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2010 | number 4 | winter<br />
Theme: space & aerospace composiTes
<strong>TenCate</strong><br />
Royal Ten Cate (<strong>TenCate</strong>) is a multinational<br />
company which combines textile technology<br />
with chemical processes in the development<br />
and production of functional materials. Various<br />
market applications have been created around<br />
this technological b<strong>as</strong>e. <strong>TenCate</strong> occupies leading<br />
positions worldwide in its core markets.<br />
<strong>TenCate</strong>’s growth is b<strong>as</strong>ed principally on global trends,<br />
namely, safety / protection and sustainability / the<br />
environment. <strong>TenCate</strong> materials are principally used for:<br />
• personal safety and the protection of<br />
living and working environments;<br />
• modernization of military and police equipment<br />
• space and aerospace (reduction in fuel<br />
costs through lighter materials);<br />
• water management and environmental protection;<br />
<strong>TenCate</strong>’s strategy is b<strong>as</strong>ed on the concept<br />
of value chain management. The four<br />
cornerstones of this policy are:<br />
• cost leadership;<br />
• product differentiation, focusing on specific<br />
applications and customer requirements;<br />
• end-user marketing and an industrial<br />
intellectual property policy;<br />
• technological innovation.<br />
These four cornerstones within the <strong>TenCate</strong><br />
business model are related to market, product,<br />
process and technology, and their interaction.<br />
In txtures the trends, cornerstones and other<br />
essential elements of the business model are referred<br />
to <strong>as</strong> often <strong>as</strong> possible. In this winter edition, we<br />
portray in particular <strong>TenCate</strong>’s performance in the<br />
field of sustainability and the environment.<br />
This winter edition gives pride of place to Space<br />
& Aerospace Composites. The use of advanced<br />
composites produces weight savings, fuel reduction<br />
and extension of the lifespan of aircraft, ships,<br />
vehicles and exploratory spacecraft. The development<br />
and production of these materials enables <strong>TenCate</strong><br />
to make a contribution to global developments<br />
relating to sustainability and the environment.<br />
2 txtures | number 4 | winter<br />
Sustainability / Environment<br />
SpaCe & aeroSpaCe CompoSiTeS<br />
Production of carbon fabrics at <strong>TenCate</strong> Advanced Composites USA in Morgan Hill<br />
<strong>TenCate</strong> co<br />
Both the Space & aerospace Composites market group and the advanced armour<br />
market group develop and produce composite materials; the former for applications<br />
primarily in the space and aerospace industry and the latter for antiballistic solutions.<br />
<strong>TenCate</strong> composite materials have proven themselves to be high flyers over many years.<br />
advanced composites combine high strength and low weight; they reduce fuel<br />
consumption, extend the lifespan of aircraft and vehicles, have excellent formability and<br />
are also flame-retardant, and acid- and moisture-resistant. Through the development<br />
and production of these materials <strong>TenCate</strong> is responding to global trends relating to<br />
sustainability and the environment.
mposites – light, strong, durable<br />
Composites are fibre-reinforced pl<strong>as</strong>tics made<br />
mostly of gl<strong>as</strong>s, carbon and aramid fibres.<br />
<strong>TenCate</strong> composite materials are b<strong>as</strong>ed on textile<br />
technology combined with chemical processes.<br />
They consist of a composition of fibres or fabrics<br />
from which semi-manufactures are made with<br />
the addition of resin systems (see also framed<br />
text on page 9). <strong>TenCate</strong> Cetex ® for example is<br />
a series of thermopl<strong>as</strong>tic composite materials,<br />
consisting of unidirectional, fabric-b<strong>as</strong>ed prepregs<br />
and tapes, semipregs, laminates and sandwich<br />
inserts. The use of advanced composites ensures<br />
fuel reduction and considerable extension of<br />
the lifespan of aircraft, ships, vehicles and<br />
satellites. These are becoming lighter, stronger,<br />
safer, more economical and – certainly in<br />
aviation – more cost efficient. <strong>TenCate</strong> operates<br />
a pyramid model with material, process, design<br />
and sustainability <strong>as</strong> its cornerstones.<br />
at home in space and aerospace<br />
Advanced composites from the Space &<br />
Aerospace Composites group are primarily<br />
used in the world of space and aerospace: in<br />
commercial and military aircraft, satellites<br />
and exploration vehicles for Mars missions<br />
for example. Both the space and aerospace<br />
markets are conservative: safety and reliability<br />
are of the utmost importance. The costs of<br />
the development and qualification of materials<br />
are high. Once a certain material is used after<br />
qualification, not a single modification may be<br />
made for follow-up deliveries – unless it relates<br />
to a proven improvement. This makes it financially<br />
unviable to seek out new materials unless there<br />
is a technical or business need for them and<br />
explains why specifications for certain parts<br />
dating from the 1970s still apply, even though<br />
better materials have since become available.<br />
Continued on page 4<br />
3
Sustainability / Environment<br />
SpaCe & aeroSpaCe CompoSiTeS<br />
To a great height<br />
Continued from page 3<br />
In addition there is a multiplicity of defence<br />
and industrial applications. Examples include<br />
the extraction of oil and g<strong>as</strong>, the recreational<br />
market and mobility concepts (solar car<br />
and the Superbus). Unmanned aircraft<br />
(UAVs) represent a major growth market.<br />
In aircraft, composite materials such <strong>as</strong><br />
<strong>TenCate</strong> Cetex ® are used in the secondary<br />
wing structure and in the primary flight<br />
structure and interior parts of the aircraft.<br />
Examples include flaps, access doors, pylons,<br />
radomes [the protective housing for radar<br />
4 txtures | number 4 | winter<br />
antenna), the fixed wing leading edge, beams,<br />
luggage containers and floor panels. For these<br />
interior and structural parts <strong>TenCate</strong> works<br />
directly with its customers, the suppliers<br />
to aircraft manufacturers and especially<br />
experts in material and process technology.<br />
Examples of applications in space include<br />
solar arrays, antenna, reflectors, parts of<br />
the skin and the supporting structure for<br />
the solar cells, antenna, booms, trusses,<br />
communication dishes and heat shields.<br />
in the lead<br />
Space & Aerospace Composites is a major<br />
player in its niche markets when it comes to<br />
the development and production of composite<br />
materials for these demanding applications.<br />
The market group is the global market leader in<br />
radomes and materials for space. Many years of<br />
knowledge and experience relating to materials<br />
and technology, flexibility and continuity, and<br />
the reliability of quality and delivery underpin<br />
this position. This expertise is partly the result<br />
of cooperation with partners in the value chain<br />
(such <strong>as</strong> Fokker Aerostructures, the TU Delft and
the University of Twente) and in development<br />
and innovation consortia like TAPAS and TPRC.<br />
There are, however, long lead times for the space<br />
and aerospace market and the time needed to<br />
recover investment costs is long. The market<br />
h<strong>as</strong>, to a limited degree, product and design<br />
knowledge, particularly of thermopl<strong>as</strong>tics. The<br />
market group itself does not produce any fibres<br />
or polymers and is consequently flexible in its<br />
choice of suppliers. The strengths of the group<br />
lie in its expertise, the technical performance of<br />
its materials and its throughput. Together with<br />
In radomes and materials for space applications <strong>TenCate</strong>’s Space & Aerospace Composites group is global market leader<br />
partners it is continuously working on improving<br />
products, processes and technologies. The<br />
group operates in markets that show growth.<br />
Cornerstones<br />
Its own PPS+ programme is focused on a new<br />
generation of <strong>TenCate</strong> Cetex ® thermopl<strong>as</strong>tic<br />
composites. PPS (polyphenylene sulfide) can<br />
withstand temperatures of more than 200°C<br />
and is flame-retardant. The programme is aimed<br />
at delivering more efficient internal processes,<br />
new composite architectures and improved<br />
temperature resistance. Thanks to intensive<br />
product development, <strong>TenCate</strong> is now able to<br />
offer more new unitapes, resins and prepregs.<br />
This means cost efficiency, product differentiation<br />
and innovation. As far <strong>as</strong> end-user marketing<br />
is concerned, the group is doing its utmost to<br />
continue to point out to customers the advantages<br />
of composite use. This it does at trade shows, in<br />
personal contacts, in technical papers and dat<strong>as</strong>ets<br />
and on the Internet, and b<strong>as</strong>ed on its proven record<br />
of service to the space and aerospace industry.<br />
www.tencateaerospacecomposites.com<br />
aerospacecomposites.europe@tencate.com<br />
5
Sustainability / Environment<br />
SpaCe & aeroSpaCe CompoSiTeS in THe US anD eUrope<br />
In the US the emph<strong>as</strong>is is on applications in space, civil aviation, the market for business jets and defence<br />
6 txtures | number 4 | winter
production<br />
and products<br />
The Space & aerospace group h<strong>as</strong> production facilities in europe<br />
(nijverdal) and the United States (morgan Hill and Benicia,<br />
California). The companies are: <strong>TenCate</strong> advanced Composites,<br />
phoenix, YLa and CCS Composites.<br />
In the US the emph<strong>as</strong>is is on applications in space,<br />
civil aviation, the market for business jets and defence.<br />
In Morgan Hill they make thermoset prepregs and<br />
thermopl<strong>as</strong>tic unidirectional (UD) prepregs. This<br />
tape technology complements existing production<br />
processes for composites and produces extra savings<br />
in production, thanks to the possibility for automation<br />
that it provides. UD tape is especially suitable for<br />
fuselage and wings, due to it optimal mechanical<br />
properties: for example, stiffness, strength, thermal<br />
and electrical conductivity, chemical and UV resistance<br />
and fire safety. This technology will make it possible<br />
in the near future to build for instance a light fuselage<br />
made of thermopl<strong>as</strong>tic composite. Fire safety is a<br />
key design criterion for fuselages. The development<br />
of UD tape technology h<strong>as</strong> enabled <strong>TenCate</strong> to<br />
strengthen its position in the aviation sector.<br />
Design techniques<br />
Benicia produces thermoset prepregs, chopped<br />
moulding compounds and compression-moulded<br />
aerospace parts for the aviation industry.<br />
Read further on next page<br />
Thermoset mounting clip for the Boeing 787<br />
7
Sustainability / Environment<br />
SpaCe & aeroSpaCe CompoSiTeS in THe US anD eUrope<br />
Continued from previous page<br />
These l<strong>as</strong>t two design techniques offer<br />
greater formability or result in finished<br />
products, such <strong>as</strong> hydraulic and fuel line<br />
clamp <strong>as</strong>semblies for the Boeing 787. This<br />
is an example of forward integration in the<br />
manufacturing process. In the US <strong>TenCate</strong><br />
also produces carbon composite prepregs.<br />
These are used by one of its customers<br />
to manufacture composite rotor tubes<br />
for a new method of uranium enrichment<br />
by supplier USEC in Piketon (Ohio).<br />
8 txtures | number 4 | winter<br />
mobility concepts<br />
In Europe production is mainly focused on<br />
commercial aviation and here primarily<br />
thermopl<strong>as</strong>tic composites are manufactured.<br />
There is a strategic alliance with Fokker<br />
Aerostructures. Composite material is also<br />
supplied for innovative mobility concepts<br />
such <strong>as</strong> the Superbus and vehicles that<br />
are driven by solar and wind energy. In the<br />
world of sports too demand for composites<br />
is growing. <strong>TenCate</strong> Cetex is eminently<br />
suitable for sports in which weight plays a<br />
major role, such <strong>as</strong> cycling and skating.<br />
There is a significant degree of production,<br />
sales and technical support between the<br />
US and Europe. Thermopl<strong>as</strong>tic prepregs and<br />
laminates (<strong>TenCate</strong> Cetex®) produced in<br />
Nijverdal are also sold in the US. In turn,<br />
thermoset prepregs from Benicia and Morgan<br />
Hill find their way to European producers in<br />
the space industry (for example radomes).
