation of polyurethane foams for flexible foams, bedding, insulation and automotive applications, has a solid worldwide footing. A focus on sustainability and innovation have been the two factors strongly contributing to the group’s leading position and are also promoted by Recticel’s two major production facilities in the Czech Republic, supplying high-quality products to the automotive sector. Romana Moares reports.

Recticel NV is headquartered in Brussels, Belgium, and employs, including staff in joint ventures, over 8400 people in 98 sites across 28 countries. The group serves diverse markets, with Europe accounting for approximately 91 per cent of net sales, and a presence in the USA and Asia. Recticel supports the innovation and sustainability efforts of its industrial clients by developing proactive, responsible, value-adding solutions.

The group’s activities are organised into four distinct business lines, each serving specific market sectors: Automotive, Bedding, Flexible Foam and Insulation. The Automotive sector is one of the most important for the group – it develops, produces and commercialises interior solutions (dashboard skins and door panels) on the basis of the unique, certified Colo-Fast® spray technology. The Automotive line operates numerous production plants in the USA, Germany, the Czech Republic and China.

Recticel’s Automotive business line is clustered around two distinct activities: Interiors and Seating. Both serve highly demanding global Tier-1 customers as well as original equipment makers (OEM) in the automotive sector. Recticel’s solutions help to make cars lighter and thus more fuel-efficient. In a demanding automotive sector where just-in-time deliveries are crucial, the group’s technical expertise and the flexibility of its manufacturing set-up are seen as a competitive advantage. Recticel Interiors products can be found in the vehicles of many leading manufacturers, including BMW, Mercedes, Volvo, VW, Porsche, PSA, Renault, and Scania.

Czech operations

The two Czech facilities, in Mladá Boleslav and Most, are the largest manufacturing units of the Automotive division. Recticel Interiors CZ was commenced as a green field development to support the group’s growing activities. In 2001, it started as a small factory employing 50 people, and series production for its first project – dashboard polyurethane skin for the Mercedes Vito and Viano – was launched in 2003. Other projects followed for BMW, Opel Astra, Volvo, Scania and others. Over the years it has grown into a large operation facility covering 15,000 square metres and employing almost 500 people.

In 2007, Recticel won a production contract for the Mercedes E-class which was assigned to the Czech operation. To this end, the second subsidiary, RAI MOST, was established in 2007. Series production for Mercedes was launched in 2010, which was followed in 2011 by production for the Peugeot 408..

For car interiors, Recticel makes instrument panels and door panels in one-piece, large surface modules with integrated lower parts and seamless surfaces. The portfolio has the potential to extend to pillar covers, roof trim panels, centre consoles, side trim com-

ponents, armrests, seat panels and rear panels. Recticel’s proprietary spray technology (Colo-Fast®) allows production in multi-tone and multi-grain designs and stands out because of the enhanced freedom it offers to designers and manufacturers. In addition, the company provides lightweight 3D components for door panels, armrests, interior trims, cabriolet top covers, load floors, rear shelves and wheel arch panelling.

The Czech plants are by no means mere processors. Several years ago, applied research and development was transferred to RAI MOST where a specific department was established focused on the development and production of technological assemblies as well as development of new materials and applications.

lighter and cleaner

Recticel’s entire development in the Czech Republic has been one on-going investment, both in technology and new product development. The portfolio is extended and innovated on an on-going basis, to reflect current trends for reduced weight and emissions and also to introduce new products to win additional projects from both existing and new customers. Recent successes include new contracts for Volvo won last year for the manufacture of instrumentation panel surfaces in a range of colours and types, planned to be launched in the first half of 2018. Last year Recticel in the Czech Republic also launched mass production with application of the innovative lightweight Colo-Sense Lite. The aim of the project is to launch the patented production of automotive interior finishes in imitation leather, and to commission independent new-generation production lines.

Sustainability has always been at the heart of Recticel’s activities and is an important element of the Automotive business line, where customer demand for reduced carbon emissions pushes the innovation processes to develop lightweight materials. Over the years, Colo-Fast® has undergone continuous improvements and upgrades, culminating in the popular Colo-Sense® Lite material, consisting of a dual-layer surface that offers considerable weight reduction and lower emissions. It makes a valuable contribution to sustainability and cost-efficiency, and is currently very well received by the market.

Sustainability will further shape the group’s portfolio strategy and its innovation priorities, and as a result, will support its long-term competitiveness. In the future, the company wants to continue to develop and employ new materials, which will bring environmental benefits, in line with its general strategy to continue providing first-class products to both new and existing customers. n