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The international <strong>plastics</strong> magazine from <strong>BASF</strong><br />
Sports:<br />
Faster, higher, stronger<br />
Honeywell:<br />
Everything properly packaged<br />
Construction:<br />
The cactus on the roof<br />
<strong>plastics</strong> 1/20<strong>04</strong><br />
www.<strong>plastics</strong>-magazine.com<br />
<strong>BASF</strong> <strong>Plastics</strong><br />
key to your success
<strong>Plastics</strong> and sport<br />
Faster, Higher, Stronger<br />
Wheels that meant the world<br />
Announcements<br />
A new look for <strong>BASF</strong><br />
European old car law<br />
Network for Europe<br />
Omnexus/Redistribution of task<br />
VDI <strong>Plastics</strong> Innovation<br />
Prize Awarded<br />
Concentrating on our strengths<br />
Cooperation, Competence,<br />
Consistency<br />
Improving efficiency with Colorflexx ®<br />
With patience and endurance<br />
Bella Plastica d’Italia<br />
Ecoflex ® for the bag from the<br />
fertile fields<br />
Smooth running on safe track<br />
Inconspicuous and yet<br />
indispensable<br />
Little figures make it big<br />
<strong>BASF</strong> and Honeywell –<br />
combined strength<br />
Marketplace Capron ®<br />
Design in the<br />
engine compartment<br />
Custom fit for everybody<br />
Lightweight, strong and versatile<br />
in terms of design<br />
They all have one thing in common<br />
A kettle proves its mettle<br />
<strong>BASF</strong> takes over Ticona’s polyamide<br />
6.6 business<br />
Getting greener…from the top<br />
A smoother ride for cyclists<br />
Something new on the Western front<br />
Always worth giving in to temptation<br />
A foam that flies all over the world<br />
Polystyrene Speciality to Spartech<br />
Joint Venture for PBT Production<br />
Fax reply<br />
Editor<br />
Contents 2<br />
Page<br />
02<br />
08<br />
10<br />
10<br />
11<br />
11<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
18<br />
20<br />
21<br />
22<br />
24<br />
26<br />
26<br />
27<br />
27<br />
28<br />
29<br />
30<br />
32<br />
33<br />
34<br />
34<br />
35<br />
35<br />
35<br />
35<br />
Faster,<br />
Higher,<br />
Stronger<br />
The Olympic motto Citius, Altius, Fortius or, in English<br />
“Faster, Higher, Stronger” is the talk of town once<br />
again. And this does not apply only to Athens in<br />
20<strong>04</strong>. The spring sun has hardly driven the winter away and<br />
droves of joggers, walkers and inline skaters are out and<br />
about, trying to lose the few extra pounds gained over the<br />
winter. One trend follows the next. Inline skaters have<br />
become a familiar sight, while Nordic walking is still a thing<br />
of the future. Whether trendy or not, sports without <strong>BASF</strong><br />
<strong>plastics</strong> are hardly conceivable.<br />
The colloquial expression is “couch potato”. It describes us when<br />
we struggle to overcome our inertia to get off the couch, go out and<br />
get our hearts pumping with a sport. Europeans dig deep into their<br />
wallets in the fight against this innate laziness: 36.25 billion euros.<br />
This is how much they paid out for sporting<br />
goods last year. The European Association of<br />
Sporting Goods Retailers sees a future that is<br />
“rosier than anything we have seen in a long<br />
time”. Movement is the one thing all buyers<br />
have in common – be it running, walking, gliding<br />
or sailing. <strong>Plastics</strong> make all of this easier.<br />
Ranging from impact absorption in shoes, UV
3<br />
Title<br />
Gliding and bouncing: kickboards are<br />
great fun to ride and are no longer<br />
used only by the pioneers of the scene<br />
on the half pipe ramp. They have<br />
become a versatile means of transportation<br />
for everyone. They run on<br />
wheels made of <strong>BASF</strong>’s polyurethanes.
Dear Readers,<br />
Soon we will once again see the ecstasy<br />
of victory and the agony of defeat. The<br />
TV will be on non-stop when the whistle<br />
is blown to mark the beginning of the<br />
European Soccer Championships in Portugal<br />
or when the Olympic torch burns<br />
brightly above Athens. In this issue of<br />
“<strong>plastics</strong>”, we would like to whet your<br />
appetite for these major events but in<br />
particular, we want to kindle your interest<br />
in being active. “<strong>plastics</strong>” had a look<br />
around the world of sports and discovered<br />
that <strong>plastics</strong> have not only replaced<br />
traditional materials, but have also paved<br />
the way for new and trendy types of<br />
sports to break through. This is where<br />
we find people like Titus Dittmann, who<br />
has become synonymous with skateboarding.<br />
Entrepreneur of the Year in<br />
20<strong>01</strong>, he gives us a glimpse backstage<br />
and makes one point very clear: <strong>plastics</strong><br />
get his world rolling. But we also have<br />
other topics in store to leave you clamoring<br />
for more. Such as the extrusion<br />
products <strong>BASF</strong> took over from<br />
Honeywell that are now part of a uniform<br />
global product portfolio.<br />
Enjoy your reading.<br />
The Editors<br />
<strong>plastics</strong> inside<br />
Title 4<br />
resistance in sportswear, abrasion resistance<br />
for wheels all the way to impact and<br />
scratch resistance for skis and snowboards.<br />
When it comes to function, <strong>plastics</strong> have<br />
long since replaced leather, rubber, textile<br />
and wood in sports gear.<br />
Shoes – a<br />
high-tech product<br />
Although doing sports does wonders for<br />
the body, the feet sometimes pay the price.<br />
This is where special <strong>plastics</strong> such as Elastollan<br />
® – a thermoplastic polyurethane (TPU)<br />
made by the <strong>BASF</strong> subsidiary Elastrogran –<br />
come to the rescue. This material can be<br />
found in soles and toe caps as well as in<br />
the reinforcing and damping elements of<br />
high-quality sports shoes. This TPU is more<br />
flexible, sturdy and durable than most other<br />
<strong>plastics</strong>. What<br />
ther-<br />
Holding firm, that is<br />
the crux. Ski manufacturers<br />
need<br />
extremely scratchresistant<br />
and UVstable<br />
<strong>plastics</strong> for<br />
the surface of their<br />
skis and snowboards.<br />
moplastic polyurethanes have to be able to<br />
withstand can be seen in the testing labs of<br />
major manufacturers such as adidas and<br />
Nike. There, to test its flexibility at low temperatures,<br />
a sole is bent to an angle of 90°<br />
40,000 times at a temperature of 20°C<br />
[minus 4°F], explains Martin Vallo, customer<br />
representative for TPU shoe applications.<br />
The objective here is to prevent the soles<br />
from breaking during use or the material<br />
from cracking too soon. In fact, the good<br />
old sneakers have become high-tech products,<br />
comprising up to 31 different construction<br />
elements. “Using the right material<br />
is decisive for a successful product,” says<br />
Vallo. Even though the annual sales volume<br />
of sports shoes has stagnated at about 800<br />
million pairs, companies like Nike introduce<br />
between 60 and 80 models into the<br />
market every year. Elastogran’s<br />
opportunity lies in responding<br />
to these trends. Thus,<br />
the annual TPU sales in this<br />
segment have actually increased<br />
by 15 per cent since manufacturers<br />
like TPU’s property profile and are increasingly<br />
turning to this product to replace other<br />
<strong>plastics</strong>. “When it comes to the further<br />
development of TPU for new applications<br />
and functions, we are first choice throughout<br />
the world,” maintains Vallo, not without<br />
pride. However, it is not only a matter of<br />
supplying the TPU, explains Vallo. A global<br />
presence is also needed. The major<br />
manufacturers produce their shoes<br />
primarily at assembly plants in
also needed. The major manufacturers pro-<br />
duce their shoes primarily at assembly<br />
plants in Asia. These assemblers, numbering<br />
about 40, not only put great stock in<br />
consistent quality and in the color of the<br />
granules, but they also demand an especially<br />
high degree of reliability and flexibility<br />
when it comes to delivery.<br />
Functional<br />
textiles<br />
Manufacturing in Asia? This does not apply<br />
only to sports shoes. Nowadays, most<br />
sportswear based on the fiber pre-product<br />
polyamide is manufactured in Asia. <strong>BASF</strong><br />
supplies this market from its polyamide facilities<br />
in Europe and the United States. Polyamide<br />
is required, among other things, in<br />
clothing that has to be stretchable while<br />
retaining its shape. It is very likely that the<br />
swimmers vying for the gold in the Olympic<br />
swimming pool in Athens will be wearing<br />
swimsuits made of <strong>BASF</strong> materials. “We at<br />
<strong>BASF</strong> hold a very significant share of the<br />
spun polymers market,” says Rolf Alles from<br />
Marketing Polymers. This market is not very<br />
transparent. “The textile value-added chain<br />
is very long,” elaborates Alles, “and our<br />
customers can hardly trace back whether<br />
the product contains <strong>BASF</strong>’s high-quality<br />
material.” According to Peter Pai, Managing<br />
Director of a Taiwanese yarn manufacturing<br />
company, Polyamid for fibers that <strong>BASF</strong><br />
sells under the brand name Ultramid ®<br />
provide an additional advantage, “I prefer<br />
5<br />
Ultramid ® because it runs smoothly during<br />
yarn production and yields the best textile<br />
properties”, he says. These outstanding<br />
characteristics are also in demand for a<br />
wide array of outwear and trekking gear<br />
made by market leaders such as VauDe and<br />
The Northface. The <strong>BASF</strong> experts have<br />
found a new market, thanks to that something<br />
extra offered by clothing made of<br />
<strong>BASF</strong> polyamide. “Functional textile” is the<br />
key word here. <strong>BASF</strong> researchers have<br />
developed a polyamide, namely, Ultramid ®<br />
BS 416N, that protects against hazardous<br />
UV radiation. When this polyamide is woven<br />
into a dense fabric, it provides UV protection<br />
not only with thick fibers but even with thin<br />
materials such as lightweight summer<br />
fabrics. The secret here, among other<br />
things, lies in the very fine and uniform<br />
incorporation of titanium dioxide into the<br />
polymer. The fibers made of this <strong>BASF</strong><br />
polyamide account for a sun screening<br />
factor of up to 80 and they look and feel like<br />
cotton. Rolf Alles exudes confidence, “We<br />
are banking on the fact that the demand for<br />
UV-resistant textiles that look and feel like<br />
cotton will continue to grow, thus creating<br />
an additional potential for sales.”<br />
The secret<br />
of the rebound<br />
When the sun beckons us outdoors, it gets<br />
us rolling. Scooters, kickboards or inline<br />
skates are no longer just a fad but now get<br />
T i t l e<br />
the masses on the move. What gets us<br />
going are the wheels made of Elasturan ®<br />
6050, a plastic manufactured by Elastogran.<br />
The important aspect when it comes to<br />
wheels is the mix. Experts<br />
speak of “soft mix” for beginners since they<br />
need traction on the pavement, and of<br />
“sport mix” for the<br />
acrobats, whose wheels have to be hard<br />
and elastic. Experts know what makes a<br />
good wheel: it all boils down to the rebound.<br />
In addition to the abrasion resistance and<br />
durability, this term refers particularly to the<br />
elasticity. Professionals test their wheels for<br />
the right rebound by bouncing them. The<br />
advantage of Elasturan ® in wheels lies in its<br />
flexibility. The hardness, rebound, wheel<br />
strength, sturdiness and abrasion behavior<br />
can all be influenced with the right composition<br />
of the components. This results in a<br />
wide array of wheel types that can be matched<br />
to every skill level.<br />
The weather-resistant<br />
ones<br />
People who are not satisfied just with the<br />
wind in their faces as they glide on inline<br />
skates may head for the water. After all, the<br />
water sports sector in Europe has booked<br />
sales to the tune of 3.1 billion euros in 2003
and it is looking optimistically towards the<br />
future. The sector anticipates an increase in<br />
sales of between 3 and 5 per cent for<br />
20<strong>04</strong>. Anyone who sails close to the wind is<br />
going to need materials that are up to the<br />
task. Particularly important features here are<br />
materials that are UV-stable and impactresistant,<br />
such as Luran ® S, <strong>BASF</strong>’s ASA.<br />
“Surfboards are covered with a sheet of<br />
Luran ® S since this material is quite weather-resistant<br />
and retains its color, particularly<br />
in the case of white,” explains Geoff Nelson,<br />
Business Development for Luran ® S.<br />
It is obvious to be thinking of summer and<br />
the sea right now. But employees of the<br />
major ski manufacturers do not know the<br />
meaning of the word summer vacation. At<br />
Isosport, the world’s leading producer of<br />
plastic materials for skis and snowboards,<br />
manufacturing runs at full throttle starting in<br />
June. About 8.5 million skis were made<br />
worldwide in the year 2002. Market observers<br />
such as corporate consultant Andreas<br />
Kreutzer speak of an Austrian-French rivalry.<br />
The marked leaders are Rossignol and<br />
Atomic, each holding a market share of 11<br />
per cent. Europe is the most important<br />
region for the ski industry; this is where<br />
about two-thirds of the production is sold.<br />
The United States accounts for 20 per cent<br />
of the ski production and Japan for 12 per<br />