Advanced composites<br />
Advanced composites combine exceptionally high strength and low weight and offer a high degree<br />
of formability. Formability plays a major role in almost every application: composites can be<br />
processed relatively e<strong>as</strong>ily into complex shapes. They require far less maintenance than traditional<br />
materials, they can be tailored to the specific application, have good impact-retardant and<br />
flame-retardant properties. In addition – depending in part on the resin system chosen – they have<br />
excellent resistance to acids, chemicals and water, they can e<strong>as</strong>ily withstand numerous cycle<br />
loadings and are thermally insulating.<br />
Composites are developed mainly within the aviation industry. Here for the most part carbon<br />
composites are used to build structures that are light and strong. Gl<strong>as</strong>s and aramid fibre structures<br />
have become popular through their use in radomes, for which radar transparency is essential.<br />
Thanks to the great variety of fibres, resins and reinforcement shapes, the freedom of design of a<br />
composite product is exceptionally great. The choice of type of fibre, the fibre architecture and type of<br />
resin are crucial for its mechanical properties.<br />
A thermopl<strong>as</strong>tic is a material made of pl<strong>as</strong>tic that softens when heated and can then e<strong>as</strong>ily be brought<br />
into the correct form. It is a physical process, and thus reversible. The characteristics of thermopl<strong>as</strong>tics<br />
include low production costs, flame and toxic smoke resistance, unlimited and non-conditioned storage<br />
and higher toughness. Thermopl<strong>as</strong>tics are used in the aviation industry, but are still limited in high<br />
load-bearing aircraft parts. All thermopl<strong>as</strong>tics are in principle recyclable.<br />
A thermoset remains hard and eventually degrades when heated. This involves a chemical process<br />
and is thus irreversible. Thermoset composite materials offer resistance to extreme temperatures and<br />
are extremely strong, low-weight and durable. Thermoset is mainly used in military aviation and the<br />
space industry. With conditions such <strong>as</strong> those on Mars – between -80º and +20º C – all materials for<br />
exploration vehicles must be completely reliable and secure.<br />
A prepreg consists of a thin foil of a substrate (a thin layer of fabric of for example gl<strong>as</strong>s, carbon or<br />
aramid fibre) that is impregnated with an epoxy or flattened by rollers into thin sheets. Prepregs are<br />
used for the shaping of layered composite materials (laminates).<br />
9
Sustainability / Environment<br />
SpaCe & aeroSpaCe CompoSiTeS HaS impreSSive CUSTomer BaSe<br />
10 txtures | number 4 | winter<br />
The major customers for civil aviation are airbus, Boeing, Bombardier and<br />
embraer and their direct suppliers. US companies account for 55% of the<br />
global market in aerospace, european companies, 25%. airbus and Boeing<br />
airworthy<br />
and reliable<br />
together have a market share of 80%. The fixed wing leading edge<br />
(J-nose) and the engine inlet among other parts of the airbus a380 are<br />
made of <strong>TenCate</strong> Cetex ® .<br />
Various parts of the A350 will also be b<strong>as</strong>ed on<br />
thermopl<strong>as</strong>tic materials from <strong>TenCate</strong>. The Boeing<br />
787 Dreamliner too uses this material and <strong>TenCate</strong><br />
supplies the composite materials for the floor<br />
panels and the moving horizontal and vertical parts<br />
of the tail for the Gulfstream G650 business jet.<br />
The Cirrus SR20 and SR22 business jets consist<br />
entirely of thermoset composite material.<br />
Other types of aircraft in which the material is used<br />
include the Airbus A320 (the ‘workhorse’ of the Airbus<br />
fleet), the A400 M, the Boeing 737, Boeing 747-8, Boeing<br />
777 and Boeing 767; the Embraer Lineage, Phenom 100<br />
and Phenom 300, the Gulfstream G550 and the Apache<br />
AH64 helicopter. <strong>TenCate</strong> is currently going through a<br />
qualification programme that is aimed at the replacement<br />
of a metal loading ramp in helicopters with thermopl<strong>as</strong>tic<br />
composite. This will produce a weight saving<br />
of 40%, greater strength and an incre<strong>as</strong>ed lifespan.<br />
<strong>TenCate</strong>’s customer b<strong>as</strong>e also includes the names<br />
of aircraft manufacturer Lockheed Martin, the<br />
defence and technology company Raytheon, Loral<br />
(satellite systems), BAE Systems (aviation), Cobham<br />
(aviation and defence), General Atomics (applications<br />
in nuclear energy, aviation and defence), ATK (space<br />
and aerospace, defence) and Astrium (space).<br />
aircraft industry: cautious<br />
The aircraft industry is sometimes depicted <strong>as</strong><br />
conservative, but ‘cautious’ is a more fitting description<br />
– at le<strong>as</strong>t that is the view of Frédérique Mutel, CEO of<br />
JEC Composites (see article on page 15). Safety and<br />
reliability are paramount and ensuring these takes a<br />
great deal of time. The major challenge here is to<br />
produce more aircraft using the same quality and to<br />
produce lighter parts for aircraft that can go f<strong>as</strong>ter at<br />
lower costs, while still retaining the same quality. The<br />
answer to all this is the automation of production<br />
processes (by robotization and simulation) and<br />
innovation of materials. ‘Aerospace h<strong>as</strong> no choice.’<br />
Continued on page 12
The Cirrus SR20 and SR22 consist entirely of composite material<br />
11
Sustainability / Environment<br />
SpaCe & aeroSpaCe CompoSiTeS HaS impreSSive CUSTomer BaSe<br />
Continued from page 11<br />
As an illustration she mentions the Boeing<br />
787, where dozens of engineers are trying to<br />
work out how to save eight grams on a single<br />
part. The only solution for weight saving is<br />
composites. In order to be able to produce<br />
more composites and make them more<br />
12 txtures | number 4 | winter<br />
competitive, automation is vital: it can speed<br />
up the production cycle, guarantee the<br />
reproducibility and quality of parts and reduce<br />
costs. JEC Composites supports the industry<br />
by providing an extensive information and<br />
training programme in automation.<br />
<strong>TenCate</strong> supplies composite materials for the moving horizontal and vertical parts of the tail of the gulfstream G650<br />
Europe, where 83% of the production<br />
processes are currently automated, acts <strong>as</strong> a<br />
driver for Asia (68%) for example. ‘The entire<br />
composites industry must, however, move<br />
forward, <strong>as</strong> a sign that it is committed to the<br />
environment.’
Lightweight composites, which meet the<br />
requirements of the aircraft manufacturers in<br />
terms of strength and stiffness, can also be<br />
used to make cars and ships lighter. To<br />
achieve this, however, f<strong>as</strong>ter, automated<br />
production techniques must become available.<br />
Biding one’s time<br />
Participation in the aviation market is a<br />
question of biding one’s time. Even now<br />
designers are already getting down to work<br />
on planes that will not take to the air before<br />
2025. The requirements made by the aviation<br />
industry change rapidly and the use of<br />
composites in this sector is incre<strong>as</strong>ing<br />
markedly. Composite is both stronger and<br />
lighter than aluminium and other metals. Each<br />
successive generation of aircraft <strong>as</strong> a rule<br />
contains yet more composite material, <strong>as</strong> it is<br />
a matter of being able to carry more<br />
p<strong>as</strong>sengers over greater distances, with<br />
reduced fuel consumption and lower<br />
production and maintenance costs. New<br />
commercial aircraft that will be delivered in<br />
2010 and the following years will have<br />
fuselages and wings in which yet more<br />
aluminium h<strong>as</strong> been replaced by (carbon fibre)<br />
composites. The same also applies to the<br />
structural parts. In 2014, 11% more<br />
composites will be used in aircraft than in<br />
2009. The Airbus A320 (1986) consists of<br />
20% composite material, the A380 (2005),<br />
35%. The new Boeing 787 and Airbus A350<br />
XWB will consist of approximately 50%<br />
composites and only 20% aluminium.<br />
The use of composites makes aircraft lighter<br />
and incre<strong>as</strong>es their lifespan. As this will also<br />
enable the air pressure and atmospheric<br />
humidity to be incre<strong>as</strong>ed, p<strong>as</strong>senger comfort<br />
too will be enhanced. With aluminium the<br />
atmospheric humidity is kept artificially low,<br />
<strong>as</strong> corrosion would otherwise occur (for<br />
example in the rivet joints). This keeps the air<br />
in the aircraft dry. At an altitude of ten<br />
kilometres the plane must be kept<br />
pressurized; in an average lifespan a plane is<br />
‘pumped up’ approximately 150,000 times.<br />
Composites thus have an advantage because,<br />
unlike aluminium, absolutely no material<br />
fatigue will occur.<br />
opting for <strong>TenCate</strong><br />
Customers have their own re<strong>as</strong>ons for opting<br />
for composite materials from <strong>TenCate</strong>:<br />
reliability and continuity, for example.<br />
<strong>TenCate</strong> offers excellent technical service,<br />
very short lead times and a wide selection of<br />
specialty products for key segments like<br />
radomes and satellites. Manufacturers of<br />
satellite systems value the benefits of the<br />
very high modulus fibres and resin systems<br />
from <strong>TenCate</strong>, which are extremely<br />
dimensionally stable. Radome manufacturers<br />
want composites that are dielectrically very<br />
pure: gl<strong>as</strong>s and quartz fabrics with no carbon<br />
fibre contamination. In the Morgan Hill facility<br />
the group h<strong>as</strong> carbon-free are<strong>as</strong>.<br />
<strong>TenCate</strong> h<strong>as</strong> wide-ranging technology in<br />
resins, both thermoset and thermopl<strong>as</strong>tics,<br />
and can also manufacture parts itself. Space<br />
& Aerospace Composites is also a good<br />
technical partner, being able to develop and<br />
qualify new materials for specific end-use<br />
applications. In both Nijverdal amd Morgan<br />
Hill, <strong>TenCate</strong> possesses some of the very<br />
latest production equipment in both<br />
thermoset and thermopl<strong>as</strong>tic prepregs and<br />
unitape.<br />
13
Sustainability / Environment<br />
TenCaTe working on new maTeriaLS anD proCeSSeS<br />
14 txtures | number 4 | winter<br />
UD tape technology will make it possible in the future to build a light fuselage of thermopl<strong>as</strong>tic composite
innovations and trends<br />
<strong>as</strong> a technology partner, <strong>TenCate</strong> works with both end-users and suppliers<br />
in the development of composite materials and their use in existing and new<br />
aircraft. in this way concepts and products can be customized <strong>as</strong> required.<br />
The <strong>TenCate</strong> Advanced Composites PPS+<br />
programme is directed at a new generation of<br />
<strong>TenCate</strong> Cetex ® thermopl<strong>as</strong>tic composites, the<br />
b<strong>as</strong>is being a new generation of<br />
polyphenylene sulfide (PPS) semipregs. PPS<br />
powder is applied directly to the carbon fabric<br />
and melted. This saves a number of steps in<br />
the processing and is thus cheaper, meaning<br />
that the material can compete on price with<br />
traditional thermoset composites. The<br />
programme thus provides more efficient<br />
internal processes, new composite<br />
architectures and better temperature<br />
resistance. <strong>TenCate</strong> can now offer new<br />
products in thermopl<strong>as</strong>tic unitapes, new<br />
resins for high-temperature applications like<br />
the Orion heat shield, new prepregs for the<br />
satellite structure and a new generation of<br />
thermoset prepregs focused on aircraft for out<br />
of autoclave processing. The adhesion of<br />
layers and hardening of the material in<br />
autoclaves is an expensive process and is<br />
therefore not fe<strong>as</strong>ible for example for the<br />
automotive industry.<br />
The most recent product introductions are a<br />
prepreg for industrial and recreational<br />
applications and a new composite surfacing<br />
film to provide a cosmetically superior surface<br />
to composite structure. CCS Composites<br />
supplies thermoset clamps for the hydraulic<br />
and fuel lines of the Boeing 787 Dreamliner.<br />
Ten Cate Advanced Composites USA h<strong>as</strong><br />
entered into an agreement with 3M for the<br />
supply to <strong>TenCate</strong> of 3M Matrix Resin for<br />
the creation of customized <strong>TenCate</strong> prepregs.<br />
The 3M Matrix Resin is a proprietary resin<br />
technology that can produce stronger, lighter<br />
