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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

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