cent. It is particularly in skis that the use of<br />
<strong>plastics</strong> has triggered a veritable revolution.<br />
After all, the modern Carver does not have<br />
much in common with the good old wooden<br />
skis. The use of <strong>plastics</strong> here has not<br />
T i t l e 6<br />
Everybody is on the<br />
move: in the summer<br />
time, inline<br />
skaters flood city<br />
streets. Experts<br />
assess the quality<br />
of wheels for inline<br />
skates on the basis<br />
of their abrasion<br />
resistance, durability<br />
and especially<br />
their elasticity.<br />
only contributed to reduction of weight, but<br />
has also improved the tension and shaping<br />
of the boards. Scratch<br />
resistance, chemical resistance and shapeability<br />
are at a prime, especially when it<br />
comes to surface materials, says Manfred<br />
Weisenbach, who is responsible for the ski<br />
industry at <strong>BASF</strong>. For these ski surfaces,<br />
companies like Isosport process thermo<strong>plastics</strong><br />
that have been manufactured by<br />
means of extrusion such as Terlux ® , which<br />
is <strong>BASF</strong>’s transparent ABS. Any plastic<br />
employed in skis has to be a jack-of-all-trades<br />
since it not only has to withstand the<br />
cold winter temperatures, but also the summer<br />
heat when stored in the attic back<br />
home. “The crucial factor,” explains<br />
Weisenbach, “is that suppliers of the ski<br />
industry have to be able to respond extremely<br />
quickly since shifts in shape and color<br />
trends occur at a breakneck pace.” The<br />
experts at Isosport confirm this, “Our customers,<br />
the major ski manufacturers, are<br />
constantly calling upon us to manufacture<br />
our products with tailor-made features, both<br />
in terms of strength and surface characteristics,<br />
as well as possible color variants. This<br />
is why we pay close attention to ensuring<br />
that our raw materials can withstand a wide<br />
temperature range and also that they meet<br />
the requirements regarding adhesion properties,<br />
UV stability and high abrasion resistance.”<br />
Hence, we certainly cannot place the blame<br />
on the<br />
quality of the materials if the “couch potato”<br />
in us gains the upper hand. The sportswear<br />
of the future will be even better adapted to<br />
new types of sports and trends. Modern<br />
materials will make the products even more<br />
ergonomic. Shock absorption, functionality,<br />
rebound – that is all fine and well but there is<br />
one thing that <strong>plastics</strong> will not be able to<br />
accomplish even in the future: to get the<br />
“couch potato” going …<br />
More information about the <strong>plastics</strong> mentioned<br />
here can be found at<br />
www.elastogran.de<br />
www.terlux.de<br />
www.luran-s.de<br />
www.basf.de/ultramid<br />
Particularly strong<br />
<strong>plastics</strong> are needed<br />
on a surfboard.<br />
Today, surfboards<br />
are coated with<br />
weather-resistant<br />
and impact-resistant<br />
materials such<br />
as Luran ¤ S.
Title<br />
Wheels that meant the world<br />
Lifestyle as a means of expression and a basis for business success<br />
Throughout the world, titus-AG is synonymous<br />
with skateboarding made in Germany.<br />
Titus Dittmann (55), after whom this company<br />
is named, was honored as “Entrepreneur of<br />
the Year” by Manager Magazine in 20<strong>01</strong>; he is at<br />
the helm of about 40 individual enterprises with<br />
450 employees all over Germany, which together<br />
amassed annual sales totaling 56 million euros in its<br />
four corporate pillars: retail (40%), wholesale (40%),<br />
media & events and technology & innovation in 2003.<br />
Mr. Dittmann, you cut the same dashing figure on<br />
the sometimes slippery business floor as you<br />
do on a skateboard. Can you explain how you<br />
have managed to bridge the gap between<br />
being highly credible among<br />
the youth and at the same time being<br />
successful as a businessman?<br />
Titus: I live the lifestyle and have been doing so<br />
for 25 years. Go ahead, write it down, I am<br />
still a youngster at heart. As a high school Titus Dittmann is<br />
as much at home<br />
teacher of geography and physical educa-<br />
on a skateboard as<br />
tion, I had already had my fill of civil service on the business<br />
after six years of teaching. I recognized at floor.<br />
an early stage that skateboards were a<br />
good tool for working with young people – they are a means of<br />
expression, like music. I brought the first skateboards with me<br />
directly from California and sold them to my pupils at cost. My<br />
venture into the business world was an ideal solution for me: to be<br />
on the move and to be successful. From the modest beginnings in<br />
the basement all the way to a stock company.<br />
It is by no means only the label of the Titus company that is<br />
hot among youngsters. They shop in retail stores, at outlets<br />
8<br />
and through catalogs. What message connects<br />
the young to the labels?<br />
Titus: Parents, who themselves<br />
wear designer clothes, should not be surprised that the<br />
way they bring up their children also leads youngsters<br />
to wear brand names. Youngsters want to be different<br />
and so they dress the way they want to be<br />
perceived. Wearing certain labels also reveals part<br />
of their personality and character. By wearing skateboard<br />
labels, they are part of a certain scene.<br />
As a businessman, you have not neglected to<br />
share your success. Do you also see it as your<br />
mission to introduce youth to the realm of<br />
sports outside of the usual sports clubs?<br />
Titus: A large part of the money that we earn from the<br />
market flows back to the youth in the form of magazines,<br />
events, championships, our youth cultural centers or skating<br />
halls. At an early point in time, we founded the Association<br />
for the Promotion of Youth Culture. The goal of this organization<br />
is to provide children and adolescents with the opportunity<br />
to engage in experience-oriented leisure activities in a sensible<br />
venue. But we also sponsor school classes in sports projects, we<br />
charter buses at our expense for children from socially disadvantaged<br />
backgrounds so that they can attend the Monster Mastership,<br />
we organize skateboard camps and, as our most recent<br />
vacation project during Easter, we are introducing the Titus Academy.<br />
How can a layman visualize research and development at<br />
Titus? Do you get on the skateboards yourself?<br />
Titus: Of course I do. I am a big fan of Funsports and Xtreme<br />
Sports: with my son Julius, we go downhill on our skateboards
at 100 kilometers per hour; my other<br />
hobbies include hang gliding, parachuting<br />
and car racing; I also competed in<br />
the first snowboarding world championships.<br />
Precision is a must in the<br />
development of our wheels. The differing<br />
hardness of the wheels, a factor that<br />
influences the skating properties, is<br />
varied by a handful of hard segments<br />
and hundreds of soft segments. In<br />
addition to hardness and speed, elasticity<br />
– which is measured during impact – and<br />
traction on the pavement are likewise<br />
important. The pros not only promote a<br />
company name, but they also play a<br />
decisive role in development.<br />
Experienced athletes, also those of our<br />
own Titus team, have tested the wheels<br />
which are developed, for the most part,<br />
in the United States.<br />
Hard shell, soft core<br />
<strong>Plastics</strong> turn shoes into trendy sports gear<br />
Admittedly, the sight of fitness fans all decked out with ski<br />
poles, modern leisure clothing and outdoor shoes, slogging<br />
over field and meadow, takes some getting used to. Nordic<br />
walking is the name of this trendy sport from Finland that is<br />
gaining more and more enthusiasts in central Europe, Japan<br />
and the United States. No wonder, Nordic walking is not only<br />
easy to learn but also extremely effective.<br />
Researchers at the Cooper Institute in Dallas have found that<br />
Nordic walking burns up to 46 per cent more calories than<br />
normal walking at the same speed. Thanks to the poles used in<br />
Nordic walking, the stress on the locomotor apparatus is reduced<br />
by as much as 30 per cent, which makes it is particularly<br />
well-suited for people with knee or back problems.<br />
This fitness sport was originally developed as a summer training<br />
method for cross-country skiers and biathlon competitors.<br />
Aside from the appropriate carbon fiber poles, the footwear is<br />
also of crucial importance if it is to provide a firm foothold even<br />
9 Title<br />
Titus Dittmann<br />
turned his hobby<br />
into a business.<br />
How important is plastic as a material<br />
for the production of skateboards and<br />
wheels? Which safety requirements<br />
does the plastic have to meet?<br />
Titus: Without <strong>plastics</strong>, especially<br />
polyurethane, there would be no skateboarding.<br />
The first wheels were made of<br />
iron, the second generation still had open<br />
ball bearings – those were true handicaps.<br />
The skateboard only got rolling<br />
really well with the advent of<br />
polyurethane. This material is an obvious<br />
choice and it delivers the same outstanding<br />
performance as the skateboarders do.<br />
The wheels range from the soft, large,<br />
colorful ones that are suitable for covering<br />
large distances all the way to small,<br />
white, especially hard wheels that are<br />
needed to do all those tricks. Every<br />
skater knows how annoying it is if the<br />
wheels already have flat spots after the<br />
first run. The color of the wheels is of<br />
secondary importance; they have to run<br />
perfectly – only then is our company logo<br />
put on them.<br />
Further information:<br />
www.titus-ag.de<br />
on difficult terrain. Thus, the shoes and boots have a soft core –<br />
a shock-absorbing insole made of <strong>BASF</strong> polyurethane foam –<br />
and are often made of fibers on the basis of polyamide pre-products<br />
also manufactured by <strong>BASF</strong>. The foam made of the plastic<br />
fibers is not only breathable, but also wind and water repellant.<br />
But polyurethanes serve other functions in shoes as well. This<br />
plastic can be adapted to varying requirements. In the case of<br />
skateboarders, the shoes make contact with the board and with<br />
the pavement. The skateboard looks as though it is glued to the<br />
feet of the skaters, even when they are performing difficult jumps<br />
on half piped ramps. The secret lies in the different properties of<br />
<strong>BASF</strong> polyurethanes. This versatile plastic is used in the ski<strong>dp</strong>roof<br />
soles, in the protected front and heel areas as well as in<br />
the hard and supporting surface of the shoe. For instance, the<br />
sturdy edge made of polyurethane gives the board the right<br />
drive during the performance of the “ollie”, that is, turning the<br />
board in the air.
Company<br />
A new look for <strong>BASF</strong><br />
Since March of 20<strong>04</strong>, <strong>BASF</strong> has been sporting a new look.<br />
Important components of the changed<br />
corporate design are new colors and<br />
design elements, as well as an expanded<br />
corporate logo. The new logo builds<br />
upon the familiar <strong>BASF</strong> lettering since it<br />
embodies endurance and an ongoing,<br />
valid and clear strategy. These four letters<br />
are now preceded by two complementary<br />
squares. “They stand for partnership<br />
and cooperation, for joint success,”<br />
explains Dr. Jürgen Hambrecht, Chairman<br />
of the Executive Board at <strong>BASF</strong> Aktiengesellschaft. “One<br />
square is the counterpart of the other and the two complement<br />
each other.” Added to this is the phrase “The Chemical<br />
Company”. Hambrecht elaborates, “With this claim, we are<br />
making a very clear statement about what we are proud of,<br />
namely, what we are and want to remain: the world’s leading<br />
chemical company.”<br />
New approach to<br />
reutilization.<br />
News 10<br />
European Old Car Law<br />
New ways of recycling<br />
It was born in Brussels and now it will have to learn how to<br />
walk in the countries of Europe: the European Law on the Disposal<br />
of Old Cars. According to this law, starting in 2007, car<br />
owners can return their old cars free of charge. The costs for<br />
the disposal and reutilization of the materials will be borne primarily<br />
by the car manufacturers. Furthermore, the requirement<br />
exists that, from 2006 on, at least 85 percent of the vehicle has<br />
to be reutilized. A look at the various countries, however,<br />
reveals quite a state of confusion. In the Netherlands, for example,<br />
buyers already pay the price for the recycling when they<br />
purchase a new car. At the present time, the system is unregulated<br />
in France, Italy and Spain. In Germany, the law has<br />
formulated complex enforcement schemes aimed at<br />
meeting the requisite recycling quotas. In cooperation<br />
with the European plastic associations APME and<br />
VKE, as well as with tecpol, the development agency<br />
for environmentally efficient polymer reutilization,<br />
<strong>BASF</strong> has now come up with a way to meet the<br />
quotas. A large-scale experiment in the secondary<br />
raw material reutilization center “Black Pump” in<br />
Saxony proved that the reutilization of the raw material<br />
from large plastic objects brings about both environmental<br />
and economic benefits. Official recognition soon<br />
followed. The ministry for the environment of the German state<br />
of Saxony has officially approved this recycling route.