and more durable composites. The resin<br />
makes it possible for manufacturers to avoid<br />
the traditional trade-off between toughness/<br />
flexibility and stiffness/hardness.<br />
global trends<br />
<strong>TenCate</strong>’s PPS+programme enables the<br />
company to respond to a number of trends<br />
that are emerging in the world of composites.<br />
The major trend in the aircraft industry is<br />
interest in improving the productivity of<br />
composite fabrication through automation and<br />
in new materials. There is also a shift towards<br />
composite aircraft fuselage and wings in new<br />
commercial planes, which is driving overall<br />
composite usage and the demand for<br />
thermopl<strong>as</strong>tic composites in interior<br />
applications. In other applications customers<br />
are seeking productivity savings from the use<br />
of automation and the elimination of very high<br />
pressure curing cycles. <strong>TenCate</strong> thermoset<br />
materials can be cured in ovens instead of<br />
autoclaves, thereby reducing the time and<br />
capital investment. With thermopl<strong>as</strong>tic UD<br />
tape the automation from thermopl<strong>as</strong>tic<br />
unitapes provides productivity savings along<br />
with the ability to store these materials at<br />
ambient temperatures.<br />
15
Sustainability / Environment<br />
TenCaTe working on new maTeriaLS anD proCeSSeS<br />
Frédérique Mutel, Chairman and<br />
CEO of JEC Composites<br />
From open to closed<br />
A development is taking place in injection<br />
processes, which goes hand-in-hand with the<br />
shift from open-moulding techniques to<br />
closed-moulding, such <strong>as</strong> resin transfer<br />
moulding (RTM). This is a low-pressure design<br />
process with two resins that are injected into<br />
a mould, after which they are cured. This<br />
technique is clean, energy efficient and<br />
enables large and relatively complex products<br />
to be made and to have an extremely smooth<br />
surface on both sides. This is a significant<br />
improvement from the point of view of quality,<br />
environment and health. It produces a more<br />
constant quality end-product and helps to<br />
significantly reduce the emission of g<strong>as</strong>es<br />
(solvents) in production. Here too there is a<br />
challenge, particularly for the emerging<br />
economies. Traditional manual processing<br />
(hand lamination in an open mould) can be<br />
harmful to humans and the environment.<br />
This development fits in with the strong<br />
growth in the share of thermopl<strong>as</strong>tics, which<br />
are lending themselves more for closed-mould<br />
processes and can be more e<strong>as</strong>ily recycled.<br />
16 txtures | number 4 | winter<br />
Moreover, unlike thermosets, they do not<br />
produce any inventory problems. The share of<br />
thermopl<strong>as</strong>tics in the value chain amounted to<br />
30% in 2002; this is currently 37%.<br />
Tailwind<br />
Another trend is the growth of applications in<br />
wind energy. In Frédérique Mutel’s view we<br />
will not be able to avoid having a variety of<br />
forms of energy. ‘We shan’t be able to<br />
continue with just one or two forms of<br />
energy.’ Rapid growth is occurring chiefly in<br />
the United States. Here they realized eight<br />
years ago that the US could face problems in<br />
many markets and it w<strong>as</strong> decided to enter<br />
new markets, such <strong>as</strong> wind turbines. The US is<br />
traditionally strong in automotive and space<br />
systems; however, knowledge of nuclear<br />
energy is still limited there. With the<br />
production of wind turbine blades you have to<br />
be close to your customer and to the place<br />
where the wind turbines are.<br />
growth in <strong>as</strong>ia<br />
There is also undeniably strong growth in the<br />
use of composites in Asia. Of the worldwide<br />
growth from 5.9 million ton (Mt) in 1999 to<br />
10.3 Mt in 2013, Asia’s share rose from 24%<br />
to 36%. Large composite companies now have<br />
production facilities all over Asia, not so much<br />
due to the wages <strong>as</strong> to the fact that the<br />
market and the demand are large there.<br />
Western players too want their share of the<br />
cake and the same applies to raw materials<br />
suppliers. These are companies with<br />
advanced technology and full control of their<br />
emissions. ‘Environmental awareness in<br />
emerging countries is growing rapidly.”<br />
Frédérique Mutel knows from her own<br />
experience. ‘From time immemorial there h<strong>as</strong><br />
been a culture there of reuse and recycling.<br />
They have a long tradition of care for water<br />
and nature. They feel involved with the quality<br />
of the natural environment - that is one of the<br />
greatest values. That’s why you don’t just<br />
throw things away.’<br />
<strong>TenCate</strong> remains principally focused on space<br />
and aerospace. There is a growing potential<br />
for aircraft interiors for thermopl<strong>as</strong>tics,<br />
radomes for military ships, oil and g<strong>as</strong><br />
applications for weight reduction and<br />
composite use in commercial aviation and the<br />
market segment for business aircraft.
Sustainability / Environment<br />
TenCaTe pLaYer in rapiDLY growing markeT<br />
a world<br />
of composites<br />
The Space & Aerospace Composites market group<br />
develops and produces composite materials<br />
primarily for space and aerospace. These are<br />
markets that are showing growth, and in which<br />
there is a major role for automation, recycling and<br />
innovation of raw materials, materials and<br />
processes.<br />
The market is dominated by the transport sector<br />
(see illustration p. 18) and the construction industry.<br />
In the transport sector weight reduction results in<br />
fuel savings. In the construction industry building<br />
light means that fewer raw materials are required.<br />
In building, roofing, spanning and infr<strong>as</strong>tructure<br />
many traditional materials lend themselves to<br />
replacement by composites. The maintenance of<br />
structures such <strong>as</strong> bridges is subject to strict<br />
regulation in the EU. Supporting structures made of<br />
composites can consequently compete with metal<br />
structures. By placing a greater emph<strong>as</strong>is on<br />
promoting itself in civil engineering and the<br />
construction industry, there is still a great deal of<br />
ground to be gained here by the industry.<br />
The aerospace market share amounts to 4%,<br />
although this sector h<strong>as</strong> the highest growth and<br />
greatest profitability (21% of the market value). The<br />
market for wind energy accounts for 3% of the total<br />
volume (6% of the total value). In the United States<br />
and Europe these two high-tech sectors are far<br />
more developed than in the rest of the world. The<br />
shipbuilding, pipelines & tanks, consumer products<br />
and electricity & electronics sectors occupy a<br />
midway position <strong>as</strong> regards market share.<br />
Space & Aerospace Composites supplies 80% of<br />
High strength and low weight, extreme formability, excellent resistance to acids,<br />
chemicals, moisture, impact and heat: these are just a few of the many advantages<br />
that advanced composites offer and which are recognized in many sectors. worldwide<br />
the composites industry serves many sectors, supplying both high-tech materials and<br />
low-value volume products.<br />
Production of carbon prepregs in Morgan Hill. The demand for carbon fibre will double between 2009 and 2012<br />
its composites to the space and aerospace industry<br />
and 20% for industrial applications.<br />
market volume and market value<br />
The market volume of the worldwide composites<br />
industry amounts to eight million tons and h<strong>as</strong> a<br />
value of €60 billion. Of this, the US accounts for<br />
35% (value 36%), the European Union (EU) 22%<br />
(33%) and Asia 43% (31%). The relatively high<br />
value of the EU can be <strong>as</strong>cribed to the high<br />
standard of composites technology. Asia is focused<br />
mainly on low-value composite materials in large<br />
volumes. Outside China the market is looking to an<br />
incre<strong>as</strong>ing extent to high-tech materials. Not only<br />
Asia, but India and South America too are emerging<br />
markets. They need new solutions for obsolete<br />
infr<strong>as</strong>tructure and transport networks. Transport<br />
and construction are the major markets there.<br />
In the US and the EU, both mature economies, the<br />
market is already saturated.<br />
improvement<br />
On average the global market is growing by 4% a<br />
year. This growth is accelerating <strong>as</strong> a result of the<br />
17
Sustainability / Environment<br />
TenCaTe pLaYer in rapiDLY growing markeT<br />
incre<strong>as</strong>ing use of composites and improvements in<br />
production processes.<br />
Across the world some 550,000 people earn their<br />
living in the composites industry.<br />
These figures were provided by JEC Composites,<br />
which h<strong>as</strong> extensively charted the ‘rich and<br />
complex’ world of composites. JEC (Journals,<br />
Exhibitions & Composites) h<strong>as</strong> set itself the t<strong>as</strong>k of<br />
promoting composite materials worldwide. JEC’s<br />
global network connects more than 250,000 people<br />
who are professionally involved in composites.<br />
The composites industry is highly innovative. This<br />
innovative attitude is also essential, <strong>as</strong> the<br />
composites industry faces a number of challenging<br />
t<strong>as</strong>ks, including automation (making production<br />
processes f<strong>as</strong>ter and cheaper through for example<br />
robotization) and the development of new raw<br />
materials, resins, and gl<strong>as</strong>s and carbon fibres. ‘Each<br />
link in the value chain h<strong>as</strong> a contribution to make to<br />
this’, Frédérique Mutel (Chairman and EO of JEC<br />
Composites) told us. ‘This makes all the players in<br />
the value chain mutually dependent.’<br />
innovations<br />
The demand for carbon fibre will incre<strong>as</strong>e between<br />
2009 and 2012. Aerospace and industrial<br />
applications are showing the strongest growth.<br />
The innovation of resins and additives involves for<br />
example low-emission resins, bio-resins, improved<br />
18 txtures | number 4 | winter<br />
prepregs and carbon and gl<strong>as</strong>s fibres with greater<br />
strength. When it comes to process innovation, the<br />
terms simulation and prototyping are often heard.<br />
‘Computers allow you to simulate anything. You can<br />
design a product on a computer; you don’t need to<br />
build a scale model to do it. After rapid prototyping<br />
you can immediately start on serial production.<br />
Also, you can simulate the ageing process of<br />
composites.’<br />
Apart from the focus on new raw materials and<br />
materials, attention is also given to obsolete<br />
products: recycling. Who does the collecting, who,<br />
the removal and who, the recycling? As far <strong>as</strong><br />
regulations are concerned, Japan and the EU are to<br />
date the most progressive in this process. EU<br />
legislation for the recycling of cars and electrical<br />
equipment provides opportunities for the<br />
composites industry. In the US regulations relating<br />
to materials, chemicals and recycling are<br />
continually improving. ‘Recycling is a great<br />
challenge for the industry and will become ever<br />
more important.’<br />
Collective<br />
One of the specific qualities of the composites<br />
industry is its collective knowledge. ‘The market<br />
wants products that don’t rust and require little or<br />
no maintenance. Companies in the value chain are<br />
constantly working together to find the best<br />
solution.’ There is also internal competition within<br />
the sector: between thermosets and<br />
thermopl<strong>as</strong>tics for example, where<strong>as</strong> the real<br />
competition is taking place outside, in other<br />
materials. She feels that not all the companies can<br />
see the big picture. ‘JEC Composites plays an<br />
important role in this by uniting all the families,<br />
representing the sector and coming up with various<br />
solutions. The collective challenge is to expand the<br />
composites markets and you can’t do that with<br />
forty different families and poor arguments and<br />
resources.’<br />
Following on from that, JEC Composites wants to<br />
incre<strong>as</strong>e the visibility of composites and<br />
communications about them. ‘There are too many<br />
expressions for the same sorts of materials. All the<br />
links in the value chain talk about composites, and<br />
<strong>as</strong> a result there are too many confusing terms. The<br />
industry is relatively young so we must present<br />
ourselves far more clearly and, with the backing of<br />
a strong industry, show end-users and markets<br />
what you can do with composites and be efficient<br />
in conveying their advantages.’
