High technology elastomers – casting a wider net Library/a... · features an interview (pages 6...
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Resin technology helps win innovation award Opening the way to a more energy efficient future PU roof tiles used to battle the elements Long-lasting bonds in the engineered wood market High technology elastomers – casting a wider net REPORTING THE WORLD OF POLYURETHANES FOR OUR CUSTOMERS www.huntsman.com/pu July 2016
Transcript of High technology elastomers – casting a wider net Library/a... · features an interview (pages 6...
Resin technology helps wininnovation award
Opening the way to a moreenergy efficient future
PU roof tiles used to battlethe elements
Long-lasting bonds in theengineered wood market
High technology elastomers –casting a wider net
REPORT ING THE WORLD OF POLYURETHANES FOR OUR CUSTOMERS
www.huntsman.com/pu
July 2016
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PUbriefing July 2016
Strengthening our differentiated elastomer products offerTony Hankins, President, Huntsman Polyurethanes
At Huntsman Polyurethanes we have a strategic focus on building our downstream footprint and capabilities, to betterprovide the innovative, differentiated products and solutions that our customers need. Our most recent acquisition,Tecnoelastomeri S.r.l., is celebrating its first anniversary as a part of the Huntsman ‘family’ and this issue of PU Reviewfeatures an interview (pages 6 to 8) with Dr. Alessandro Gramellini, Global Business Director of the Business.
Tecnoelastomeri is a highly regarded manufacturer of MDI-based hot-cast elastomer systems and processing machines that was founded in 1985 by Dr. Gramellini’s father, Ermes, and is based in Modena, Italy. Its high technology elastomersystems – marketed under the TECNOTHANE™ brand – are used to create a wide variety of industrial applications, including bumper pads, coated conveyor belts, gears, rollers and wheels – which are used in the automotive, rail, oil and gas, mining and steel industries, among others.
The addition of Tecnoelastomeri’s highly experienced team to our Polyurethanes business has significantly strengthened our offer to the growing, downstream hot-cast elastomer markets globally. Together with our innovative thermoplasticpolyurethane (TPU) product range, we now have the largest portfolio of polyurethane elastomers that are based on MDI technology.
If you’re visiting Utech Asia in Shanghai this August, or the K trade fair in Dusseldorf in October, Huntsman Tecnoelastomeriwill be there, together with the rest of our team. So please come visit our booth – we’d love to talk to you!
The deal builds on a prior arrangementbetween the two companies, which coveredFrance, Benelux, Germany and Austria. Thenew countries added include Poland, CzechRepublic, Slovakia, Hungary, Bulgaria,Romania, Croatia, Serbia, Bosnia, Moldaviaand Albania.
Previously, Huntsman supplied customers inthese countries direct. However, with demandfor its ACE chemistries growing in thesemarkets, the team decided it was the right time to hand distribution to a trusted partner.Products covered by the new agreementinclude some of Huntsman’s core polyurethanechemistries, such as SUPRASEC®MDI, as well as related products and crosslinkingtechnologies for industrial adhesiveapplications.
Johan Van Tongelen, Commercial Director atHuntsman Polyurethanes, said: “The time isright to grow our ACE business in East Europe,and working with an experienced distributor isthe best way to achieve this. We know that
many of our customers value the extra flexibilitythat comes from sourcing products via a thirdparty. One of the main advantages is access toa range of complementary products. We’veworked with Azelis since 1993 and know thiswill continue to be a fruitful partnership withbenefits for all concerned.”
Azelis has recently made a series ofinvestments at its technical center in SanktAugustin, Germany – a move that will helpcompanies sourcing Huntsman’s polyurethaneproducts through the business. At the site nearCologne, Azelis has expanded the capabilitiesof its coatings application laboratory, whichcontains equipment dedicated to theformulation of coatings and the testing ofpolyurethanes for thin-layered elastomerapplications. Azelis has also hired additionalskilled commercial staff to sell the specialtychemicals it distributes.
For formulators purchasing Huntsmanproducts from Azelis, the investment inadditional technical equipment will have a
number of advantages. With the latestmachinery on hand, Azelis will be able to testproducts and systems on behalf of customers– helping to cut costs, simplify decision-makingand reduce time to market. There will also besynergies for suppliers of polyols and additivesusing MDI-based products from Huntsman tocreate specialist coatings. |
Huntsman has extended the scope of its working relationship with Azelis –one of its distribution partners. Under the terms of a new agreement, Azelisis now supplying key polyurethane products and systems from Huntsman’sadhesives, coatings and elastomers (ACE) range throughout Eastern Europe.
Huntsman extends cooperation with Azelis
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Resin technology helps Bright LiteStructures win Innovation Award
The chassis is based on a patent-pending,structural carbon fiber composite system thatis lighter, more versatile, less expensive andfaster to manufacture than conventionalcomposite fibers. The system uses Huntsman’sVITROX resin technology.
The chassis is made from a novel sandwichconstruction with a thin layer of recycled and virgin carbon fiber and a central core ofrecycled plastic honeycomb. Huntsman’sVITROX resin system and automotive resintransfer molding (RTM)-grade epoxy are usedto form the skins and bond these elements to the plastic honeycomb core.