<strong>Plastics</strong> Association<br />
New Network for Europe<br />
A new network of the <strong>plastics</strong> industry is being created in<br />
Europe. The members’ meeting of the Association of <strong>Plastics</strong><br />
Manufacturers in Europe (APME) recently approved the next<br />
phase of a project that will culminate with the foundation of a<br />
new pan-European <strong>plastics</strong> association that is to include all<br />
current APME members. This would be the first time that<br />
European and regional representations would be under the<br />
umbrella of an organizational network having a joint strategy<br />
and coordinated action plans. The centers of this new association<br />
are going to be Belgium, Germany, Italy, Spain, France<br />
and the UK. Representations are also planned in all European<br />
countries.<br />
VDI Pize<br />
VDI <strong>Plastics</strong> Innovation Prize Awarded<br />
11<br />
The plan calls for the new association to start its operations<br />
on January 1, 2005. The new association of <strong>plastics</strong> manufacturers<br />
will handle broad topics on general <strong>plastics</strong> issues, as<br />
well as product-specific topics on individual <strong>plastics</strong>.<br />
The APME is the representative of the <strong>plastics</strong> industry in<br />
Europe. Currently, the APME has about 50 member companies<br />
that account for more than 90 per cent of the <strong>plastics</strong><br />
production in Western Europe, with sales of over 29 billion<br />
euros.<br />
A special commendation for <strong>BASF</strong> researchers: VDI, the German<br />
Association of Engineers, has awarded <strong>BASF</strong> and its partners<br />
this year’s <strong>Plastics</strong> Innovation Prize for their Paintless-<br />
Film-Molding (PFM ® ) process. With this process, coated or<br />
dyed plastic films made by <strong>BASF</strong> ensure that exterior car body<br />
parts made of plastic can no longer be distinguished from the<br />
steel parts.<br />
The films are manufactured by <strong>BASF</strong> to meet specific customer<br />
requirements, as a result of which expensive adaptations<br />
by the OEM – for instance, coating work – are no longer<br />
necessary. The special advantage for automotive manufactur-<br />
News<br />
eCommerce/Omnexus<br />
Redistribution of task<br />
What first was just a rumor became reality at the end of 2003.<br />
Omnexus was one of the last Internet trade forums from the<br />
boom year of 2000 to close its doors. Omnexus was founded<br />
by the <strong>plastics</strong> manufacturers <strong>BASF</strong>, Bayer, Dow, DuPont and<br />
Ticona with investments to the tune of 50 million dollars.<br />
Several companies have now taken over where Omnexus left<br />
off. Thus, Omnexus has advised its customers who used the<br />
automatic order placement system “Ultralite” to now transact<br />
their business via Elemica Buyer Direct. The Application Database<br />
and the Material<br />
Data Center have been<br />
taken over by M-Base<br />
Engineering + Software.<br />
Most of the<br />
e-marketing services<br />
are now run by one of<br />
Omnexus’ competitors,<br />
SpecialChem<br />
(www.specialchem.com). The former Omnexus Material Data<br />
Center and the Application Database have been setup at the<br />
following address: http://www.materialdatacenter.com/. <strong>BASF</strong><br />
customers will find plenty of opportunities for ordering and<br />
other offerings at www.<strong>plastics</strong>portal.com<br />
ers is that parts produced with the<br />
PFM ® process weigh considerably<br />
lesser than wet-coated sheet steel.<br />
This also benefits drivers since fuel<br />
consumption is lower. The new<br />
technology is already being used in<br />
the plastic full roof of the MCC<br />
Smart. “This is a clear indication<br />
that PFM ® is ready for serial<br />
production,” explained the VDI representatives during the<br />
award ceremony.
Balance Sheet 12<br />
Concentrating on our strengths<br />
Result below that of previous year –<br />
<strong>plastics</strong> restructuring continues.<br />
Strengthening the core sectors and, at the same time, tapping<br />
into new fields: <strong>BASF</strong>’s plastic divisions have set<br />
themselves ambitious goals. In 2003, <strong>BASF</strong> already came<br />
closer to achieving these goals, but this has not yet translated into<br />
an improvement in the largely disappointing operating results. We<br />
look back upon a year marked by acquisitions in the realm of engineering<br />
<strong>plastics</strong>, new capacities for polyurethanes and the closing of<br />
plants for styrene <strong>plastics</strong>. Moreover, 2003 will be remembered as a<br />
year plagued by very high raw material costs and very unfavorable<br />
exchange rates. Major new acquisitions, expanded capacities and<br />
plant closings on a small scale: these were all activities that left their<br />
imprint on <strong>BASF</strong> in 2003. Before the backdrop of difficult market<br />
conditions, <strong>BASF</strong> succeeded in boosting its sales by 3.7 per cent<br />
last year, to a total of Euro 8.8 billion. Nevertheless, <strong>BASF</strong> did not<br />
manage to compensate for the higher raw material costs and the<br />
unfavorable exchange rates, which translated into a sharp drop in<br />
earnings before interest and taxes (EBIT) from Euro 582 million to<br />
Euro 296 million (minus 49%).<br />
Cooperation<br />
with partners<br />
On May 1, 2003, <strong>BASF</strong> turned over its fiber business to Honeywell<br />
and, in return, acquired their engineering <strong>plastics</strong> business. At the<br />
end of the year, the business of polyamide-6,6 materials was<br />
purchased from Ticona. Dr. John Feldmann, member of the<br />
executive board in charge of this field, makes a positive assessment<br />
of the takeover as he states, “This has made us into a leading world<br />
supplier for our customers in this field”. In the meantime, 500 former<br />
Honeywell employees, as well as their customers and production<br />
facilities, have been integrated into <strong>BASF</strong>. <strong>BASF</strong> continues to put<br />
stock in efficient, world-scale plants strategically situated in the most<br />
significant markets, at times in cooperation with partners. For<br />
instance, in 2003, <strong>BASF</strong> started the construction of a site for the<br />
Dr. John Feldmann<br />
makes a positive<br />
assessment of the<br />
Honeywell acquisition.<br />
production of isocyanates in Caojing, China, an undertaking that is<br />
going to be operated jointly with Chinese partners and Huntsman,<br />
an American company. This will create capacities that will also allow<br />
us to supply other companies such as, for example, Bayer. At the<br />
same time, the Polyurethane <strong>Plastics</strong> Division started up a new<br />
installation for TDI in Yeosu, Korea, and also considerably expanded<br />
the production of MDI in Antwerp, Belgium.<br />
Together with the Japanese company Toray, the Engineering<br />
<strong>Plastics</strong> Division is going to build an installation for polybutylene<br />
terephthalate (PBT) in Kuantan, Malaysia. The closure of styrene<br />
<strong>plastics</strong> plants was on the agenda. In this vein, the division discontinued<br />
the production of ABS in Geleen, The Netherlands, closed<br />
the Styrolux plant here in Ludwigshafen, and is also going to shut<br />
down the facility for polystyrene compounds as of July 1, 20<strong>04</strong>.<br />
Within the scope of these measures, <strong>BASF</strong> has also sold its business<br />
with polystyrene compounds to Spartech Polycom SAS. With<br />
this step, the styrene <strong>plastics</strong> division is steadfastly pursuing its<br />
standard product strategy of concentrating on a portfolio with just a<br />
few product lines, a few production sites and highly efficient<br />
marketing processes. <strong>BASF</strong> also interprets the concept of highly<br />
efficient marketing as being synonymous with the expansion<br />
of e-commerce. <strong>BASF</strong>’s eCommerce activities such as the<br />
<strong>Plastics</strong><strong>Portal</strong> (www.<strong>plastics</strong>portal.com) chalked up sales of over<br />
one billion euros in 2003 – in some business fields, this accounted<br />
for more than 50 per cent of their sales.
13<br />
Markets and Products<br />
Cooperation, Competence, Consistency<br />
Manufacturers of medical technical products need more than “just” granules<br />
Division of labor – that is the key to<br />
success in the healthcare sector.<br />
Wherever all of the preparations<br />
needed for medical care have to be available<br />
at all times, inter-company research<br />
and cooperation are a must. With this in<br />
mind, pharmaceutical companies are concentrating<br />
more and more on developing<br />
and manufacturing the pure ingredients<br />
themselves. According to experts, a look at<br />
the packaging reveals two essential trends.<br />
As far as customers are concerned, the<br />
packaging is supposed to be simpler and<br />
safer, whereas for <strong>plastics</strong> processors, the<br />
packaging is becoming more varied and<br />
complex in terms of its function and structure.<br />
This is a development that is turning<br />
<strong>plastics</strong> manufacturers such as <strong>BASF</strong> into<br />
more than mere supplier of raw materials.<br />
Consequently, during the development of<br />
the <strong>plastics</strong>, <strong>BASF</strong> works together with its<br />
customers in considering and complying<br />
with all criteria related to processing<br />
technology and approval procedures.<br />
Furthermore, within the scope of work<br />
groups and associations, <strong>BASF</strong> cooperates<br />
with the health authorities to continuously<br />
improve the testing and analysis methods<br />
so as to guarantee a consistently high<br />
product quality and purity.<br />
Reliable<br />
supply<br />
“When it comes to the medical sector, the<br />
goal is to be able to offer a product that is<br />
tailor-made for each particular application<br />
and whose quality is consistently high and<br />
always ready for delivery,” explains Marcus<br />
Anders, who is in charge of the medical<br />
technology sector at <strong>BASF</strong>’s Unit for Innova-<br />
tion Management of Specialty Polymers.<br />
The outcome of joint product development<br />
and product maintenance is <strong>BASF</strong>’s special<br />
plastic Terlux ® (MABS), with which additional<br />
needs in the realm of medical technology<br />
can and should be met. Manufacturers of<br />
pharmaceutical packaging already employ<br />
<strong>BASF</strong>’s MABS for breathing filters and ventilation<br />
equipment, as well as for infusion and<br />
tubing systems. “The advantages of Terlux ®<br />
really come to the fore in the case of breathing<br />
filters. It can be processed quickly and<br />
easily, it exhibits an ideal ratio of stiffness to<br />
toughness, it is especially resistant to acids,<br />
cleansers and other external influences, and<br />
it can also be sterilized without any problems,”<br />
says Anders. According to Sven<br />
Riechers, product manager for Terlux ® ,<br />
<strong>plastics</strong> employed in medical technology<br />
have not nearly exhausted their potential. On<br />
the contrary, owing to the ever-growing legal<br />
stipulations in the medical realm, the requirements<br />
made of the material are becoming<br />
more stringent. “This is precisely the reason<br />
why the segment of medicine offers<br />
application opportunities for a specialty like<br />
Terlux ® ,” elaborates Riechers. As far as<br />
healthcare is concerned, know-how in the<br />
development and production of the plastic is<br />
not all that is needed, but rather, pharmaceutical<br />
manufacturers also have to be able<br />
to count on reliable and consistent deliveries<br />
so that these time-sensitive products can<br />
also be supplied to hospitals on short<br />
notice. “Our customers confirm that, when it<br />
comes to the aspect of supply reliability, we<br />
are way ahead of the competition,” he says<br />
proudly.<br />
www.terlux.com<br />
Contact person:<br />
Marcus Anders, Phone: +49 621 60-91153<br />
Sven Riechers, Phone: +49 621 60-59349<br />
Be it breathing filters, multi-flow devices or<br />
tubes – all technical products employed in<br />
the medical sector have to comply with the<br />
strictest requirements.