Concentration<br />
Another challenge is the concentration of<br />
companies. There are too many small and<br />
medium-sized companies in the composites<br />
industry. They all have expertise and knowledge.<br />
‘It would be good to form alliances and clusters of<br />
companies, so you have to consolidate, buying up<br />
other companies or forming clusters of small<br />
companies in technology or on a regional b<strong>as</strong>is.<br />
This will mean the end of many such companies if<br />
they don’t have the means to invest or to set up<br />
elsewhere. If you’re small and aren’t open to<br />
change, you won’t stand a chance. There are some<br />
companies that are conservative. They behave in<br />
a very protective way and are not open to the<br />
outside world.’<br />
Spirit of cooperation<br />
When it comes to <strong>TenCate</strong>, Frédérique Mutel is<br />
positive. ‘<strong>TenCate</strong> is a company that works with<br />
partners in a spirit of cooperation and believes that<br />
alliances are very important. When I got to know<br />
<strong>TenCate</strong> in the US, and then in Asia, I saw the<br />
company’s dynamism. Its people are open and very<br />
innovative. So it’s no small wonder that the<br />
company won the JEC Innovation Award 2010 in<br />
Paris. Mr De Vries h<strong>as</strong> vision. When I met him, he<br />
stressed that <strong>TenCate</strong> is a company that makes a<br />
difference. <strong>TenCate</strong> is important to us <strong>as</strong> JEC for<br />
our references.’<br />
Space & Aerospace Composites’ contacts are<br />
limited for the time being to the JEC organization.<br />
Frédérique Mutel believes that <strong>TenCate</strong> could<br />
benefit even more from its network of experts and<br />
decision-makers. ‘We could be partners to get our<br />
message across more clearly and to make the<br />
brand more visible.’<br />
• Composites industry is an innovative<br />
sector within which a great deal of<br />
knowledge is shared.<br />
• There is an important role for automation,<br />
recycling and innovation of raw materials,<br />
materials and processes.<br />
• JeC appreciates <strong>TenCate</strong>’s open and<br />
innovative attitude<br />
www.jeccomposites.com<br />
info@jeccomposites.com<br />
19
Sustainability / Environment<br />
Ten CaTe aDvanCeD CompoSiTeS SignS SUppLY ConTraCT<br />
Laminates for<br />
airbus a350 XwB<br />
an enabled material contract h<strong>as</strong> been signed to supply <strong>TenCate</strong> Cetex ®<br />
carbon fabric laminates for use in the new airbus a350 XwB among other<br />
eaDS applications. B<strong>as</strong>ed on this award <strong>TenCate</strong> advanced Composites<br />
europe will start the delivery of <strong>TenCate</strong> Cetex ® towards several Tier 1 and<br />
Tier 2 partners of airbus that produce fuselage panels and components for<br />
the airbus a350 XwB.<br />
20 txtures | number 4 | winter<br />
<strong>TenCate</strong> Cetex ® material – which can be characterized <strong>as</strong> high<br />
strength and low weight – will be applied to the stiffening<br />
structure of the body of the Airbus A350 XWB. The thermo-<br />
pl<strong>as</strong>tic material is already used in existing Airbus programs,<br />
including the Airbus A380. These advanced fabric reinforced<br />
thermopl<strong>as</strong>tic composite materials are already used for many<br />
structural and semi-structural exterior <strong>as</strong> well <strong>as</strong> interior<br />
applications in aircraft. The supply of <strong>TenCate</strong> Cetex ® material<br />
to the Airbus A350 XWB program once again underlines the<br />
importance of light and moldable thermopl<strong>as</strong>tic material. One of<br />
the advantages of the application of thermopl<strong>as</strong>tic composite is<br />
the posibility for the serial production in large numbers.<br />
www.tencateaerospacecomposites.com<br />
aerospacecomposites.europe@tencate.com
Sustainability / Environment<br />
Ten CaTe aDvanCeD CompoSiTeS reDUCeS waSTe STreamS<br />
Carbon composite<br />
for reprocessing<br />
Ten Cate advanced Composites is realizing considerable savings in the costs of its w<strong>as</strong>te streams. The high-grade composite<br />
w<strong>as</strong>te that is offered pre-eminently lends itself for reprocessing – a win-win situation in terms of material and environment.<br />
More and more companies are realizing that the<br />
raw and auxiliary materials used in the industry<br />
will not be endlessly available. Through smart<br />
design and production and through selecting<br />
reprocessable b<strong>as</strong>ic materials and ‘green’<br />
suppliers, it is possible to give many costly<br />
w<strong>as</strong>te materials a new life. Ten Cate Advanced<br />
Composites h<strong>as</strong> a multiyear contract with CFK<br />
Valley Recycling in Stade. CFK is the German<br />
designation for pl<strong>as</strong>tics reinforced with carbon<br />
fibre. With small logistic adjustments to the<br />
collection system for carbon woven edges,<br />
thermopl<strong>as</strong>tic prepregs and sawing w<strong>as</strong>te from<br />
laminates, the company in Nijverdal is managing<br />
to realize considerable savings in the costs of its<br />
w<strong>as</strong>te streams. In addition the company is a<br />
frontrunner when it comes to providing<br />
high-grade composite w<strong>as</strong>te that is particularly<br />
suitable for recycling. Ten Cate Advanced<br />
Composites is also a member of the CFK Valley<br />
consortium.<br />
rules<br />
The European Union is working on rules<br />
regarding the reprocessing of discarded<br />
aeroplanes comparable to those applicable to<br />
cars. Making the disposal of these aircraft more<br />
efficient and profitable is also of great<br />
importance to the aviation industry itself. So it is<br />
working together with the w<strong>as</strong>te processing<br />
industry to develop new forms of reprocessing<br />
carbon material.<br />
End products b<strong>as</strong>ed on ‘milled’ carbon fibres are<br />
used, among other things, for reinforcing injection<br />
moulding components for industrial or possibly<br />
automotive applications. They can also be used to<br />
make carbon fleece – a sort of non-woven mat that<br />
serves <strong>as</strong> cost-effective, high-grade reinforcement<br />
in composites and laminates.<br />
knowledge network<br />
The aim of CFK Valley in Stade (North Germany) is<br />
to develop a leading international knowledge<br />
network for the technology and production of<br />
carbon fibre-reinforced polymers. The focus lies<br />
on the application of (recycled) materials in<br />
aircraft building, ship building, railways,<br />
commercial vehicles and car engineering The best<br />
partners in the world in the field of carbon<br />
fibre-reinforced polymers are brought together in<br />
this network. With approximately 1,900<br />
employees, this is the most important knowledge<br />
centre for large carbon fibre-reinforced pl<strong>as</strong>tic<br />
aircraft components, such <strong>as</strong> wings.<br />
CFK Valley is closely connected with the Airbus<br />
production plant 50 km away. Airbus itself produces<br />
the tail of the Airbus A380 aircraft in Stade.<br />
www.tencateaerospacecomposites.com<br />
aerospacecomposites.europe@tencate.com<br />
The high-grade carbon selvages are collected<br />
and offered for recycling<br />
21
Safety & Protection<br />
TenCaTe LiBa ® ComeS THroUgH Firing TeST wiTH FLYing CoLoUrS<br />
22 txtures | number 4 | winter<br />
Setting sights on<br />
advanced armour<br />
Ballistic experts inspect the impact of heavy artillery on <strong>TenCate</strong> Liba ®
naTo and US soldiers in iraq and afghanistan are frequently exposed to multiple<br />
threats, such <strong>as</strong> roadside bombs. one of the possible ways of protecting them is through<br />
the development of lightweight protection solutions with <strong>TenCate</strong> Liba®. <strong>TenCate</strong><br />
advanced armour and Dynamit nobel Defence invited a number of business relations to<br />
become better acquainted with the antiballistic properties of these solutions. The heavy<br />
artillery w<strong>as</strong> brought in, which w<strong>as</strong> comparable to that used on the scene of battle.<br />
<strong>TenCate</strong> Liba® came through the test with flying colours.<br />
The demonstrations were held on 13 and 14<br />
October in one of the bunkers on the v<strong>as</strong>t,<br />
heavily protected complex of Dynamit Nobel<br />
Defence among the wooded hills near Burbach<br />
(Germany). An international gathering w<strong>as</strong><br />
<strong>as</strong>sembled there, including technicians and<br />
designers from ministries of defence, other<br />
government agencies and weapon and vehicle<br />
manufacturers. This contact directly reached<br />
among others five of <strong>TenCate</strong> Advanced<br />
Armour’s major customers.<br />
effective systems<br />
<strong>TenCate</strong> Advanced Armour develops protective<br />
solutions b<strong>as</strong>ed on lightweight armour<br />
composites. These effective systems are used in<br />
personal equipment, light and armoured<br />
vehicles, ships, aircraft, helicopters and<br />
installations. They incorporate the most<br />
advanced ceramic and composite technology<br />
that is currently available.<br />
<strong>TenCate</strong> Liba ® is a proprietary lightweight<br />
protection solution b<strong>as</strong>ed on ceramic pellets<br />
embedded in an el<strong>as</strong>tic polymer matrix, and from<br />
this panels are made. There is a wide range of<br />
solutions in both modular products and systems.<br />
Work is being carried out together with partners<br />
on product differentiation and innovation. This is<br />
a matter of pure necessity <strong>as</strong> the number and<br />
level of threats are incre<strong>as</strong>ing and soldiers in the<br />
field are regularly the target of explosively<br />
formed projectiles (EFP), improvised explosive<br />
devices (IEDs or roadside bombs) and portable<br />
rocket-propelled grenades.<br />
High level of threat<br />
Some seven tests were conducted in Burbach.<br />
Sights were set on lightweight repaired<br />
protection solutions using <strong>TenCate</strong> Liba ® .<br />
It w<strong>as</strong> decided to reproduce a high level of<br />
threat in accordance with STANAG 4569.<br />
This NATO standard covers the levels of<br />
protection for occupants of logistic and light<br />
armoured vehicles.<br />
A damaged <strong>TenCate</strong> Liba ® insert can be quickly<br />
and e<strong>as</strong>ily repaired. One of the firing tests<br />
showed that an insert that h<strong>as</strong> been repaired<br />
and once again shot at provides excellent<br />
protection. Moreover, <strong>TenCate</strong> Liba ® is also<br />
considerably lighter in weight than traditional<br />
steel, which makes a substantial difference to<br />
the weight, fuel consumption, speed and<br />
manoeuvrability of the armoured vehicle.<br />
optimum solution<br />
Ulrich R<strong>as</strong>mussen and Kenn Jensen (Sales<br />
Managers <strong>TenCate</strong> Advanced Armour) were two<br />
of the hosts. They too look back on the two-day<br />
event with a feeling of satisfaction. ‘Our goal<br />
w<strong>as</strong> to show that <strong>TenCate</strong> Advanced Armour can<br />
provide protection against many different<br />
threats, that we are the only company that<br />
offers a fully repairable solution and that we can<br />
work together with suppliers of other protection<br />
solutions to provide the customer with the<br />
optimum solution.’ In this aim they appear to<br />
have succeeded. The fitted <strong>TenCate</strong> Liba ®<br />
inserts proved to be sufficiently impactresistant.<br />
The same applied to an insert that had<br />
markeT – advanced armour (personal and<br />
vehicle protection). proDUCT – <strong>TenCate</strong><br />
Liba ® . TeCHnoLogY – ceramic and polymer<br />
technology. proCeSS – inserts are fitted<br />
into bulletproof vests and vehicle armouring.<br />
previously been shot at and then repaired. The<br />
visitors accepted the waiting time between the<br />
<strong>as</strong>sembly and dis<strong>as</strong>sembly of the installations <strong>as</strong><br />
a necessary part of the procedure. ‘Different<br />
customers told us that they had found it<br />