Colorflexx ® 14<br />
Improving efficiency<br />
with Colorflexx ®<br />
By switching its ABS processing to <strong>BASF</strong>’s<br />
Colorflexx ® concept, Josef Mawick<br />
Kunststoff-Spritzgusswerk GmbH & Co. KG<br />
has increased its flexibility.<br />
For some years now, the self-coloring<br />
of plastic granules by means of<br />
color metering devices on the<br />
machines has been a standard procedure<br />
at Josef Mawick Kunststoff-Spritzgusswerk<br />
GmbH & Co. KG, a <strong>plastics</strong> injectionmolding<br />
company in Werl, Germany that<br />
processes bulk <strong>plastics</strong> such as PS, PE<br />
or PP. As far as Willi Röer, head of sales<br />
at the Mawick company, is concerned,<br />
the reason is obvious, “Self-coloring<br />
increases our flexibility to respond to<br />
customer requirements and also allows<br />
us to optimize the aspects of plant logistics<br />
and storage.”<br />
Profitable<br />
effects<br />
Such advantages are now also being utilized<br />
by Mawick in the realm of ABS processing,<br />
which accounts for a 15 to 20<br />
percent share of its production. Among<br />
the first examples of applications that<br />
have been realized by <strong>BASF</strong> and its masterbatch<br />
partners employing the Colorflexx<br />
® concept are a multi-compartment<br />
garbage can dyed blue or gray for mobile<br />
homes, as well as an orange discharge<br />
chute for lawnmowers.<br />
Even though experience is still being<br />
acquired in homogenously blending the<br />
colour concentrate, the so-called masterbatch,<br />
with the ABS natural-colored<br />
products, Röer can already see profitable<br />
effects. There is a reduction in the<br />
purchase price of the material since the<br />
acquisition of large amounts of the natural-colored<br />
product avoids the surcharges<br />
for small quantities of dyed products. At<br />
the same time, there is greater flexibility<br />
when the color is changed.<br />
More than 8000<br />
metric tons<br />
Giving shape to ideas by using <strong>plastics</strong> has<br />
been one of the core competences of<br />
Josef Mawick Kunststoff-Spritzgusswerk<br />
GmbH & Co. KG for 45 years now. Located<br />
in Werl, Germany, this company has 270<br />
employees, 55 injection-molding machines<br />
in the clamping force range from 50 to<br />
1200 tons, two blow-molding installations<br />
for article volumes of up to 120 liters as<br />
well as a competent team of engineers and<br />
technicians in development and construction<br />
and its own tool production capability,<br />
From the white natural-colored product to the colorful design<br />
object – garbage cans dyed using Colorflexx ® .<br />
all of which ensure speed, flexibility and<br />
quality at all times. (More information can<br />
be found at www.mawick-online.de)<br />
In addition to its own line of office furniture,<br />
Mawick has gained a solid foothold in the<br />
automotive industry. The manufacturing<br />
program of its automotive sector, in addition<br />
to battery housings and battery<br />
covers, also comprises fully assembled<br />
housings for headlights, the production of<br />
lamp covers in one-component and<br />
two-component technology, cover frames<br />
and all sorts of caps, some of them with<br />
installed gaskets. Furthermore, Mawick also<br />
manufactures technical injection-molded<br />
parts weighing up to 6 500 grams for many<br />
other branches of industry. These include<br />
boxes and lids in the sanitary sector,<br />
discharge chutes and motor supports for<br />
lawnmowers as well as wheels, hoods and<br />
spoilers for children’s cars. The company<br />
processes more than 8 000 metric tons of<br />
<strong>plastics</strong> per year. Except for PVC, just<br />
about all types of thermo<strong>plastics</strong> are used.<br />
www.colorflexx.com<br />
Your contact person at <strong>BASF</strong>: Christian<br />
Janeba, Phone: (+49) 172 7437 485
With patience and endurance<br />
To develop markets in Asia – that is the challenge<br />
facing the Specialty Polymer Team in Asia<br />
Asia – extraordinary markets,<br />
extraordinary business, extraordinary<br />
people. A team, like the one<br />
that <strong>BASF</strong> has established two years ago<br />
for its specialties business with styrene<br />
polymers in Europe, has been in place for<br />
a year in the markets in Asia. A team that,<br />
together with customers, is aiming to discover<br />
and develop new areas of application<br />
for specialty <strong>plastics</strong>. Where are the<br />
markets in Asia? What is the potential there<br />
for specialty <strong>plastics</strong>? How do the regions<br />
differ from each other? <strong>BASF</strong>’s magazine<br />
“<strong>plastics</strong>” spoke with Jürgen Keck. Based<br />
in Singapore, he is responsible for market<br />
development for specialties in Asia.<br />
Mr Keck, after one year in Asia, where<br />
do you see the markets for styrene<br />
specialties?<br />
We need to bear in mind that we are in a<br />
region where some of the largest automobile<br />
manufacturers in the world are headquartered.<br />
Our products such as Luran ® S<br />
for exterior applications on car bodies or<br />
Terblend ® N for the interiors of vehicles and<br />
our Terluran ® specialties have quite a lot to<br />
offer to the Asian automotive market. We<br />
also see great potential in the business<br />
with motor scooters. Some 30 million<br />
motor scooters are produced here every<br />
year, all of which could be made using<br />
specialty <strong>plastics</strong>. We plan to intensify our<br />
efforts in the construction sector, which is<br />
particularly important in China. Building<br />
elements made of weather-resistant and<br />
15<br />
easy-to-process <strong>plastics</strong> such as Luran ® S<br />
certainly have a market here. The mere fact<br />
that global customers such as Schick-<br />
Wilkinson have production facilities in Asia<br />
already means that Terlux ® , our transparent<br />
ABS, has a promising future in this region.<br />
What is the difference between the<br />
specialty business in Asia and in<br />
regions like Europe or North America?<br />
It is quite simple: things that have a market<br />
in Europe or NAFTA cannot simply be<br />
transferred to Asia in unchanged form.<br />
Take, for instance, lawnmowers, a common<br />
application for specialty <strong>plastics</strong> in<br />
Europe but not easily transferable to Asia<br />
since there are hardly any private lawns.<br />
But all in all, the specialty business is<br />
basically the same. We help with application<br />
design and with flow mold studies and<br />
we also have to offer services such as customer<br />
specific colors.<br />
Let us talk concretely about customers.<br />
Do their requirements differ<br />
from those in Europe?<br />
We quickly learned that the common European<br />
notion that it is possible to cut back<br />
on quality in Asia is simply wrong.<br />
Precisely, in China and India, our customers<br />
produce for the world market.<br />
Patience and endurance are required here.<br />
When we present our products in China or<br />
Malaysia, we talk to a larger audience. Up<br />
to 40 people, ranging from mechanics to<br />
researchers, are all involved in the<br />
Markets and Products<br />
Taking the pulse of new markets in<br />
Asia: Jürgen Keck.<br />
decision-making process. I am also<br />
learning quite a lot from my colleagues in<br />
Singapore, Korea, Japan, India and China.<br />
Let us fast-forward to the future.<br />
Where will the specialties business<br />
stand in Asia five years from now?<br />
All I have to do is turn to the market analyses<br />
that we have drawn up for our target<br />
sectors, namely automobiles and construction.<br />
To put it in a nutshell, five years from<br />
now, we will be the preferred partner of the<br />
Asian automotive industry and we will have<br />
made a name for ourselves in the construction<br />
sector. And if everything runs<br />
according to our plan, we could also visualize<br />
building new capacities. Let me wrap<br />
up by telling you about my dream: in five<br />
years, all of China will be sleeping under<br />
plastic roofs.<br />
Your contact persons for specialty <strong>plastics</strong> in<br />
Asia:<br />
Juergen Keck, Singapore<br />
keckj@basf-sea.com.sg +65 6432 3285<br />
Dr. Piyada, Singapore<br />
charoep@basf-sea.com.sg +65 6398 5037<br />
Roland Huang, China<br />
huangxjr@basf-china.com.cn +86 21 6385 1630<br />
H.J. Kim, Korea<br />
kimhj2@basf-korea.co.kr +82 2 3707 7720<br />
J.H. Lee, Japan<br />
JongHoo.Lee@basf-japan.co.jp +81 3 3238 2421<br />
Satej Nabar, India<br />
nabars@basf-india.co.in +91 22 5661 8227<br />
Ross Kung, Taiwan<br />
kungpyr@basf-taiwan.com.tw +886 2 2518 7667<br />
Geoff Beilby, Australia<br />
beilbyg@basf-australia.com.au +61 3 9212 1617<br />
Gecha Ritvirulh, Thailand<br />
gechar@basf-thai.co.th +66 2 2<strong>04</strong> 9483<br />
Muhamad Nasir, Malaysia<br />
muhamnat@basf-malaysia.com.my +60 3 5628 3637<br />
Benny Tjen, Indonesia<br />
tjentb@basf-indonesia.co.id +62 21 526 2481
Markets and Products 16<br />
Bella Plastica d’Italia<br />
Not only a travel destination but also a business location for many<br />
companies, Italy has evolved into the second largest market for<br />
styrene <strong>plastics</strong>.<br />
“If I had not made the decision<br />
that I am now carrying out,<br />
I would certainly have been<br />
ruined: the desire to see Italy<br />
with my own eyes had thus<br />
reached such a heightened state<br />
in my mind.”<br />
An observer might accuse German poet<br />
Johann Wolfgang von Goethe of having a<br />
penchant for pathos. But his achievements<br />
are undeniable when it comes to singing the praises<br />
of the country that was his favorite travel destination<br />
back in the 18th century. And what held true for<br />
Goethe almost 300 years ago, continues to apply<br />
on a small scale in the 21st century as well. Italian<br />
wine, Italian food, Italian design – we love everything<br />
that comes from this boot-shaped country<br />
because we equate it with the lightness of<br />
being.<br />
Innovations<br />
in product design<br />
A lightness whose appearance is essentially<br />
defined by <strong>plastics</strong>. In fact, one out of every<br />
(Johann Wolfgang von Goethe)<br />
four <strong>plastics</strong>-processing operations in<br />
Europe is located in the Apennine Region.<br />
In total, there are 11,000 companies. After the area<br />
comprising of Germany, Austria and Switzerland, the<br />
southern tip of Europe has now become the<br />
second largest injection-molding market on the<br />
continent. No wonder, since this is where<br />
brand name producers such as De<br />
Longhi, Hotform or Whirlpool can<br />
manufacture their products<br />
cost-effectively thanks<br />
to the numerous<br />
small and<br />
mediumsized
thanks to the numerous small and medium-sized processors with<br />
1 7<br />
their relatively inexpensive cost structures. And wherever refrigerators,<br />
television set housings, washing machines, vacuum cleaners and<br />
CDs are produced, there is a great demand for standard <strong>plastics</strong><br />
such as polystyrene and ABS. Even though these products are<br />
already quite advanced in terms of their life cycle, market analysts still<br />
expect a growing market for polystyrene and ABS, namely, about two<br />
per cent for polystyrene and about four per cent for ABS (slightly<br />
above the projected gross domestic product). Maurizio Campagna,<br />
head of sales for styrene polymers in Italy, has no doubts about the<br />
source of this growth, “Continuous innovations in product design and<br />
competitive processing costs are the best thing that Italian processors<br />
and manufacturers have to offer. This is why we will continue to<br />
find new applications for plastic products that can be made with polystyrene<br />
and ABS.”<br />
The Italian market is also benefiting from the introduction of the selfcoloring<br />
of ABS into the Italian market. According to Campagna, the<br />
availability of the self-coloring service Colorflexx ® will allow <strong>BASF</strong> to<br />
strengthen the competitiveness of processors in the realms of refrigerators,<br />
household articles and appliances, as well as toys and leisure<br />
articles.<br />
M a r k e t s a n d P r o d u c t s<br />
The country that gave us the chocolate egg with a surprise in it, however,<br />
is not only an important market for injection-molded products.<br />
Companies such as Ferrero, CDS, Hotform or the Pibergroup are<br />
among the world’s largest consumers of plastic packaging and are<br />
thus customers of a polystyrene manufacturer such as <strong>BASF</strong>. All in all,<br />
packaging – including cosmetics and CD cases – makes up almost<br />
50 per cent of the Italian <strong>plastics</strong> Market for<br />
market. In Italy, a total ofplastic 47 plastic packaging<br />
manufacturers court the favor of<br />
the 11,000 processors that currently serve a<br />
market of about 5.5 million metric tons of standard <strong>plastics</strong>, or about<br />
18 billion euros. This industry is concentrated primarily in the triangle<br />
between Turin, Milan and Genoa and in the north east of the country.<br />
The Emilia-Romagna region near Bologna, parts of Tuscany and of<br />
the Latium also have a considerable number of operations.<br />
Your contact person at <strong>BASF</strong>:<br />
Maurizio Campagna,<br />
Phone: 0039 0362 512 430
Markets and Products 18<br />
Ecoflex ® for the bag from the fertile fields<br />
The use of biodegradable materials has increased greatly throughout the world, but<br />
in Germany, overregulation prevents their widespread introduction onto the market.<br />
Europe is a union now. Not only<br />
politically but also, to an increasing<br />
extent, in terms of the consumption<br />
behavior of the population. Bioproducts,<br />
for instance, are becoming more<br />
and more popular, particularly among consumers<br />
in the Netherlands, Great Britain<br />
and France, now that their bioproducts<br />
come in biodegradable and compostable<br />
packaging. The building blocks of such<br />
packaging are resource-saving and CO2 neutral renewable raw materials stemming<br />
from agriculture. This packaging acquires<br />
its functionality from the combination of<br />
renewable raw materials with biodegradable<br />
substances on the basis of synthetic<br />
raw materials such as <strong>BASF</strong>’s Ecoflex ® . “A<br />
biodegradable composite made of starch<br />
or polylactic acid obtained from corn or<br />
potatoes together with Ecoflex ® greatly<br />
improves films and packaging so that their<br />
enhanced functionality will make them suitable<br />
for more applications,” explains Dirk<br />
Stärke, product manager for Ecoflex ® at<br />
<strong>BASF</strong>.<br />
Successful<br />
pilot project<br />
However, what is a reality in many European<br />
countries is still a far-off dream for<br />
German consumers. In Germany, excessive<br />
legislation on packaging, biowaste<br />
and fertilizers regulates the use and reutilization<br />
of compostable packaging, with<br />
the result that<br />
nothing gets<br />
done in this<br />
labyrinth of regulations.<br />
Even<br />
the successful<br />
implementation<br />
of a model project<br />
in the city of<br />
Kassel did not do a bit of good. In this the packaging regulations with the objec-<br />
experiment, the organizers, funded by tive of increasing the sales and, thus, the<br />
government subsidies, studied the use of use of renewable raw materials.<br />
biopackaging in actual practice, thereby In order to facilitate the market introduction<br />
confirming that this packaging can be col- while at the same time improving the funclected<br />
and utilized without any problem. tionality of biodegradable materials, the<br />
Consumers responded particularly posi- German Farmer’s Association and the Gertively<br />
to biodegradable packaging. And man Association of the Chemical Industry<br />
now, it seems that the path might be clear are objecting to the statutory stipulations<br />
for bio<strong>plastics</strong> in Germany as well.<br />
pertaining to the raw material base of<br />
“Bio<strong>plastics</strong> made of corn, potatoes or cel- biodegradable materials. For instance, with<br />
lulose are on the threshold of a very prom- their requirement that biodegradable packising<br />
future,” explains Matthias Berninger, aging materials have to “consist primarily<br />
state secretary at the German Ministry for of renewable raw materials”, these regula-<br />
Consumer Affairs, at the same time revealtions run counter to the objective of proing<br />
that a major hurdle to their widespread moting the market introduction of renew-<br />
introduction could soon be eliminated.<br />
“The German government supports the<br />
able raw materials.<br />
approach of exempting bio<strong>plastics</strong> from Approval of Ecoflex<br />
the Green Dot in the future,” elaborates<br />
Berninger. Manufacturers of biodegradable<br />
<strong>plastics</strong> have now found a prominent<br />
advocate in the German Farmer’s Association.<br />
In a statement issued jointly with the<br />
German Association of the Chemical<br />
Industry, farmers are calling for a change in<br />
® Ecoflex<br />
for food<br />
products in the United States<br />
The parties involved are confident that,<br />
over the long run, the costs for biopackaging<br />
will also drop as these materials enjoy<br />
more widespread use. For instance, the<br />
raw material costs for renewable raw<br />
® is certified in the United States …,
As biodegradable as its<br />
contents: the bag made<br />
of Ecoflex ® .<br />
in Japan ...<br />
materials are lower than those for synthetic<br />
biodegradable materials. “Starch, for<br />
example, which is the basic building block<br />
of many biodegradable <strong>plastics</strong>, is cheaper<br />
than any synthetic material,” says Dr. Harald<br />
Kaeb, Managing Director of German<br />
Biodegradable <strong>Plastics</strong> Association.<br />
Recent figures confirm that, in the meantime,<br />
biodegradable materials have<br />
achieved considerable growth. Thus, in<br />
19<br />
Europe alone,<br />
consumption rose from 8,000<br />
to 45,000 metric tons between 1998<br />
and 2003.<br />
Those in charge of Ecoflex ® anticipate a<br />
decisive step forward once this product<br />
receives worldwide certification as a completely<br />
biodegradable material. Ecoflex ®<br />
has long since been registered in Europe<br />
and Japan as a biodegradable raw material.<br />
Recent additions are its approval in<br />
America under ASTM 6400 and also its<br />
approval for food products for the American<br />
market – the so-called Food Contact<br />
Notification. According to Dietmar Heufel,<br />
who is in charge of the worldwide Ecoflex ®<br />
Markets and Products<br />
business,<br />
“We currently<br />
sell nine time as much in<br />
Japan as in Germany, but we hope that<br />
this will soon change.”<br />
www.basf.de/ecoflex<br />
Your contact person at <strong>BASF</strong>: Dietmar Heufel,<br />
Phone: +49 621 60-78969<br />
... and in Europe.
The beginnings<br />
of model trains<br />
Applications 20<br />
Company founder Theodor Friedrich<br />
Wilhelm Märklin began to make parts for<br />
dolls house kitchens in 1859. In 1891,<br />
his sons – the Märklin brothers – laid the<br />
tracks leading to the later success of the<br />
company: at the Leipzig Easter Fair, they<br />
exhibited the first standardized wind-up<br />
train set shaped like a figure-eight, with a<br />
variable track layout. Whereas the<br />
“Storchenbein” (Stork’s Leg) model was<br />
still driven by clockwork, models that<br />
were driven by steam or electricity followed<br />
just a few years later. Starting in<br />
1926, the train sets became even more<br />
convenient and carefree with the introduction<br />
of the 20-volt system. Since<br />
1935, the H0-model train has been<br />
designed for set-up on a tabletop.<br />
The “mini-club” at a scale of 1:220, was<br />
the sensation of the Nuremberg toy fair<br />
in 1972. It immediately earned a spot in<br />
the Guinness Book of Records, in addition<br />
to which it also holds the world<br />
record for continuous operation, at 1219<br />
hours over a distance of 720 kilometers<br />
or approximately 450 miles.<br />
In order to produce its realistic models,<br />
Märklin values attention to detail as well<br />
as sturdiness under actual operating<br />
conditions. Aside from sheet metal, the<br />
materials employed also include metal<br />
alloys, thin sheet metal, aluminum, highgrade<br />
<strong>plastics</strong> and even wood.<br />
Smooth running<br />
on safe track<br />
<strong>BASF</strong> specialty plastic for Märklin railway track<br />
Because children sometimes play<br />
rough, materials used in model<br />
railways should resist breakage<br />
and if possible last forever. That’s why<br />
Märklin, the world<br />
biggest manufacturer<br />
of model railways,<br />
has recently<br />
begun to use<br />
<strong>BASF</strong>’s Luran ® S for<br />
in its new C-series<br />
track. Luran ® S is<br />
an ASA copolymer,<br />
a specialty among<br />
<strong>BASF</strong>’s range of<br />
styrenic <strong>plastics</strong>.<br />
“The benefits of<br />
this plastic lie in its<br />
resistance to chemicals”,<br />
explains Ulf<br />
Meissner, production<br />
manager at<br />
Märklin. Such a<br />
property allowed the company to eliminate<br />
an entire production operation. Normally<br />
the oil lubricant used in drawing the<br />
metal rails has to be cleaned off before<br />
the plastic sleepers (crossties) are fitted,<br />
otherwise it may cause the plastic to<br />
crack, weakening its structure. Luran ® S<br />
on the other hand is resistant to this socalled<br />
environmental stress cracking<br />
thanks to the polymer’s acrylic rubber<br />
component, which as <strong>BASF</strong>’s market<br />
development manager Hans Barthelmess<br />
explains, “makes the polymer more polar,<br />
enabling it to resist chemicals more easily<br />
compared with standard products.”<br />
Märklin, which has been using <strong>plastics</strong> in<br />
its model railways products for over 30<br />
years, switched to plastic track at the<br />
beginning of the 1980s. Track sections<br />
made from plastic are much easier to<br />
assemble than<br />
those of metal—a Making “maintenance<br />
work on the<br />
welcome property<br />
tracks” superflu-<br />
in the 140,000<br />
ous: rails made of<br />
starter sets sold to <strong>BASF</strong>’s special<br />
plastic Luran<br />
children each year.<br />
The company,<br />
which has been<br />
manufacturing<br />
model railways for<br />
nearly a century<br />
and a half, employs<br />
2145 people and in<br />
2002 had sales of<br />
Euro 170 million.<br />
® S<br />
www.maerklin.de<br />
Your contact person<br />
at <strong>BASF</strong>:<br />
Hans Barthelmess,<br />
Phone:<br />
+49 172 742 4667
21<br />
Applications<br />
Inconspicuous and yet indispensable<br />
Greater precision with the new mass air flow sensor from Siemens VDO<br />
Air is not the same everywhere –<br />
the air density varies depending<br />
on whether you are on the top of<br />
a mountain, in the lowlands or at sea level.<br />
It is not only humans who notice this; air<br />
changes also affect engine combustion.<br />
After all, the number of air molecules needed<br />
for optimal fuel combustion varies, for<br />
instance, as a function of the geographic<br />
location. But to ensure consistent quality in<br />
regulating performance, a so-called mass<br />
air flow sensor is needed. It is an inconspicuous<br />
and yet indispensable element in<br />
every modern car. This sensor measures<br />
the volume of air drawn in by the engine,<br />
so that the engine’s electronic system can<br />
then precisely calculate the quantity of fuel<br />
needed and transmit this information to the<br />
fuel-injection system. This is the only way<br />
to attain optimal fuel combustion, in other<br />
words, with high performance, low emissions<br />
and reduced engine load.<br />
Ultradur ®<br />
in the mass air flow sensor<br />
Siemens VDO Automotive AG has professional<br />
expertise in the realm of mass air<br />
flow sensors. This company, which is a<br />
supplier to the automotive industry in the<br />
electric, electronic and mechatronic realms,<br />
has already produced more than ten million<br />
mass air flow sensors. Siemens VDO has<br />
now launched an innovative mass air flow<br />
Air flow sensors ensure optimal fuel combustion.<br />
sensor (SIMAF) and is already serially producing<br />
it for two major car makers.<br />
Ultradur ® , a PBT manufactured by <strong>BASF</strong>, is<br />
part of this equation. The most important<br />
plastic components that go into the SIMAF<br />
mass air flow sensor are made of this engineering<br />
plastic since properties such as<br />
dimensional stability, resistance to various<br />
media and heat deformation resistance are<br />
of paramount importance under the engine<br />
hood.<br />
High level of<br />
measuring accuracy<br />
The new sensor entails several advantages:<br />
it separates the measuring function<br />
from an integrated plugging function so<br />
that it can be adapted to a wide array of<br />
engines and intake geometries. If so<br />
desired, it can also be integrated directly<br />
into the air filter housing. The measuring<br />
device consists of three compact parts that<br />
are joined together, namely, the central carrier<br />
for the electronic sensor, a snap-on<br />
cover to protect the electronic components<br />
and the flow channel. The latter is made of<br />
uncolored Ultradur ® and is laser-welded to<br />
the sensor carrier so as to be precisely<br />