extremely interesting. In particular, all<br />
customers, wherever they may be in the world,<br />
are experiencing a great demand for protection<br />
against EFPs.’<br />
knowledge and experience<br />
Both inside and outside <strong>TenCate</strong> a great deal of<br />
knowledge and experience h<strong>as</strong> been gained<br />
relating to projectiles and the consequences for<br />
armouring when they are ignited. And yet the<br />
behaviour and results of heavy explosives<br />
remain difficult to calculate. At such a high level<br />
of threat ‘we leave the field of science and enter<br />
the domain of the unpredictable’, <strong>as</strong> Dynamit<br />
Nobel Defence’s Herbert Weisshaupt put it. This<br />
underlines the importance of the protection of<br />
people and vehicles using lightweight solutions<br />
which incorporate <strong>TenCate</strong> Liba ® .<br />
• Simulation of conditions in iraq and<br />
afghanistan at the demonstration of<br />
lightweight protection solutions<br />
• <strong>TenCate</strong> Liba ® offers advanced armour<br />
protection in accordance with high<br />
STanag level<br />
www.tencateadvancedarmour.com<br />
advancedarmour.europe@tencate.com<br />
23
Trading update<br />
THirD qUarTer FigUreS For 2010<br />
24 txtures | number 4 | winter<br />
Loek de Vries, Chairman and CEO<br />
<strong>TenCate</strong> n<br />
47% in thi<br />
‘<strong>TenCate</strong>’s results in the third quarter, with 47%<br />
growth, demonstrate that the recovery is continuing.<br />
qualification of the profit growth is, however, called<br />
for. The underlying operational trend is more<br />
positive than is shown by the reported profit growth.<br />
This can also be seen from the sharp rise in sales in<br />
the third quarter to the level of the top year 2008.<br />
• Sales in third quarter of €273 million at the level of<br />
the top year 2008<br />
• Profit growth of 47%<br />
• Profit trend in third quarter affected by non-recurring<br />
high costs for the coordination of downstreaming of<br />
synthetic turf operations
et profit up<br />
rd quarter of 2010<br />
In the first place, the direct consequence of<br />
the pick-up in some markets is that shortages<br />
have occurred in certain types of fibre.<br />
<strong>TenCate</strong> h<strong>as</strong> contributed to this to a<br />
significant extent through the success of<br />
<strong>TenCate</strong> Tec<strong>as</strong>afe Plus and <strong>TenCate</strong><br />
Defender M.<br />
Although <strong>TenCate</strong>, <strong>as</strong> global market leader in<br />
protective fabrics, is relatively well served by<br />
its suppliers, this h<strong>as</strong> resulted in some delays<br />
and h<strong>as</strong> led to somewhat higher costs, which<br />
will be of a temporary nature.<br />
reorganization<br />
A second effect comes from the synthetic turf<br />
markets. As market leader, <strong>TenCate</strong> heads the<br />
field in the reorganization of the synthetic turf<br />
market, which is entering a new ph<strong>as</strong>e. This<br />
development w<strong>as</strong> accelerated by the financial<br />
crisis of 2009. The financing of se<strong>as</strong>onal sales<br />
may produce problems for some parties.<br />
Other market-related developments are,<br />
however, also playing a role in this.<br />
In this development ph<strong>as</strong>e there will be a<br />
consolidation of the markets; market parties<br />
will start to work together more in the chain.<br />
The main demands of end-users relate to<br />
quality and durability. Local authorities are<br />
often the owner of sports complexes, and<br />
environmental <strong>as</strong>pects are also playing an<br />
ever greater role here. Cooperation is<br />
necessary in order to pool specific<br />
knowledge. <strong>TenCate</strong> is seeking to enter into<br />
this cooperation through alliances with<br />
companies that operate close to the end<br />
markets. This process will initially require<br />
the appropriate investments and<br />
management focus.<br />
positive outlook<br />
There is also a more positive outlook for the<br />
aerospace market, although this is <strong>as</strong> yet not<br />
fully reflected in the current figures. <strong>TenCate</strong><br />
with its composite materials occupies a<br />
prominent position in this market.<br />
It h<strong>as</strong> already been announced through a<br />
press rele<strong>as</strong>e that the sale of <strong>TenCate</strong><br />
Defender M to the US Army will be<br />
substantial in the fourth quarter.<br />
Cautious<br />
We repeat the profit outlook for the second<br />
half of the year referred to above. The<br />
financial markets have, however, reacted<br />
cautiously so far. <strong>TenCate</strong> announced its<br />
expectation of achieving this outlook <strong>as</strong> a<br />
minimum. The trends observed also express<br />
confidence about a number of key future<br />
developments that will support the further<br />
growth of <strong>TenCate</strong>.’<br />
25
Sustainability / Environment<br />
TenCaTe CeTeX ® in moBiLiTY ConCepT SUperBUS<br />
Safe<br />
flexible<br />
sustainable<br />
Superbus is nearing completion and this innovative mobility concept will be officially launched in just a few months’ time. everything within the<br />
Superbus concept is geared to sustainability. Ten Cate advanced Composites is involved in the project <strong>as</strong> material supplier. The <strong>TenCate</strong> Cetex ®<br />
materials are used in the body and the eight doors of the vehicle. Safety, flexibility and sustainability are the characteristics of Superbus, and safety,<br />
lightness and strength were the demands and therefore the re<strong>as</strong>ons for choosing <strong>TenCate</strong>.<br />
On 22 September Superbus w<strong>as</strong> unveiled to<br />
the press and public at the International Motor<br />
Show (IAA) in Hannover. ‘Amazing!’, ‘Wow!’,<br />
exclaimed Wubbo Ockels in regard to the<br />
reactions to his brainchild. ‘The general public<br />
thought it w<strong>as</strong> super and wondered why it<br />
hadn’t been thought of before. But it came <strong>as</strong><br />
quite a shock to the professional market, such<br />
<strong>as</strong> Daimler Benz and Mercedes, because for<br />
them it’s such a great leap. It goes much<br />
further than anything they’re working on or<br />
can devise.’<br />
In how far the market will ultimately be<br />
interested is a process of the market itself.<br />
26 txtures | number 4 | winter<br />
‘We will demonstrate Superbus more and<br />
more frequently, until it claims political<br />
attention.’<br />
An opportunity is being organized for the<br />
Dutch press to ride in it, on the RDW test track<br />
in Lelystad or somewhere in Germany.<br />
Afterwards the campaigns will begin − but not<br />
before Superbus is ‘in tiptop condition’.<br />
B<strong>as</strong>ic principles<br />
Superbus is an innovative mobility concept<br />
where the b<strong>as</strong>ic principles include mobility,<br />
flexibility, energy efficiency, safety and<br />
reliability. Superbus delivers ‘comfortable,<br />
demand-dependent and point-to-point<br />
transport’. The luxury vehicle can reach a<br />
speed of 250 km an hour on dedicated<br />
Superbus lanes and run at a normal speed on<br />
existing roads. The vehicle h<strong>as</strong> the same<br />
length <strong>as</strong> an average city bus but looks longer<br />
because it is not so high. Thanks to the<br />
rear-axle steering, Superbus h<strong>as</strong> a modest<br />
turning circle.<br />
Wubbo Ockels is justly proud – of his<br />
brainchild naturally, and of the team of people<br />
from Delft University of Technology led by<br />
Antonia Terzi that he manages and that is<br />
working on the realization. Moreover the
number of members h<strong>as</strong> now been reduced to<br />
five, who together compose the test team. It<br />
w<strong>as</strong> an extraordinary experience to ride in<br />
Superbus for the first time. ‘It’s like a<br />
combination of a sportscar and a jet<br />
aeroplane.’<br />
relationship with <strong>TenCate</strong><br />
Impact-resistant, strong, light in weight, and<br />
the combination of these qualities – such were<br />
the requirements and for Wubbo Ockels the<br />
re<strong>as</strong>ons to choose <strong>TenCate</strong>. ‘<strong>TenCate</strong> makes<br />
these materials. The relationship dates back to<br />
the development of the Nuna, the car powered<br />
by solar energy, so I automatically landed up at<br />
<strong>TenCate</strong> again.’ Nor is it likely to be the l<strong>as</strong>t<br />
time. Wubbo Ockels still h<strong>as</strong> many ide<strong>as</strong> and<br />
dreams. The most advanced is sky sailing, ‘a<br />
sort of pioneering stunt with two planes on<br />
one line, one flying in the jet stream and the<br />
other outside. You need <strong>TenCate</strong> for these<br />
lightweight constructions.’<br />
Sustainability <strong>as</strong> b<strong>as</strong>is<br />
For <strong>TenCate</strong>, sustainability is the b<strong>as</strong>is and<br />
reverberation of its pursuit of continuity.<br />
<strong>TenCate</strong> products and systems make an<br />
essential contribution to a world where themes<br />
such <strong>as</strong> safety, protection and sustainability<br />
have become self-evident. The related trends<br />
include personal safety, protection of the<br />
everyday world, restriction of energy<br />
consumption and CO2 emissions, water<br />
management and care for the environment. It is<br />
an important t<strong>as</strong>k of <strong>TenCate</strong> to formulate<br />
answers to these trends, devise solutions and<br />
thus compel developments. Thanks to<br />
composite materials, <strong>TenCate</strong> h<strong>as</strong> a series of<br />
sustainable solutions available.<br />
The earth <strong>as</strong> spaceship<br />
The interest of the professor of Sustainable<br />
Engineering and Technology at Delft University<br />
in sustainability w<strong>as</strong> awakened during his time<br />
<strong>as</strong> an <strong>as</strong>tronaut. ‘The Earth is really a space ship<br />
with a thin layer of protection. This is no<br />
markeT – aerospace, industrial<br />
applications. proDUCT − <strong>TenCate</strong> Cetex ® .<br />
TeCHnoLogY – weaving and impregnation<br />
technology. proCeSS – materials installed<br />
<strong>as</strong> pre-shaped panels in the body parts.<br />
laughing matter; every process can damage it.’<br />
And the exhaustibility of fossil fuels also plays a<br />
role. These are threats that, according to him,<br />
are still insufficiently recognized. He himself<br />
attempts in different ways to stimulate the<br />
enthusi<strong>as</strong>m of young people for sustainability<br />
and a sustainable society. ‘As far <strong>as</strong><br />
sustainability is concerned, the Netherlands is a<br />
vacillating country. It’s shameful that what we<br />
produce in terms of sustainable energy lags so<br />
far behind. This is a problem for the young<br />
people coming later. They are taking no action<br />
and that worries me. I think it’s important for<br />
young people to develop initiatives in this<br />
respect.’<br />
• material demands for Superbus determine<br />
choice for <strong>TenCate</strong> composite materials<br />
• efforts of the netherlands <strong>as</strong> far <strong>as</strong><br />
sustainability concerned ‘shameful’<br />
tencateaerospacecomposites.europe.com<br />
aerospacecomposites.europe@tencate.com<br />
27
Safety & Protection<br />
TenCaTe aDvanCeD armoUr STrengTHenS iTS poSiTion<br />
28 txtures | number 4 | winter<br />
Ballistic<br />
protection<br />
<strong>TenCate</strong> advanced armor USa received additional contracts in<br />
September for vehicle armouring, worth $18.5 million. The materials<br />
will be delivered to two major manufacturers of military vehicles and<br />
to the US army before the end of 2010. This order will enable the<br />
company to cement its strong position in the market for vehicle<br />
armouring in the United States.<br />
<strong>TenCate</strong> is a specialist in the production of lightweight, protective ceramic<br />
and composite armour systems for use in vehicles, aircraft, ships and<br />
personal protection. These materials replace traditional ones such <strong>as</strong> steel<br />
and aluminium and ensure weight saving and improved functional<br />
properties.