positioned without mechanical stress. This<br />
type of air flow configuration yields an even<br />
more accurate measurement, not least<br />
because the flow channel is made of a particularly<br />
dimensionally stable plastic.<br />
Another plus point is the fact that the<br />
sensor is considerably smaller and more<br />
compact than its predecessors and is well<br />
protected against dirt.<br />
www.basf.de/ultradur<br />
Your contact person at <strong>BASF</strong>:<br />
Reinhard Stransky<br />
Phone: +49 621 60-99621
Applications 22<br />
Little figures make it big<br />
Playmobil turns children’s dreams into reality<br />
Who hasn’t seen them? They<br />
are about 3 inches (7.5 cm)<br />
tall, they have a perpetual<br />
smile on their faces and kids simply adore<br />
them. We are talking about the beloved<br />
Playmobil figures. They saw the light of<br />
day 30 years ago. That is when the company<br />
geobra Brandstätter first presented<br />
this friendly, palm-size figure that had been<br />
developed by designer Hans Beck. It was<br />
without a nose and looked quite neutral<br />
but the friendly facial expression was<br />
already the same as it is today. Whereas<br />
buyers for toy stores responded cautiously<br />
to the novelty introduced at the<br />
trade fair in 1974, children and<br />
parents were very enthusiastic.<br />
Initially simple figures<br />
with just a few<br />
accessories<br />
were later<br />
joined by<br />
entire<br />
Be it Indians, building<br />
workers or<br />
pirates – Playmobil<br />
makes children´s<br />
hearts beat faster.<br />
play worlds of their own.<br />
The stuff of which knights,<br />
dragons and pirates are made<br />
However, the road from the original idea to<br />
the realization was a long one. For<br />
instance, a decision had to be made about<br />
which plastic was suitable for the<br />
figures. It had to be impactresist-<br />
ant,<br />
light-resistant and compliant with the food<br />
product laws and also had to display<br />
excellent resilience. Moreover, in 1974, toy<br />
manufacturer and entrepreneur Horst<br />
Brandstätter had his very own idea about<br />
what a Playmobil figure<br />
should be able to withstand,<br />
namely, the full<br />
weight of an adult.<br />
This requirement<br />
was and still is met<br />
by <strong>BASF</strong>’s plastic<br />
Ultraform ® . Every hand<br />
and every inner part of<br />
the Playmobil toy figures<br />
are made of<br />
Ultraform ® , and so are the<br />
articulated arms of the dragons<br />
and the gauntlets of the<br />
knights. Aside from<br />
Ultraform ® , other<br />
<strong>plastics</strong> made by<br />
<strong>BASF</strong> are<br />
also hidden<br />
in<br />
these little<br />
playmates.<br />
For example,<br />
the transparent blinking<br />
lights of the fire truck<br />
are made of Terlux ® , while<br />
polystyrene can be found<br />
in the gray rocky land-
scape and there is Terluran ® in the body<br />
and clothing of the little people. “For Playmobil,<br />
we were able to offer products for<br />
many different applications from <strong>BASF</strong>’s<br />
wide assortment, continuously increasing<br />
the quantities of plastic consumed,”<br />
explains Reiner Scheer, <strong>BASF</strong>’s Key<br />
Account Manager for this toy maker.<br />
Playmobil has a<br />
cult following<br />
Over all these years, children’s wishes<br />
have time and again been incorporated<br />
into the ideas of designers, engineers and<br />
mold builders. The men and women were<br />
23<br />
joined by babies and children. Moreover,<br />
the diminutive inhabitants of the Playmobil<br />
world have kept pace with the spirit of the<br />
times, which is why the women now wear<br />
trousers and Playmobil classics such as<br />
pirates and knights now have numerous<br />
sisters populating the towns and the airports.<br />
In the meantime, Playmobil has<br />
acquired a cult following. For example, a<br />
Wild West house from the first series will<br />
now set you back 500 euros or more.<br />
Back then, the original cost a mere 30<br />
German marks (about 15 euros). “No<br />
boots, stiff hands and flat feet,” describes<br />
an aficionado. “Such a cowboy belongs to<br />
the first generation.” More recent succes-<br />
Applications<br />
Life-like worlds made of plastic. Attention to detail is what has<br />
made Playmobil so successful.<br />
sors have moveable hands and highheeled<br />
boots. These little playmates have<br />
survived decades in many households<br />
and they are as cherished by today’s children<br />
as they were by their first owners. It<br />
is quite rare for children to play with the<br />
same toys as their parents, but the little<br />
guys with the friendly smile are such an<br />
exception. And like every year, thousands<br />
of children will once again glue their noses<br />
to the display windows of toy stores. After<br />
all, in addition to the long-anticipated<br />
dinosaur, Playmobil will also be launching<br />
many other attractive novelties onto the<br />
market as it commemorates its 30th<br />
anniversary.
Integration Honeywell 24<br />
<strong>BASF</strong> and Honeywell – combined strength<br />
Product line optimization delivers greater value to customers<br />
Responsible for the worldwide business<br />
with polyamide extrusion grades: Rolf Alles,<br />
Bruno Defendini, Rainer Hanelt (from left to<br />
right).<br />
Fibers for T-shirts and carpets, flexible<br />
packaging for sausage casings,<br />
and packed for cheese and cold<br />
meats – not many people know that<br />
all of these products are produced from<br />
Ultramid ® high-performance polymer. This<br />
material is well known from injection-molding<br />
applications in the automotive and<br />
electrical sectors, but is also used in the<br />
packaging sector. The reason: Ultramid ® is<br />
classified as non-hazardous under food<br />
legislation and has excellent barrier properties<br />
with respect to oxygen, organic solvents,<br />
and flavors. The acquisition of<br />
Honeywell’s engineering <strong>plastics</strong> business<br />
has brought additional expertise to the<br />
extrusion team. The primary goal is to<br />
combine the best from the two<br />
companies.<br />
Powerful<br />
team<br />
“We are a global team, small but effective” is<br />
how Dr. Thomas Liese-Sauer of Global Marketing<br />
Extrusion describes his Group. “Our<br />
know-how and expertise has been increased<br />
to new levels with the support provided by<br />
our new colleagues.” Regular meetings with<br />
Marketing colleagues worldwide, and close<br />
collaboration with Business Management<br />
colleagues from Europe and Asia – Mark<br />
Dobson, Business Management in North<br />
America rates both of these as vitally impor-
tant. Market developments occurring in<br />
Europe or North America can rapidly achieve<br />
relevance in Asia or South America, and vice<br />
versa. “We are managing a business which<br />
is growing globally,” explains Bruno Defendini,<br />
previously with Honeywell and now working<br />
in Global Marketing. “This means the<br />
customers and markets in every region are<br />
expecting the same high levels of service<br />
and product quality.”<br />
Global<br />
Portfolio<br />
Production of<br />
packaging films<br />
made of Ultramid ® .<br />
A global business requires a global portfolio<br />
of products. The foundation for the new<br />
portfolio is the <strong>BASF</strong> Ultramid ® and<br />
Honeywell Capron ® product lines. The<br />
extensive market and technical knowledge<br />
incorporated in this portfolio will enable<br />
<strong>BASF</strong> to achieve their strategic target of<br />
above average market growth. This new<br />
portfolio will benefit global and regional customers<br />
with less complexity, faster response,<br />
greater consistency of quality and increased<br />
reliability of supply. The nomenclature for the<br />
portfolio has been restructured so that all<br />
contact points within the customer’s organization<br />
can easily associate product properties<br />
with names. <strong>BASF</strong> will likewise benefit<br />
from this streamlined system within the global<br />
and regional frameworks we operate in.<br />
“In the past we have carried out significant<br />
enhancements of the Ultramid ® product line<br />
25<br />
with successful results,” says Rainer Hanelt,<br />
Global Marketing Extrusion. “We expect our<br />
new combined portfolio to receive a high<br />
level of acceptance in the market. We’re<br />
also providing global technical support to<br />
our customers.”<br />
Strengthened<br />
market position<br />
Results of the Honeywell acquisition included<br />
not only the integration of new products<br />
into <strong>BASF</strong>’s business, but also a strengthening<br />
of its market position – particularly in the<br />
USA, where the company has now a leading<br />
market position in extrusion. Alongside the<br />
USA and Europe, another focus for the marketing<br />
team is the high-growth Asian market.<br />
Take China as an example: the growth rate<br />
for packaging is much higher than in North<br />
America and Europe. “We meet the demand<br />
generated by this growth by supplying our<br />
Asian customers from both the USA and<br />
Europe,“ explains Dr. Volker Rauschenberger,<br />
responsible for the Business Management<br />
in Asia.<br />
Your contact:<br />
Dr. Thomas Liese-Sauer,<br />
Phone: +49 621 60-93464<br />
Integration Honeywell<br />
Dr. Thomas Liese-Sauer is the new director<br />
of marketing Extrusion Polymers.
Applications<br />
Design in the engine compartment<br />
Air filter made of Capron ® in the Golf IV – multifunctional and shapely<br />
Styling is in vogue these days, even<br />
in the engine compartment. Designers<br />
are increasingly looking towards<br />
both esthetic and branding-typical solutions.<br />
The multifunctional designer air filter<br />
of MANN+HUMMEL, a development partner<br />
and supplier of serial parts for the international<br />
automotive and mechanical engineering<br />
industries, fits right into this concept.<br />
This air filter, developed for the 1.4liter<br />
and 1.6-liter FSI engines in the new<br />
Golf, also serves as a shapely cover for the<br />
engine. But design is not everything. For<br />
such a part to be able to withstand temperatures<br />
of up to 120°C [248°F] in the engine<br />
compartment, it has to meet other requirements<br />
as well: it must be heat-resistant,<br />
low-warping and exhibit a good stiffnessto-strength<br />
ratio. The material that<br />
MANN+HUMMEL relies on here is Capron ® ,<br />
You don’t have to be the CEO to<br />
have a custom-fit work chair at your<br />
desk thanks to the Mirra design<br />
from Herman Miller, the U.S. office furniture<br />
manufacturer. Mirra has the flexibility to adapt<br />
to the size, posture and movements of the<br />
user. Flexible zones in the backrest of the<br />
chair support the entire spinal column and<br />
distribute the pressure evenly across the<br />
back. An office chair that responds to human<br />
activity was the concept devised by the<br />
designers at Studio 7.5. And it gained Mirra<br />
first prize in last year’s “Best of NeoCon”<br />
competition held by the American furniture<br />
industry. And that isn’t all: The Society of<br />
26<br />
a polyamide-6 made by <strong>BASF</strong>. Since 2002,<br />
MANN+HUMMEL has been using three<br />
different filled Capron ® grades for this friction-welded<br />
air filter.<br />
The metallic glossy<br />
Capron ® in the center<br />
of the cover is not<br />
reinforced and it contains<br />
special pigments<br />
that have been<br />
incorporated into the<br />
plastic. All of the<br />
Capron ® brands have<br />
just recently been<br />
added to <strong>BASF</strong>’s<br />
assortment of engineering<br />
<strong>plastics</strong>.<br />
Your contact person at<br />
<strong>BASF</strong>: Stefan Schäfer<br />
Phone: +49 6151 896357<br />
Custom fit for everybody<br />
Capron ® nylon used in award-winning Mirra work chair<br />
Good for the spine: the Mirra office chair.<br />
Air filters are not only functional but also<br />
nice to look at.<br />
<strong>Plastics</strong> Engineers recently recognized the<br />
Mirra work chair with the Environmental<br />
Design Award 20<strong>04</strong> at Global <strong>Plastics</strong> Environmental<br />
Conference in Detroit. Ninety-six<br />
per cent of Mirra’s materials can be economically<br />
recycled at the end of the chair’s useful<br />
life. Herman Miller used Capron ® nylon from<br />
<strong>BASF</strong> for all the main components of the<br />
award-winning chair. One of the key features<br />
of this material is its durability, a significant<br />
requirement demanded by this manufacturer<br />
for all of its products. The strong and dimensionally<br />
stable polyamide is used in the spinal<br />
column support, seat frame, the adjustable<br />
seat rim and the arm rests.