Producing modern ballistic protective<br />
solutions requires advanced weaving and<br />
pressing technology and specially designed<br />
cutting technology. <strong>TenCate</strong> Advanced Armour<br />
elects to use the most advanced ceramic and<br />
composite technology available and it<br />
provides the lightest, most efficient armouring<br />
possible for these demanding applications.<br />
access<br />
The American market for ballistic protection is<br />
by far the largest worldwide, while in Europe<br />
the UK is a dominant market. As a result of<br />
the acquisition of the British armour company<br />
AML UK in Swindon (UK), <strong>TenCate</strong> now h<strong>as</strong><br />
unlimited access to the British market for<br />
lightweight composite armour solutions,<br />
which are used in vehicles, aircraft and ships.<br />
Customers for these products are mainly large<br />
industrial conglomerates in the defence<br />
industry, manufacturers of trucks, aircraft,<br />
helicopters, etc. or related suppliers.<br />
Governments (ministries of defence) lay down<br />
the specifications for these.<br />
System approach<br />
<strong>TenCate</strong> Advanced Armour focuses on a<br />
system approach by working together with<br />
manufacturers of vehicle, ships and aircraft<br />
(and their customers) in order to achieve the<br />
best possible configuration for protection. In<br />
the design of armoured vehicles for example<br />
the balance between protection and mobility<br />
is a key factor: the weight of the armoured<br />
protection must be <strong>as</strong> low <strong>as</strong> possible, while<br />
providing the highest level of protection.<br />
During the design and development stages<br />
consideration is given to such factors <strong>as</strong> the<br />
level of threat of the weapons and the cost of<br />
the entire lifespan of the application.<br />
All the solutions are tailor-made for customers<br />
and end-users, whether they are for<br />
permanent integration into the structure of<br />
new vehicles and ships or for carrying out<br />
improvements to existing vehicles and ships.<br />
<strong>TenCate</strong> Advanced Armour can provide<br />
support for its customers worldwide.<br />
www.tencateadvancedarmour.com<br />
advancedarmour.europe@tencate.com<br />
29
Sustainability / Environment<br />
TenCaTe geoTUBe ® in porTUgaL<br />
environmentally responsible<br />
dewatering method<br />
<strong>TenCate</strong> geosynthetics h<strong>as</strong> supplied <strong>TenCate</strong> geotube ® containers for a dewatering project in almeirim (portugal), which involves the removal<br />
and dewatering of 12,500 m³ of organic sludge. This first project in portugal is the result of cooperation between <strong>TenCate</strong> geosynthetics,<br />
<strong>as</strong>hland Hercules water Technologies and geosin, the local partner.<br />
30 txtures | number 4 | winter<br />
poLYmer<br />
DoSing UniT
<strong>TenCate</strong> Geosynthetics and Ashland Hercules<br />
Water Technologies are working closely together<br />
to bring integrated dewatering solutions b<strong>as</strong>ed<br />
on <strong>TenCate</strong> Geotube ® and polymers on to the<br />
market. <strong>TenCate</strong> supplies the dewatering system<br />
and supports customers at home and abroad in<br />
setting up the installation. Fired by enthusi<strong>as</strong>m<br />
for <strong>TenCate</strong> Geotube ® during a workshop in<br />
November 2009, Geosin, the <strong>TenCate</strong> distributor<br />
in Portugal, went in search of a suitable partner<br />
for the project in Almeirim. Egeo, an important<br />
player in the w<strong>as</strong>te industry in Portugal, showed<br />
interest. Thanks also in part to the <strong>as</strong>sistance of<br />
Ashland Portugal, the first steps could be taken<br />
on Portuguese soil with a dewatering project<br />
using <strong>TenCate</strong> Geotube ® .<br />
Fruit juices<br />
The project related to the removal and<br />
dewatering of 12,500 m³ of organic sludge from<br />
two storage b<strong>as</strong>ins for a major producer of<br />
fruit juices. The production<br />
process rele<strong>as</strong>es<br />
residual water with<br />
organic w<strong>as</strong>te, and this<br />
sludge is stored in two<br />
b<strong>as</strong>ins. For years <strong>TenCate</strong><br />
Geosynthetics h<strong>as</strong> been world<br />
leader when it comes to dewatering<br />
sludge from lagoons, but the dewatering of<br />
100% organic sludge is a different story, <strong>as</strong><br />
Gerben van den Berg (market manager <strong>TenCate</strong><br />
Geotube ® Dewatering) well knows. ‘It’s no e<strong>as</strong>y<br />
matter to dewater this using conventional<br />
techniques, but the <strong>TenCate</strong> Geotube ®<br />
technology offers various advantages for such a<br />
process. It is a cost-effective solution with<br />
minimal impact on the environment; large<br />
quantities can be processed in a relatively short<br />
time; and minimal manpower is required.’<br />
Satisfied faces<br />
That the project led to highly satisfied faces is<br />
thanks to <strong>TenCate</strong> Geotube ® , the polymer<br />
technology, the selected approach (training local<br />
people) and the sound choice of partner to<br />
secure small-scale projects of this kind and see<br />
them through to a good conclusion. ‘We’re in the<br />
forefront of other suppliers in this respect, <strong>as</strong> it<br />
requires much more applied knowledge. It’s a<br />
question of polluted organic sludge and you have<br />
to know exactly what you can and can’t do. The<br />
right dose of polymers in combination with the<br />
selected <strong>TenCate</strong> Geotube ® container is crucial.<br />
This solution offers the customer the greatest<br />
certainty and reliability − and that we speak the<br />
language of the local market is also a<br />
distinguishing factor.’<br />
Whoever can do this well h<strong>as</strong> considerable<br />
market potential. ‘Environmental dredging is an<br />
attractive niche in the dredging market. With the<br />
right partners in the chain, who can benefit from<br />
our know-how and experience, we can identify<br />
work of this kind and make it profitable.’<br />
markeT – environment and infr<strong>as</strong>tructure<br />
(bank protection, dewatering<br />
etc.). proDUCT – <strong>TenCate</strong> Geotube ® .<br />
TeCHnoLogY – extrusion, weaving and<br />
coating technology. proCeSS –storage<br />
and dewatering of (polluted) sludge.<br />
The project in Portugal is not an isolated c<strong>as</strong>e.<br />
A project of the same kind is being set up in<br />
Hungary with UTB Hungary and Ashland. In<br />
addition projects are slowly getting off the<br />
ground in various other European countries.<br />
‘This is a good development. Success means<br />
that customers are gaining even greater<br />
confidence in us.’<br />
• <strong>TenCate</strong> geosynthetics realizes first<br />
dewatering project with <strong>TenCate</strong> geotube ®<br />
in portugal<br />
• <strong>TenCate</strong> geotube ® technology is costeffective,<br />
environment-friendly, rapid and<br />
reliable solution<br />
• Cooperation with chain partners offers<br />
good prospects in environmental dredging<br />
www.tencategeosynthetics.com<br />
geosynthetics.europe@tencate.com<br />
Organic sludge is dewatered in an environmentally responsible manner<br />
31
Information Technology<br />
TenCaTe reaLizeS own gLoBaL neTwork<br />
Connected worldwide<br />
The process to realize the Global <strong>TenCate</strong><br />
Network consists, among other things, of<br />
concentrating the IT services by means<br />
of three IT shared service centres: EMEA<br />
(Europe and Dubai), USA and Asia. Within<br />
this network all companies are being<br />
standardized in terms of IT infr<strong>as</strong>tructure<br />
(Microsoft Exchange), which brings numerous<br />
advantages. Employees worldwide will have<br />
at their disposal – besides the traditional<br />
telephone system − internet, intranet, e-mail<br />
and Office Communicator, which serves for<br />
audio communication, video conferencing and<br />
the exchange of documents and other data.<br />
Sharing the systems, IT know-how and costs<br />
32 txtures | number 4 | winter<br />
means saving costs for external consultants,<br />
<strong>as</strong> well <strong>as</strong> promoting internal cooperation.<br />
The project applies to the generic (applicable<br />
to all market groups) systems, and<br />
concentration will only occur if it makes<br />
sense. Company-specific systems are<br />
being standardized within the groups.<br />
Successful<br />
The process started in 2008 with the <strong>TenCate</strong><br />
companies in Europe and Dubai (EMEA). After<br />
a successful start, the pace e<strong>as</strong>ed off in the<br />
course of 2009 because of the economic<br />
circumstances. The corporate IT department<br />
w<strong>as</strong> t<strong>as</strong>ked with bringing costs into line with<br />
the sales. Through a partial reorganization, the<br />
postponement of projects and new techniques,<br />
the consolidation and standardization of<br />
systems, and through server virtualization,<br />
operational costs could by reduced by 20%.<br />
Thanks to the ‘virtualization of servers’,<br />
several applications can run on one server,<br />
which means fewer servers are necessary,<br />
and therefore less power and lower costs.<br />
This then is process innovation and it fits in<br />
nicely with <strong>TenCate</strong>’s Green IT objective.<br />
in america<br />
By the end of 2010 <strong>TenCate</strong> Gr<strong>as</strong>s in Dayton<br />
(Tennessee) and <strong>TenCate</strong> Advanced Armour
<strong>TenCate</strong> is putting the finishing touches to realizing the global <strong>TenCate</strong> network. all the <strong>TenCate</strong> companies across the<br />
world will be interconnected within this global iT network. a process of over three years will then be complete. result: rapid,<br />
reliable communication and iT support accessible to all, <strong>as</strong> well <strong>as</strong> cost efficiency and a contribution to a clearcut<br />
presentation of the company.<br />
(Newark, Ohio) will be connected up with the<br />
IT shared service centre USA according to<br />
plan. The IT department of <strong>TenCate</strong> Protective<br />
Fabrics USA is responsible for the IT shared<br />
service centre USA. With this, 90% of all<br />
<strong>TenCate</strong> companies will be standardized. The<br />
shared service centre USA will be operational<br />
from January 2011. Just <strong>as</strong> in the Netherlands,<br />
the hosting will fall under an external partner<br />
that will provide IT services. Next year all<br />
the remaining <strong>TenCate</strong> companies in the<br />
United States will likewise be connected<br />
up. For the time being this does not apply to<br />
<strong>TenCate</strong> Geosynthetics. The IT systems of this<br />
group are b<strong>as</strong>ed on IBM technology. Given<br />
the investment involved in the migration to<br />
the Global <strong>TenCate</strong> Network, this work is<br />
on hold until ‘a natural time slot’ arises.<br />
Hitching a ride<br />
At the moment the Asian companies are<br />
‘hitching a ride’ on the SSC EMEA, but in 2011<br />
the SSC Asia will be realized. <strong>TenCate</strong> h<strong>as</strong><br />
facilities in Singapore, Hong Kong, Malaysia<br />
and China (Zhuhai), and an investigation is<br />
being carried out to see which of these four<br />
is the best location for the shared service<br />
centre. It will examine such <strong>as</strong>pects <strong>as</strong><br />
languages, reliability of the infr<strong>as</strong>tructure,<br />
and restrictions imposed by government<br />
authorities on, for example, internet traffic.<br />
When this unit h<strong>as</strong> also been completed,<br />
<strong>TenCate</strong> will have a worldwide network<br />
that can rival the best in terms of process<br />
optimalization and cost efficiency.<br />
• global <strong>TenCate</strong> network h<strong>as</strong> three iT<br />
shared service centres worldwide and<br />
ensures optimal communication and cost<br />
efficiency<br />
• project fits in with the pursuit of<br />
sustainable iT<br />
• middle of 2011 will see choice of<br />
location for iT centre in <strong>as</strong>ia<br />
33
Sustainability / Environment<br />
TenCaTe CompoSiTeS in CLimaTe-neUTraL veHiCLe<br />
Sustainable driving<br />
to antarctica<br />
34 txtures | number 4 | winter<br />
in January 2012 mountaineer and ‘adventurer’ wilco van rooijen and co-pilot Fokke van velzen are embarking on a<br />
trip to the South pole with a Co2-neutral vehicle running on solar energy. part of the bodywork consists of <strong>TenCate</strong><br />
composites. with this expedition, Team wilco wants to highlight the importance of sustainable energy and draw<br />
attention to the fact that in 2048 this continent will no longer enjoy protected status.<br />
The vehicle is designed by Team Antarctica, students at the<br />
Faculty of Natural Sciences and Technology of the University<br />
of Applied Sciences Utrecht. The climate-neutral vehicle that<br />
they are now building is powered by solar energy. It seats two<br />
people, can drive on granular snow <strong>as</strong> well <strong>as</strong> hard ice waves,<br />
h<strong>as</strong> a speed of 15 to 20 km an hour, and can cover a distance<br />
of 2300 km. Because it is equipped with solar cells, it is sturdy<br />
in build and <strong>TenCate</strong> Cetex ® h<strong>as</strong> been selected to limit the<br />
weight. This composite laminate b<strong>as</strong>ed on carbon fibre is<br />
manufactured by Ten Cate Advanced Composites in Nijverdal.<br />
<strong>TenCate</strong> Cetex ® can withstand the low temperatures during<br />