Lightweight, strong<br />
and versatile in terms of design<br />
Borscheid & Wenig chooses plastic for the center console of the Audi A4<br />
Be it in the engine compartment, be it for<br />
the interior paneling or exterior<br />
trim or in the dashboard,<br />
the percentage of <strong>plastics</strong><br />
used in cars continues to<br />
grow. Whereas 10 years ago<br />
the proportion of <strong>plastics</strong> in an<br />
European mid-size car was 9 per<br />
cent of the total weight, nowadays<br />
we are in range from 13 to 16 per cent<br />
and the projections for 2<strong>01</strong>5 are<br />
already around 20 per cent. The<br />
reason is that plastic is cheaper,<br />
lighter and more versatile in terms of<br />
27<br />
What do the Golf V, the Audi A3, Scoda Octavia, Seat<br />
Altea, or Polo, Audi A2, Scoda Fabia and Seat Ibiza<br />
have in common? In all of these models, the frame<br />
on which are mounted the radiator blades and that houses the<br />
motors, the so-called fan case, is made of Capron ® , a <strong>BASF</strong><br />
plastic. After all, VW puts great stock in uniformity in the engine<br />
compartment. Already since the beginning of 2000, the VW company<br />
has used polyamide 6 filled with 30 per cent fiberglass for its<br />
Golf and Polo platforms. And this is not without good reason since<br />
the quality consistency of this plastic speaks for itself. And that is<br />
not all. Nowadays, 250-HP engines are no longer a rarity.<br />
However, enhanced engine performance also requires enhanced<br />
radiator performance. Consequently, a plastic employed in the<br />
Applications<br />
design than metals. In addition, it is very strong<br />
and thus can replace metal parts. The<br />
Borscheid & Wenig company is also aware of<br />
this. This <strong>plastics</strong> processor is going with plastic<br />
in the frame used for the radio, temperature<br />
control and navigation systems, the so-called<br />
center console for the Audi A4. To be more<br />
precise, it is going with a very special plastic,<br />
namely, Capron ® , a polyamide made by <strong>BASF</strong>. It<br />
has been optimized in terms of its flow and warping<br />
properties, and it displays a high creep strength<br />
and rigidity. 320,000 Audis have already been<br />
driving around Germany with this plastic center console since 2002.<br />
The console for the Audi A4<br />
is made of Capron ® .<br />
They all have one thing in common<br />
The fan cases of VW’s Polo and Golf platforms are made of Capron ®<br />
radiator area has to be low-warpage and especially heat-resistant.<br />
Considering the longevity of an engine, there is also a need for<br />
resistance to ageing. The fact that Capron ® meets all of these<br />
requirements is confirmed time and again by this plastic, for<br />
example, right now in the new Golf generation.<br />
Fan case<br />
made of<br />
Capron ® .
A p p l i c a t i o n s 2 8<br />
A kettle proves its mettle<br />
Ultramid ® shows what it is made of in the rough and tumble<br />
of daily routine in the kitchen<br />
Undercover assignment: retaining the traditional coffee flavor.<br />
Adaily routine: you fill the automatic water kettle with the<br />
desired amount of water, you switch it on and wait until<br />
for the water to boil. What used to be indicated by a<br />
whistle back in grandma’s days – the unmistakable reminder that<br />
the kettle should quickly be removed from the stove to prevent the<br />
water from boiling over – is solved more elegantly nowadays: as<br />
soon as the water starts to bubble, the kettle switches off automatically.<br />
The idea behind this technique originated 25 years ago<br />
at the English company Strix, a manufacturer of control elements<br />
for water boiling applications. John Taylor, the company’s executive<br />
director back then, developed the first kettle control, which was<br />
guaranteed to switch off automatically once steam had built up. A<br />
lot has changed in the meantime. Today, Strix, headquartered on<br />
the Isle of Man, holds a 70 per cent-market share and is the leading<br />
producer of control elements and cordless interfaces for water<br />
kettles, with the result that well-known companies such as Tefal,<br />
Moulinex, Philips, Kenwood, Bosch, Siemens and Braun are<br />
among its customers.<br />
Tapping into<br />
new markets<br />
This company has recently entered the coffee market as well.<br />
Thanks to the new Strix heat-control system, the traditional Mocha<br />
Express coffee maker made by the coffee machine manufacturer<br />
Bialetti is now also available in an electric version. As soon as the<br />
espresso, café au lait, cappuccino or latte macchiato is ready, the<br />
coffee maker switches off automatically. Here, Bialetti’s brewing<br />
experts and Strix’s development engineers have achieved the feat of<br />
retaining the traditional flavor and aroma of the coffee in combination<br />
with the advantage of automatic brewing. Strix has recently started<br />
developing electric systems for water filtration as well. Strix’s executive<br />
chairman, Eddie Davies, sees great potential for growth in this<br />
market as more and more people are clamoring for clean drinking<br />
water, particularly in the developing countries.<br />
Material<br />
of choice<br />
Control elements and cordless interfaces made by Strix are used<br />
more than a billion times every day in households throughout the<br />
world. All of them are made of the plastic Ultramid ® , a polyamide<br />
manufactured by <strong>BASF</strong>. Why? Because this plastic has all of the<br />
properties that are needed for the rough and tumble of daily routine<br />
in the kitchen. It is robust, mechanically very strong, and<br />
exhibits outstanding temperature resistance and dimensional stability,<br />
features that renders Ultramid ® particularly well-suited for hotwater<br />
applications. Another plus point is that Ultramid ® can be<br />
processed without problems – thus design engineers can give free<br />
rein to their imagination when it comes to combining intricate<br />
design and precision. “Today, <strong>BASF</strong> is our number-one supplier,”<br />
explains Paul Snowden, Supply Chain Director at Strix. “With its<br />
know-how in mould-flow techniques, <strong>BASF</strong> has helped us improve<br />
our product design and quality while lowering our costs.”<br />
www.strix.com
<strong>BASF</strong> takes over Ticona’s<br />
polyamide 6.6 business<br />
Market position in engineering <strong>plastics</strong> strengthened<br />
As of December 31, 2003, <strong>BASF</strong><br />
has taken over the polyamide 6.6<br />
business from Ticona, which is the<br />
engineering <strong>plastics</strong> company of Celanese<br />
AG. Its sales were approximately 45 million<br />
euros in the year 2002. Within the scope of<br />
the transaction, all of the production sites<br />
and installations remain under the control<br />
of Ticona. To start with, Ticona will be<br />
manufacturing the polyamide 6.6 products<br />
on behalf of <strong>BASF</strong> at its American facilities<br />
in Bishop, Texas, and Florence, Kentucky.<br />
With this transaction,<br />
<strong>BASF</strong> is<br />
strengthening<br />
its market<br />
position<br />
in the<br />
sector<br />
of<br />
Expanded<br />
portfolio<br />
29<br />
polyamide 6.6, especially in the all-important<br />
North American market. Raimar Jahn,<br />
President of <strong>BASF</strong>’s Division Performance<br />
Polymers, underscores, “We are dedicated<br />
to being the supplier of choice for<br />
engineering plastic customers around the<br />
world. <strong>BASF</strong>’s acquisition of Ticona’s nylon<br />
6.6 business will complement and enhance<br />
the range of product solutions we can<br />
offer.” With this sale, Ticona is concentrating<br />
on its core businesses. “The sale of the<br />
polyamide 6.6 business is a further step in<br />
Celanese’s<br />
overall<br />
Markets and Products<br />
strategy of focusing on those products<br />
which hold a leading global market position”,<br />
says Lyndon Cole, member of the<br />
Celanese AG Management Board and President<br />
of Ticona. Already at the beginning of<br />
2003, <strong>BASF</strong> took over Honeywell’s business<br />
with engineering <strong>plastics</strong>. As a result, <strong>BASF</strong><br />
was not only able to tap into new markets,<br />
but also to nicely complement its product<br />
portfolio. Polyamide 6.6 is an extremely versatile<br />
engineering plastic that is used not<br />
only in automotive construction, but also<br />
in household products, toys and<br />
electrical equipment.<br />
Typical application for<br />
polyamides: a car manifold.
Applications 30<br />
Getting greener…<br />
from the top<br />
It’s an increasing trend for buildings to add a little color to<br />
their roofs using polyurethane insulation. ELASTOGRAN has<br />
come up with a great new system…
31<br />
Applications<br />
Have you ever looked<br />
out of your window<br />
and been faced with<br />
the sight of grim, depressing<br />
rooftops? The overwhelming<br />
picture is usually dreary town roofs in various shades of murky<br />
reds, dirty greys and boring browns. But now it’s really easy to<br />
things up. Moss, herbs, bushes, shrubs and even flowers and<br />
cacti are actually the simplest thing in the world to grow on tiles.<br />
It’s all a matter of effective insulation. And once again,<br />
ELASTOGRAN is way out in front with its hard foam Elastopor ® and heavy rain. On flat roofs,<br />
you can even grow herbaceous<br />
perennials, bushes<br />
and trees.<br />
Unlike other greening methods, this technique needs fewer construction<br />
layers and is long lasting and simple to install. Laying<br />
. and roof construction are the same as for normal tiled roofs. For<br />
optimum heat insulation, roof elements can be sandwiched with<br />
Adding some color<br />
a polyurethane core and attached to the roof beams. The hard<br />
to your roof<br />
foam system Elastopor<br />
atka Kunststoffverarbeitung Plc. of Lohne, Germany, has developed<br />
a new green-roof technique in collaboration with<br />
ELASTOGRAN. This system is for flat and steep roofs, with a<br />
synthetic material underlay for plants to grown on. Traditionally,<br />
plants grow directly on the roof cladding, but atka has developed<br />
a different approach. Various types of plants can be sown on a<br />
mineral substrate, which forms a culture medium that stays<br />
green all year. This is especially suitable for low-growing plants<br />
like moss, sedum and herbs, that cope well with frost, dryness<br />
® Oh, how green is my roof! And in the front parlor, the insulation material<br />
Elastopor<br />
H guarantees high insulation combined<br />
with low weight.<br />
Insulation elements with flexible, diffusion-promoting coatings<br />
can be used on steep and flat roofs as well as areas subject to<br />
heavy load. Green roofs with a polyurethane underlay are perfect<br />
as the combination of materials really enhances heat and cold<br />
insulation and helps with energy savings. Dust and harmful<br />
chemicals are bound, sound is dampened and electro-smog<br />
avoided, leading to a lasting improvement in room air condition.<br />
For industrial buildings, warehouses or milking plants, green<br />
roofs ensure balanced air conditions all year round.<br />
® ensures a comfortable climate.<br />
The future’s<br />
green
Applications 32<br />
A smoother ride for cyclists<br />
Cellasto ® springs cope with even the toughest tracks<br />
Anew, high-tech suspension<br />
designed just for<br />
bikes has been developed by<br />
Elastogran. Cellasto ® (made from microcellular<br />
polyurethane) has been used to<br />
produce suspension springs that are<br />
suitable for free riders, cross-country<br />
professionals and downhill bikers.<br />
The suspension element SSD-210 has<br />
been developed in collaboration with DT<br />
Swiss Biel/Switzerland, one of the<br />
biggest international manufacturers of<br />
high-end bicycle spokes and hubs. The<br />
spring system is a precision product and<br />
also one of the lightest on the market<br />
and as a result came out top in a comparative<br />
test by biking magazine Mountainbike.<br />
The perfect<br />
choice<br />
There are many other benefits too. The DT<br />
Swiss shock absorber is a pneumatic<br />
cylinder, combined with a Cellasto ® negative<br />
spring. This is an ideal combination, as<br />
other<br />
types of air<br />
springs have a high failure risk.<br />
The characteristic curve important for professionals<br />
is very similar to a steel spring,<br />
but much lighter. When the shock<br />
absorber is compressed during riding, the<br />
partition shifts against a second Cellasto ®<br />
spring and increases air volume. As a<br />
result, pressure’s reduced and the characteristic<br />
curve progression flattens out. This<br />
means even suspension for the cyclist,<br />
and no unpleasant or painful jolts whenever<br />
they have to push harder on the pedals.<br />
The polyurethane elastomers in the<br />
shock absorber are highly elastic<br />
and can be precisely tuned to the<br />
cyclist and type of bicycle. They’re also<br />
abrasion resistant, fail-safe, service-free<br />
and extremely durable. So, Cellasto’s ideal<br />
for cycling enthusiasts who don’t want the<br />
hassle of steel springs but still want sensitive<br />
suspension to get them there safely.<br />
Cellasto ®<br />
Cellasto ® shock absorber<br />
element – the facts<br />
Material: Cellasto ® – microcellular<br />
polyurethane elastomers<br />
Use: Suspension element for<br />
mountain bikes<br />
Properties: Volume compressible,<br />
absorbs noise and<br />
vibration, high dynamic<br />
resilience, abrasion<br />
resistant<br />
Damping elements made of <strong>BASF</strong>’s<br />
Cellasto ® can be found in DT Swiss shock<br />
absorbers.