this period in Antarctica.<br />
reinforcement<br />
Panels of <strong>TenCate</strong> Cetex ® are processed for reinforcement<br />
purposes in the lid of the boot (where the solar cells are<br />
installed), in the interior of the bonnet and the doors, <strong>as</strong> well<br />
<strong>as</strong> in the climate box. This is the electronic component that<br />
contains sensors and other parts that cannot withstand the<br />
extreme cold. The material w<strong>as</strong> deliberately chosen: ‘We<br />
were looking for a reliable partner who is big enough and is<br />
b<strong>as</strong>ed in the Netherlands,’ explains Emma Recter (product<br />
design & engineering). ‘<strong>TenCate</strong> seemed to be the right place<br />
to find the desired materials, and we’re very ple<strong>as</strong>ed that we<br />
can use this material.’ Besides materials, <strong>TenCate</strong> is delivering<br />
technical support.<br />
With this expedition the team wants to demonstrate that it is<br />
possible to travel CO2-neutrally across Antarctica to the<br />
South Pole. Wilco van Rooijen and Fokke van Velzen hope to<br />
cover the distance of 2300 km in 30 days.<br />
protected<br />
Antarctica is the coldest place on Earth. Once a temperature<br />
of -89.2 C w<strong>as</strong> registered some 1000 km from the South Pole.<br />
The continent is almost completely covered with ice.<br />
Currently this continent is still protected by the Environmental<br />
Protocol, part of the Antarctic Treaty, against drilling for<br />
minerals. The protection by this protocol ends in 2048. This<br />
project is intended to provoke dialogue with the pundits and<br />
government leaders of the future. ‘By making the youngsters<br />
of today aware of this virgin continent and the possibilities of<br />
sustainable energy, they can later protect Antarctica.’<br />
www.tencateaerospacecomposites.com<br />
www.teamantarctica.nl
Innovation<br />
TenCaTe SponSorS kanJa ULTraLigHT gLiDer<br />
glider with<br />
composites<br />
<strong>TenCate</strong> composite materials are used in large and small<br />
aircraft, but application in gliders is rather less common.<br />
Carbon composites from Ten Cate Advanced Composites<br />
in Nijverdal are used in the wing ribs of the lightweight<br />
Kanja glider. This a project carried out by eight students at<br />
INHolland University of Applied Sciences. The wing of the<br />
glider spans 11 metres, with a surface area of 10.35 m².<br />
Through sponsoring in kind, <strong>TenCate</strong> wants to familiarize<br />
students here too with the processing and possibilities<br />
of strong and lightweight composites. In the realm of<br />
gliding there is considerable demand for high-grade,<br />
ultralight aircraft.<br />
The Kanja w<strong>as</strong> exhibited at the Composites Europe Fair<br />
in Essen, the biggest trade fair for composites in Europe.<br />
At the exhibition the team members were clothed in<br />
overalls b<strong>as</strong>ed on protective materials sponsored by<br />
<strong>TenCate</strong> Protective Fabrics.<br />
www.tencateaerospacecomposites.com<br />
www.kanja.nl<br />
35
Sustainability / Environment<br />
TenCaTe oUTDoor FaBriCS UnveiLS viSion<br />
36 txtures | number 4 | winter<br />
Tents of the future<br />
The future of the camping world will be determined<br />
by new designs and innovative functionalities.<br />
When it comes to design, manufacturers<br />
of tents and awnings will be making incre<strong>as</strong>ing<br />
use of young designers. As far <strong>as</strong> functionalities<br />
are concerned, the developments are focused<br />
on self-cleaning and insulating capabilities, high<br />
visibility, glow in the dark, and an anti-mosquito<br />
finish. The glow-in-the-dark finish will afford<br />
night visibility thanks to the sunlight absorbed<br />
during the day. This ensures that the tents are<br />
clearly visible at any time of the day or night for<br />
emergency services and the army. A special finish<br />
smelling of lemon can keep mosquitoes away.<br />
www.tencateoutdoorfabrics.com<br />
outdoorfabrics.europe@tencate.com<br />
www.youtube.com/watch?v=jimibSU6jwi<br />
Self-cleaning Insulating<br />
Anti-mosquito
in 2010 <strong>TenCate</strong> outdoor Fabrics w<strong>as</strong> again present at the Camping and Caravan Show – with a digital stand.<br />
at www.outdoorlivinginthefuture.com the company presented its vision on existing and future functionalities<br />
of fabrics for tents. moreover the digital presentation underlined the fact that <strong>TenCate</strong> outdoor Fabrics is<br />
technologically driven and works on product differentiation and innovation.<br />
High-visibility Glow in the Dark (night visibility thanks<br />
to sunlight absorbed during the day)<br />
37
Sponsoring<br />
TenCaTe graSS aT worLD eXpo 2010<br />
38 txtures | number 4 | winter
Better<br />
gr<strong>as</strong>s<br />
The Dutch pavilion in Shanghai attracted over<br />
7 million visitors. every day thousands of Chinese<br />
took advantage of the opportunity to relax in a park<br />
equipped with <strong>TenCate</strong> gr<strong>as</strong>s.<br />
The Netherlands could rejoice in considerable<br />
international interest during the World Expo Better City.<br />
Better Life in Shanghai (China). The pavilion Happy<br />
Street welcomed more than 7 million visitors − a feat<br />
that placed the Netherlands among the top 5 most<br />
visited pavilions. Many took a peek at this compact<br />
dynamic city, which w<strong>as</strong> organically constructed by<br />
designer and architect John Körmeling along a<br />
pedestrian strip in the form of the Chinese lucky number<br />
8 and illustrated every facet of Dutch life.<br />
Beneath this elevated city w<strong>as</strong> a kind of Vondelpark in<br />
miniature with synthetic turf (made from fibres and<br />
backing from <strong>TenCate</strong> Gr<strong>as</strong>s). Every day thousands of<br />
visitors, including many Chinese, sought the shade to rest<br />
for a while.<br />
The World Expo closed at the end of October and the<br />
pavilion is now being dismantled. The materials will be<br />
reused or recycled.<br />
Over the p<strong>as</strong>t years <strong>TenCate</strong> h<strong>as</strong> built up a leading<br />
position in the Asian synthetic turf market. This market is<br />
characterized by consistent growth, which is stimulated<br />
by an incre<strong>as</strong>ing number of new users and a growing<br />
preference for synthetic turf.<br />
www.tencategr<strong>as</strong>s.com<br />
gr<strong>as</strong>s.<strong>as</strong>ia@tencate.com<br />
photo: Peter Cox<br />
39
Innovation<br />
TenCaTe preSenTeD wiTH awvn innovaTion awarD<br />
recognition for<br />
social innovation<br />
royal Ten Cate h<strong>as</strong> received the quarterly innovation award and with<br />
this h<strong>as</strong> also been nominated for the awvn annual innovation<br />
award 2010. awvn (the general employers’ <strong>as</strong>sociation) praised <strong>TenCate</strong><br />
for its integrated approach to technological and social innovation.<br />
40 txtures | number 4 | winter<br />
According to the jury, <strong>TenCate</strong> sets the trend in product and<br />
process innovation in its core markets through ‘an appealing<br />
vision, entrepreneurship, the consistent implementation of<br />
the strategy and corresponding core values: progressiveness,<br />
proficiency, inventiveness and reliability. These core values<br />
are translated within the organization and the HR policy in<br />
such a way that the AWVN Innovation Trophy for social<br />
innovative policy is thoroughly deserved.’<br />
Ron Bijkersma, <strong>TenCate</strong> corporate director HRM, sees it <strong>as</strong> an<br />
‘award for the whole body of work. The AWVN is enormously<br />
impressed by the transformation we have undergone. We<br />
have consistently reinvented ourselves, and you can only do<br />
that by taking good care of your people and by innovating.’<br />
Development<br />
Social innovation is an integral part of <strong>TenCate</strong>’s whole<br />
company policy, especially the management model and the<br />
company philosophy. The company applies a clear business<br />
model and a flat management model. Authorities and<br />
responsibilities are established decentrally <strong>as</strong> far <strong>as</strong> possible,<br />
with the exception of those matters that must be centralized.<br />
‘In this way you get entrepreneurs rather than managers. By<br />
giving employees freedom and responsibilities, there is room<br />
for creativity and you create entrepreneurship. That’s how<br />
innovative power is stimulated within the company. There’s<br />
no actual blueprint but this philosophy incorporates an<br />
important b<strong>as</strong>is for innovative entrepreneurship. We’re<br />
therefore on the lookout for entrepreneurial people. And the<br />
fact that people like working for <strong>TenCate</strong> is also a<br />
contributive factor.’<br />
Ron Bijkersma, corporate director HRM<br />
Schooling and training<br />
Social innovation also takes shape within the <strong>TenCate</strong><br />
People Programme, a schooling and training programme<br />
that stimulates employees to look at new or other<br />
product-market-technology combinations. Within the<br />
<strong>TenCate</strong> Active programme, which is part of this, potential<br />
managers from different market groups worldwide work<br />
intensively together. ‘We try to see that exchange<br />
between managers and workers takes place <strong>as</strong> much <strong>as</strong><br />
possible,’ says Ron Bijkersma. ‘This cross-fertilization<br />
leads to new ways of working and new products and<br />
services.’<br />
Because of the economic circumstances, <strong>TenCate</strong><br />
soft-pedalled the training programme to a certain extent in<br />
2009 and at the start of 2010. Nevertheless, the<br />
international <strong>TenCate</strong> Business Game w<strong>as</strong> wound up in<br />
2010. Activities will again be initiated within the <strong>TenCate</strong><br />
Active and <strong>TenCate</strong> Talent programmes in 2011.<br />
• awvn impressed by the transformation that<br />
<strong>TenCate</strong> h<strong>as</strong> undergone<br />
• By giving employees freedom and responsibilities,<br />
<strong>TenCate</strong> provides room for creativity and<br />
entrepreneurship<br />
• activities will again be initiated within the <strong>TenCate</strong><br />
active and <strong>TenCate</strong> Talent programmes<br />
www.tencate.com
Safety & Protection<br />
TenCaTe TeCaSaFe® pLUS gainS groUnD<br />
key products in quality and durability<br />
<strong>TenCate</strong> protective Fabrics is continuing to work on product differentiation, innovation and end-user marketing. The <strong>TenCate</strong><br />
Tec<strong>as</strong>afe ® and the <strong>TenCate</strong> Defender m platforms are being expanded. incre<strong>as</strong>ingly stringent demands and the desire for more<br />
cost-efficient solutions also lie at the bottom of this. Through directly approaching the customer and end-user, these become<br />
acquainted with the characteristics, durability and cost benefit of these and other protective fabrics.<br />
Daniel Hauert (middle) (president <strong>TenCate</strong> Protective Fabrics USA) at the international trade fair for safety and<br />
protection in São Paulo (Brazil)<br />
At the beginning of October three teams from<br />
<strong>TenCate</strong> Protective Fabrics USA showc<strong>as</strong>ed<br />
Tec<strong>as</strong>afe ® Plus, <strong>TenCate</strong> O<strong>as</strong>is and <strong>TenCate</strong><br />
Tuffweld ® in North and South America, with a view<br />
to promoting these three key products. These<br />
<strong>TenCate</strong> materials are b<strong>as</strong>ed on own fibre blends<br />
developed for specific applications. <strong>TenCate</strong> O<strong>as</strong>is<br />
is an inherently fire-resistant fabric that is light in<br />
weight and offers protection against, for example,<br />
molten aluminium spattering and radiation heat. It<br />
is therefore applied extensively in the aluminium<br />
industry. <strong>TenCate</strong> Tuffweld ® is a flame-retardant,<br />
protective fabric competitively priced for the<br />
clothing of welders, mechanics and the like.<br />
Successfully launched on the market for industrial<br />
safety in the United States at the beginning of<br />
2007, <strong>TenCate</strong> Tec<strong>as</strong>afe ® Plus is the most popular<br />
fabric of the three.<br />
Further development<br />
<strong>TenCate</strong> Tec<strong>as</strong>afe ® Plus is a further development of<br />
<strong>TenCate</strong> Tec<strong>as</strong>afe ® in Europe. It owes its US<br />
success to the focused end-user marketing in the<br />
US <strong>as</strong> well <strong>as</strong> the quality of the material. It is<br />
reliable, cost-efficient, and is more comfortable and<br />
h<strong>as</strong> greater durability than the industrial flameretardant<br />
fabrics of other suppliers. Safety and<br />
protection of workers is high on the agenda in the<br />
US too. This explains why 2 million metres of<br />
<strong>TenCate</strong> Tec<strong>as</strong>afe ® Plus have left the production<br />
facilities to date (October 2010) − an amazing<br />
achievement for such a new product in a mature<br />
market with numerous competitors. In view of the<br />
price and durability, it means an important cost<br />
advantage for industrial laundries and rental<br />
services. So <strong>TenCate</strong> Protective Fabrics scores also<br />
in terms of cost leadership.<br />
electric arc protection<br />
One specific application of <strong>TenCate</strong> Tec<strong>as</strong>afe ® Plus<br />
concerns equipping the American navy in risk cl<strong>as</strong>s<br />
2 electric arc protection in compliance with NFPA<br />
(National Fire Protection Association) standards.<br />
A five-year contract w<strong>as</strong> recently concluded in this<br />
respect. <strong>TenCate</strong> Protective Fabrics USA h<strong>as</strong><br />
collaborated with the navy and its customer<br />
UniFirst on a version that is Berry Compliant, which<br />
means to say in accordance with the Berry<br />
Amendment. This relates to the purch<strong>as</strong>e of<br />
articles, including fabrics, manufactured preferably<br />
in the home country. The development started after<br />
an investigation into alternatives to the current<br />
fire-resistant cotton fabric, which had caused<br />
comment <strong>as</strong> far <strong>as</strong> thermal and allergenic properties<br />
were concerned. The new version of <strong>TenCate</strong><br />
Tec<strong>as</strong>afe ® Plus w<strong>as</strong> developed by Craig Tutterow<br />
(senior development engineer), while John<br />
Blackmon (marketing manager air force and navy),<br />
through his contacts with the Department of the<br />
Navy, and Peggy Holcomb (industrial sales<br />
manager), who coordinated the activities with<br />
UniFirst, also contributed to this positive result.<br />
Since August 2010 the cotton fabric used up till<br />
then h<strong>as</strong> been replaced by <strong>TenCate</strong> Tec<strong>as</strong>afe ® Plus.<br />
Coupled with end-user marketing<br />
The teams – consisting of sales & marketing<br />
managers and a product developer – have been<br />
present at leading trade fairs, conventions and the<br />
like. Craig Tutterow and Mike Stanhope (global<br />
manager for product development) were at the<br />
National Safety Congress in San Diego, where they<br />
also attended the meeting of the NFPA Standards<br />
Committee. The NFPA is a US authority in the field<br />
of fire safety. Charles Dunn (director of product<br />
development) helped a team during the National<br />
Electrical Contractors Association convention in<br />
Boston. <strong>TenCate</strong> Tec<strong>as</strong>afe ® Plus h<strong>as</strong> also been<br />
enthusi<strong>as</strong>tically received in the end-user market<br />
for electronics.<br />
www.tencateprotectivefabrics.com<br />
protectivefabrics.america@tencate.com<br />
41
Safety / Protection<br />
TenCaTe DeFenDer m SaLeS ConTinUe To grow<br />
<strong>TenCate</strong> Defender M fabrics are repeatedly chosen by the American army and the American marine corps for the<br />
FR-ACU and FROG programmes for their ground troops<br />
42 txtures | number 4 | winter
protection<br />
US army<br />
and navy<br />
a significant rise in the demand for <strong>TenCate</strong> Defender m is indicated in the fourth quarter of 2010,<br />
and sales amounting to approximately 60 million US dollars are anticipated for this quarter (fourth<br />
quarter 2009: 29 million US dollars). The incre<strong>as</strong>e in demand is expected to continue well into the<br />
first quarter of 2011. The success of <strong>TenCate</strong> Defender m fabrics is b<strong>as</strong>ed on the unique blend and<br />
application of the Lenzing Fr fibre.<br />
The rise in growth began in the third quarter,<br />
after a temporary relapse in sales <strong>as</strong> a result of<br />
changes in the camouflage print. The <strong>TenCate</strong><br />
Defender M fabrics now supplied are<br />
processed in the Flame Resistant Army Combat<br />
Uniform (FR-ACU) of the American army and in<br />
the Flame Resistant Organizational Gear<br />
(FROG) issued by the navy. <strong>TenCate</strong> Defender<br />
M fabrics are repeatedly chosen by the<br />
American army and the American marine corps<br />
for the FR-ACU and FROG programmes for their<br />
ground troops.<br />
Blend<br />
<strong>TenCate</strong> Defender M is durable and h<strong>as</strong> good<br />
wear resistance and excellent colourf<strong>as</strong>tness.<br />
It offers not only protection against heat and<br />
fire, but also antistatic properties and room to<br />
move. This is attributable to the self-developed<br />
blend of fibres that are used to make <strong>TenCate</strong><br />
Defender M. Together with fibre<br />
manufacturer Lenzing (Austria), knowledge is<br />
shared regarding the development and<br />
production of fire-resistant fabrics using fibres<br />
that are inherently fire-resistant and<br />
comfortable. The Lenzing FR® fibre is an<br />
important ingredient in <strong>TenCate</strong> Defender M<br />
fabrics. In contr<strong>as</strong>t to other fire-resistant fibres,<br />
the Lenzing FR® offers inherent fire-resistant<br />
characteristics, while at the same time the fibre<br />
absorbs moisture. This combination allows the<br />
fabric to breathe and ensures comfort.<br />
www.tencateprotectivefabrics.com<br />
protectivefabrics.america@tencate.com<br />
43
Sustainability / Environment<br />
TenCaTe CeTeX ® roUnD engine BLoCk oF ConCepT Car<br />
44 txtures | number 4 | winter<br />
Historic<br />
car make revived<br />
avions voisin, an historic French car make, is soon to take on a second le<strong>as</strong>e of life. in a hangar on the Twente air b<strong>as</strong>e,<br />
work is in progress on a new, luxury concept car with this name. Design, sustainability and eco-efficiency are of paramount<br />
importance in this mobility concept – that’s also why <strong>TenCate</strong> Cetex® is one of the materials applied.
Visitors to the AutoRAI in April 2011 will<br />
probably see its first outing and be eyewitnesses<br />
to the revival of Avions Voisin. The<br />
hand-made Voisin A-JT is the brainchild of<br />
Mattthijs Meulenbelt and Frans Lievaart. These<br />
two Delft engineers are working on this jointly<br />
with the University of Twente, where they are<br />
responsible for the m<strong>as</strong>ter cl<strong>as</strong>s on automotive<br />
design. As an innovative Dutch car company,<br />
they are going to design and build hand-made<br />
cars for the executive sector.<br />
Heat resistant<br />
The bodywork of the prototype consists mainly<br />
of aluminium, which makes the car lighter and<br />
ensures fuel savings., The temperature in the<br />
engine compartment can rise considerably, so<br />
that’s why <strong>TenCate</strong> Cetex ® is used here. This<br />
material is durable and heat-resistant, and<br />
consists of a Nomex honeycomb core between<br />
two carbon layers.<br />
Every component is scrutinized for possibilities<br />
to save costs and fuel, and the ide<strong>as</strong> being<br />
developed in this respect are also interesting<br />
for the car industry <strong>as</strong> a whole. Applications<br />
have now been made for patents in a number of<br />
c<strong>as</strong>es. The sale price will be around €75,000.<br />
The prototype in aluminium will be unveiled at<br />
the AutoRAI.<br />
revolutionary<br />
Gabriel Voisin w<strong>as</strong> an aviation pioneer, who<br />
from 1919 applied his experiences and<br />
revolutionary ide<strong>as</strong> to cars. Until 1939 the<br />
company produced luxury cars. The design of<br />
the second-generation Voisin is taking careful<br />
account of the buyer’s wishes. M<strong>as</strong>s production<br />
is out of the question, so the A-JT is not a car<br />
for the multitude; it is distinctive – just like the<br />
<strong>TenCate</strong> materials it incorporates.<br />
• Concept car seeks to be distinctive and<br />
eco-efficient<br />
• <strong>TenCate</strong> Cetex ® is being applied in the<br />
first instance in engine compartment<br />
45
Sustainability / Environment<br />
TenCaTe geoSYnTHeTiCS USa eDUCaTeS STUDenTS in geoTeXTiLeS<br />
46 txtures | number 4 | winter<br />
geosynthetics<br />
in the college desks<br />
once every year or two <strong>TenCate</strong> geosynthetics USa welcomes students in their final year who wish to get their bearings<br />
in the production and possibilities concerning the design and application of geosynthetics. within this context a group<br />
of students in Civil and environmental engineering at the University of north Carolina (US) recently paid a visit to the<br />
production facilities in pendergr<strong>as</strong>s and Cornelia (georgia, US).<br />
The students, with on the right Prof. Kimberly Warren, professor of Geotechnical Engineering, Geosynthetics and Soil Improvement Techniques<br />
Prior to the visit Fred Chuck (director reinforcement<br />
markets) gave a presentation on the<br />
campus on the diversity of geosynthetics, their<br />
applications and how to distinguish between<br />
the different types of wovens, non-wovens<br />
and geogrids. The visits to the plants in<br />
Jefferson and Cornelia were coordinated and<br />
managed by Bruce Lacina (senior engineer).<br />
authority<br />
For <strong>TenCate</strong> the most important feature of<br />
such visits is helping to confirm <strong>TenCate</strong><br />
Geosynthetics <strong>as</strong> the authority on the<br />
manufacture of geosynthetics. Attention is also<br />
paid to the practical side, with the universities<br />
being briefed <strong>as</strong> far <strong>as</strong> possible about current<br />
projects where geosynthetics are being applied.<br />
The response of the students to their visit h<strong>as</strong><br />
been very good, and an additional advantage<br />
is that students will be predisposed to value<br />
<strong>TenCate</strong> positively during their future career.<br />
www.tencategeosynthetics.com<br />
geosynthetics.america@tencate.com
txtures in 2011<br />
Looking aHeaD To THe Spring eDiTion<br />
Theme: Connected with end-user marketing<br />
<strong>TenCate</strong> seeks to know what motivates its<br />
end-users and what their requirements are. This<br />
is why it is stepping outside its traditional role of<br />
supplier. <strong>TenCate</strong> is allowing itself to be inspired<br />
by the challenges that it sees in its direct<br />
contacts with the end market. This does not<br />
mean, however, that <strong>TenCate</strong> will deal directly<br />
iaa award of excellence for 2010<br />
In 2010 <strong>TenCate</strong> Geosynthetics North<br />
America h<strong>as</strong> for the fifth time won the IAA<br />
Award of Excellence in the Geosynthetic<br />
Products category. This is the sixth year in a<br />
row that the company h<strong>as</strong> won an IAA<br />
award. The winning project w<strong>as</strong> our<br />
contribution to the Incheon Bridge Project in<br />
South Korea.<br />
‘We are honoured to have been awarded the<br />
2010 IAA Award of Excellence for <strong>TenCate</strong><br />
Geosynthetics’, John Henderson, Senior<br />
Vice-President at <strong>TenCate</strong> Geosynthetics<br />
innovatie route Twente<br />
<strong>TenCate</strong> is a partner in the Innovatie Route<br />
Twente. The presentation of the report ‘Op Koers’<br />
(On Course) w<strong>as</strong> given on 20 October l<strong>as</strong>t.<br />
This related to a study of the innovation route,<br />
which w<strong>as</strong> carried out by the E<strong>as</strong>tern Netherlands<br />
Audit Office. <strong>TenCate</strong>’s activities in the context of<br />
regional innovation programmes will be explained<br />
in txtures and an outline will be given of their<br />
connection with the company’s strategic themes.<br />
Volume 44 – number 4 – winter 2010<br />
with the end-user. The company is familiarizing<br />
the market with the possibilities and <strong>as</strong> a result<br />
is endeavouring to exert influence on the<br />
specifications, quality criteria and/or functional<br />
requirements that end-users lay down.<br />
‘Connected with the end-user’ is the theme of<br />
the 2010 annual report.<br />
NA, said. ‘We are also proud to have won<br />
an IAA Award for the sixth straight year.<br />
This year’s winning entry, submitted by Yee<br />
Tack Weng, highlights <strong>TenCate</strong>’s unique<br />
position to provide solutions for critical<br />
projects around the globe.’<br />
2010 annual figures<br />
<strong>TenCate</strong> will publish its 2010 annual figures<br />
on 2 March and in this edition we will provide<br />
the background to the results achieved.<br />
Digitex<br />
conference<br />
The 2010 Digitex conference will be held in<br />
Bergamo and Gr<strong>as</strong>sobio (Italy) on 2 & 3 December.<br />
At this conference the results of the Digitex project<br />
will be shown and new process technologies presented.<br />
There will also be an impression given of<br />
the new functionalities that can be achieved with it.<br />
txtures is a corporate review of Royal Ten Cate for its employees and external stakeholders. The magazine is<br />
published four times a year in a Dutch and English version. Reproduction of articles or parts of articles is authorized,<br />
providing the source is acknowledged and that p<strong>as</strong>sages and quotations are not placed in a different context.<br />
editor’s address Translations Design printing<br />
Royal Ten Cate Gay Howells DeNK•creatieve vrijdenkers LulofDruktechniek<br />
Coen Heldeweg (chief editor)<br />
phone +31 546 544 305<br />
c.heldeweg@tencate.com<br />
Janice Collins Almelo Almelo<br />
47
Our sandwiches are stiff panels<br />
In the world of aerospace, it is vital that all systems work perfectly, to guarantee lifelong service. As a leader in high<br />
performance composites for primary and secondary aerostructures, <strong>TenCate</strong> supplies materials that can provide the<br />
lightest weight and highest strength, whilst making no compromise to safety.<br />
<strong>TenCate</strong> supplies the aerospace industry with <strong>TenCate</strong> Cetex® and its derivative sandwich panels, which are also<br />
used in aircraft trolleys. So, the next time you bite into your sandwich at 20,000 feet, just remember that it w<strong>as</strong> kept<br />
fresh between a set of rigid, yet lightweight trolley panels.<br />
www.tencateadvancedcomposites.com