Something new<br />
on the Western front<br />
<strong>BASF</strong> acquires the American polyurethane foam manufacturer Foam Enterprises<br />
33<br />
Since March 20<strong>04</strong>, the <strong>BASF</strong> family has had a new member,<br />
the American company Foam Enterprises, Inc., a<br />
manufacturer of rigid polyurethane foams used, among<br />
other things, for roof and wall insulation, walk-in freezers, sanitary<br />
applications and boat building. The company had sales of approximately<br />
U.S. $80 million in 2003. <strong>BASF</strong> is also a manufacturer of<br />
rigid polyurethane foam systems. “This acquisition reflects <strong>BASF</strong>’s<br />
global strategy to strengthen its network of Polyurethane System<br />
houses to offer tailor-made solutions for our customers worldwide,”<br />
explains Bill Bernstein, head of <strong>BASF</strong>’s polyurethane business in<br />
North America.<br />
Dennis Holbert, founder and president of FEI, will continue to head<br />
the company. FEI employs a total of 80 people at the company<br />
headquarters in Minneapolis, Minnesota and at its research and<br />
production operations in Houston, Texas. Holbert is confident that<br />
the two companies are a very good match. “When we founded<br />
Foam Enterprises back in 1977, our goal was to be the best in our<br />
field. Over the past 27 years, we have acquired a great deal of<br />
knowledge in rigid foam development and applications technology.<br />
Now we are taking another giant step towards that goal. As part of<br />
<strong>BASF</strong>, we are bringing our unique capabilities to the business. We<br />
see the coming challenges as opportunities and are looking forward<br />
to our future together with <strong>BASF</strong>.”<br />
“Customers will benefit from this acquisition because <strong>BASF</strong> and<br />
FEI will learn a great deal from each other and share the practices<br />
in areas such as technology development, product quality, supply<br />
consistency, research, global support, and customers and technical<br />
service”, sad Bernstein. “By teaming up, we will be able to<br />
bring optimal material solutions that meet the specific needs of our<br />
customers.”<br />
Both <strong>BASF</strong> and FEI will continue to supply their own customers<br />
with individualized polyurethane systems. <strong>BASF</strong>, in turn, will supply<br />
many of the polyurethane raw materials that FEI uses to develop<br />
tailor-made solutions for its customers.<br />
For additional information, please contact:<br />
David A. Elliott<br />
Corporate Communications<br />
<strong>BASF</strong> Corporation<br />
Phone: +1 734 324-6148<br />
E-mail: elliotd1@basf.com<br />
Markets and Products
Applications 34<br />
Always worth giving in to temptation<br />
Ice-cold fresh pleasure from Coppenrath & Wiese<br />
”<br />
Anyone who decides to give in to<br />
the temptation of cake or pastry<br />
is going to do it right – with<br />
whipped cream,” reveals Udo Voss, market<br />
researcher at the Coppenrath & Wiese<br />
company. The triumphant march of frozen<br />
cake over the last quarter of a century is<br />
unstoppable. Alois Coppenrath traveled to<br />
major cities in Germany and each time, he<br />
went to the best address in town and<br />
ordered a Black Forest cherry cake,<br />
cheesecake or some kind of chocolate<br />
cake. He found, however, that there were<br />
no standards for “the mother of all baked<br />
goods”. In a bold move, he and his cousin<br />
Josef Wiese from Mettingen in Westphalia<br />
got to work and created the cake that<br />
today is the talk of the town as Black forest<br />
cherry cake – for the freezer. Every day,<br />
80,000 liters of whipped cream and 80<br />
tons of apples are processed in the pastry<br />
”<br />
Please fasten your seat belts and<br />
raise your seatbacks to the<br />
upright position. We will be landing<br />
at the airport within a few minutes. We<br />
hope that you have had a pleasant flight<br />
and wish you an enjoyable stay in New<br />
York.” While this is the final destination for<br />
this group of passengers, the plane will<br />
soon take off again with new passengers to<br />
far-flung regions of the globe. In order to<br />
ensure that the airplane seats can withstand<br />
all this stress and remain comfortable<br />
for years on end, they have to be durable<br />
and resilient. JSO group, with its companies<br />
CELSO, a foam convecter, and PMV Indus-<br />
Germany’s favorite bakers: Josef Wiese and<br />
Aloys Coppenrath.<br />
shop. And as the “icing on the cake”, there<br />
are oranges from Spain, nuts from<br />
California, cherries from Italy, marzipan<br />
from Lübeck and, of course, distilled<br />
“Kirsch” spirits from the Black Forest.<br />
From the seed of an idea<br />
to the recipe for success<br />
High quality standards are a given: when the<br />
pastries leave the oven, they are shock-<br />
A foam that flies all over the world<br />
trie, a seat manufacturer, is well aware of<br />
this and has chosen a composite system<br />
consisting of Basotect ® – a melamine resin<br />
foam made by <strong>BASF</strong> – and a standard<br />
foam for its seat cushions. The reason<br />
behind its decision is that the properties of<br />
this combination surpass those of the standard<br />
foams that have been used so far in<br />
airplane interiors – also when it comes to its<br />
fire behavior. The real beauty here is that<br />
the use of Basotect ® makes the seat cushions<br />
50 per cent lighter in weight. This<br />
translates into lower fuel consumption and,<br />
thus, cost savings for the airlines. Of course,<br />
what makes airplanes weigh less can also<br />
frozen right away in an ice<br />
storm at a temperature of<br />
minus 48°C [minus 54.4°F].<br />
The advantage of this process is that neither<br />
flavor nor valuable ingredients are lost. A<br />
total of 27,000 cakes are stored at minus<br />
21°C [minus 5.8°F] in one of the world’s<br />
most modern freezers. Such a volume<br />
leaves the warehouse every two weeks. The<br />
cakes are protected by sturdy Styropor ®<br />
packaging. This impact-resistant and coldretaining<br />
Styropor ® packaging ensures that<br />
the cakes will survive the trip all the way<br />
home unharmed, and it also prevents undesired<br />
thawing for up to four hours. In addition<br />
to its outstanding heat-insulation capacity<br />
and impact-resistance, <strong>BASF</strong>’s Styropor ®<br />
combines other properties such as pressureresistance,<br />
low weight and low sensitivity to<br />
moisture – all aspects of crucial relevance<br />
when it comes to keeping frozen foods fresh.<br />
Be it en route to Singapore, New York, Sidney or Paris – Basotect ® is always on board<br />
Flying is lighter with Basotect ® seats.<br />
be transferred to other sectors. For<br />
instance, the trucks, cars, buses and trains<br />
we see crisscrossing the country could likewise<br />
soon be fitted with the new seats.<br />
Your contact:<br />
Werner Lenz, Phone: +49 621 60-42379
Newsflash<br />
Polystyrene Specialty<br />
to Spartech<br />
<strong>BASF</strong> sells its specialty polystyrene<br />
business - which includes compounds<br />
of flame retardant and antistatic<br />
polystyrene specialty products - to<br />
Spartech Polycom SAS, a subsidiary of<br />
Spartech Corporation and a leading<br />
producer of polymer compounds with<br />
production facilities in the U.S., Mexico<br />
and France. The deal took effect on<br />
April 15, 20<strong>04</strong>. Annual sales of the<br />
business amount to approximately<br />
9 million euros in Europe for 2003.<br />
The production of polystyrene compounds<br />
will be transferred to Spartech’s<br />
production plant in Donchery, France.<br />
<strong>BASF</strong> will close its polystyrene compounds<br />
production in Ludwigshafen, as<br />
announced in October 2003.<br />
These polystyrene compounds add to<br />
Spartech’s product range of compounded<br />
polystyrene and polyolefins.<br />
Yes, I want to win.<br />
Please send me more<br />
Informations on<br />
Ultramid ® BS 416 N<br />
Ultramid ®<br />
35<br />
Newsflash<br />
Joint Venture for<br />
PBT Production<br />
<strong>BASF</strong> Aktiengesellschaft and Toray<br />
Industries Inc. of Tokyo, Japan have<br />
announced the founding of a 50:50<br />
joint venture for the production of<br />
polybutylene terephthalate (PBT). The<br />
joint venture will supply the growth<br />
market of Asia with this engineering<br />
plastic.<br />
The newly founded company, Toray<br />
<strong>BASF</strong> PBT Resin Sdn. Bhd., is going<br />
to set up a world-scale plant for PBT<br />
basic polymer with an annual capacity<br />
of 60,000 metric tons at <strong>BASF</strong>’s<br />
integrated network site in Kuantan,<br />
Malaysia. Construction of the plant will<br />
start in the middle of the year and the<br />
start-up is planned for the beginning<br />
of 2006.<br />
Both companies will market the PBT<br />
produced in the new plant separately<br />
under their own brand names (<strong>BASF</strong>:<br />
Ultradur ® ; Toray: Toraycon ® ).<br />
Fax reply to the editorial staff<br />
Terlux ® in Medical Technology<br />
Luran ® S<br />
Ecoflex ®<br />
Colorflexx ®<br />
Ultradur ®<br />
Ultraform ®<br />
® = reg. Trademark of <strong>BASF</strong> Aktiengesellschaft<br />
Elastollan ®<br />
Elastopor ®<br />
Cellasto ®<br />
® = reg. Trademark of Elastogran GmbH<br />
Name<br />
Company<br />
Road<br />
Town/post code<br />
Telephone<br />
Fax<br />
Editor<br />
<strong>plastics</strong><br />
Editorial Team:<br />
Waldemar Oldenburger, <strong>BASF</strong> Aktien-<br />
gesellschaft (responsible)<br />
Sarah Kittner, KS/KC<br />
David A. Elliott/<strong>BASF</strong> Corporation/USA<br />
Wim Peters/<strong>BASF</strong> Nederland<br />
Natsuko Yamada/<strong>BASF</strong> Japan<br />
Chris Wilson/<strong>BASF</strong> UK<br />
Gerald Teo/<strong>BASF</strong> South East Asia<br />
Dr. Sylvia Kaufmann/Elastogran<br />
Editorial Adress:<br />
<strong>BASF</strong> Aktiengesellschaft<br />
KS/KC – E 100<br />
67056 Ludwigshafen<br />
Phone: +49 621 60-46910<br />
Fax: +49 621 60-49497<br />
Distribution:<br />
<strong>BASF</strong> Aktiengesellschaft<br />
Layout:<br />
Spektrum, Ludwigshafen<br />
<strong>BASF</strong> Aktiengesellschaft<br />
„<strong>plastics</strong>“ editorial office<br />
KS/KC – E 100<br />
Fax: +49 621 60-49497<br />
Fax<br />
<strong>plastics</strong>
Design works.<br />
Terlux ® . That’s for sure.<br />
Terlux ® – <strong>BASF</strong>’s transparent ABS – is the essential material for<br />
sophisticated design and high quality. Terlux ® has transparent, pastel<br />
and sparkle colors which easily meet every requirement for flowability,<br />
surface quality and chemicals resistance – the vital factor in casings<br />
for electrical or electronic equipment. At consistently high quality –<br />
of course. Take a look at:<br />
www.terlux.com<br />
Terlux ®<br />
<strong>BASF</strong> <strong>Plastics</strong><br />
key to your success<br />
You can find more information at our Infopoint: Phone: +49-6 21-60-4 14 46 Fax: +49-6 21-60-4 94 97<br />
® = registered trademark of <strong>BASF</strong> Aktiengesellschaft