The chassis manufacturing process is capableof molding complex, deep draw designs in one step. Normally, this would not be possiblewithout complex and expensive pre-formingand a significantly larger capital expenditure.Huntsman’s VITROX resin system has beendesigned to have a low, stable initial viscositywith minimal viscosity increase; followed by atunable induction period; and then a full, snapcure. This reaction behaviour enables longworking times in the fabrication of large partsfor automotive and other applications. At thesame time, the VITROX resin system maintainsthe high physical property performance andimpact strength for which polyurethanecomposite resin systems are renowned.
Antony Dodworth, Chief Technology andManufacturing Officer at Bright Lite Structures,said: “This award would not have beenpossible if Huntsman had not supported andencouraged individual staff to work with BrightLite Structures to develop a better compositefiber solution that addresses many of thedrawbacks of conventional carbon fiber.”
This accolade is the second award forHuntsman’s VITROX resin technology, whichreceived the Center for the PolyurethanesIndustry’s (CPI) Polyurethane InnovationAward in 2012 for a cure-in-place pipe (CIPP) application.
The mission of SPE ACCE is to inform andupdate the automotive industry about theincreasing significance of thermoset andthermoplastic composites in passengervehicles, light trucks and other modes ofground transportation. |
Huntsman’s VITROX®resin technology helped Bright Lite Structures win a prestigiousindustry award at the 2015 Society of Plastics Engineers (SPE) Automotive CompositesConference & Exhibition (ACCE). The event took place in September in Michigan.Bright Lite Structures took home the ‘Most Innovative Composites Part’ award in theMaterials Innovation category for its Zenos E10 sports car chassis.
New web channel for ordering onlineHuntsman has launched a new web channel to make it easier forcustomers to order its polyurethane products and systems online.
ECHO, which stands for Energizing Customers for Huntsman Online, is an e-commerce platform that enables customers to order what they need quickly and efficiently, 24 hours-a-day, seven days-a-week. Customers can use ECHO to place new orders and reorder products; review orderhistory; check invoice details and status; preview and download documents (delivery notes, invoices,certificates of analysis and safety data sheets) and keep up-to-date with the latest Huntsman news.
ECHO was created to give Huntsman customers additional channels and self-service options to use when they want, and during times when Huntsman customer service representative may not be available. ECHO is accessible via an iPad®, iPhone®or other mobile devices. |
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Working together, Huntsman, the ShanghaiCollodin Material Science & TechnologyDevelopment Co., Ltd., and Owens Corning,developed TICO PUR Energy-Efficient Windowand Door System – an airtight, wind-resistantframe that can reduce heat loss by up to 18%compared to traditional aluminium or PVCmodels with metal stiffeners.
Designed in response to China’s prioritization ofenergy efficiency and sustainable development,TICO products are manufactured using aninnovative pultrusion continuous moldingprocess, which employs Huntsman’spolyurethane chemistry.
During production, fibers are reinforced throughsaturation with a liquid polymer resin. They arethen carefully formed and pulled through aheated dye. The resin used in the pultrusionprocess is a two-component system based onHuntsman’s RIMLINE®polyol blend andSUPRASEC®MDI isocyanate. This specialcombination delivers excellent wettingcharacteristics, accelerated line speeds andlow pull forces. The resulting resin system iswell suited for structural profiles in demandingapplications where superior strength anddurability are required.
Sun Shenggen, President of the ShanghaiCollodin Material Science & TechnologyDevelopment Co. Ltd., said: “In addition to thehigh material performance and ease ofprocessing delivered by Huntsman’s resinsystem, the technical input and set-up
assistance provided by the company was key– enabling us to continuously pultrude thecomplex, multi-mandrel TICO window lineals.”
Enshan Sheng, Director of Huntsman’s AsiaTechnology Center in Shanghai, said: “Heatloss through windows and doors accounts foraround half of a building’s energy consumption.Chinese authorities estimate that upgrading tomore energy efficient models could savearound 420 million tons of coal per year – 10%of the nation’s annual output. This wouldrepresent a major step forward in China’sefforts to save energy and reduce air pollution.We are honored that our efforts with ShanghaiCollodin and Owens Corning have beenrecognized by Shanghai’s municipalgovernment and its associates.”
The ‘Best Innovation Practices’ awards arepart of the Shanghai Municipal Government’sefforts to turn the city into an internationalscience and technology hub. The awardsprogram took place on October 22, 2015, andwas sponsored by the Information Office ofShanghai Municipal Government, ShanghaiMunicipal Commission of Commerce andmedia outlets Shanghai Daily andEastDay.com. |
Huntsman technical input and set-upassistance was key to enabling Collodinto continuously pultrude the complex,multi-mandrel TICO window lineals.
Window and door innovation opens theway to a more energy efficient futureAn energy efficient window and door material technology, which polyurethane experts fromHuntsman helped to develop, has been named one of 40 ‘Best Innovation Practices’ in Shanghai.
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Equivalent of nearly one billion plastic bottlesrecycled into TEROL polyols line
Latest figures from the business show that in 2015 Huntsman recycled the equivalentof nearly one billion 500ml polyethylene terephthalate (PET) plastic water bottles atthe plant.
According to Stanford University it takes, on average, 76% less energy to produce a product from recycled plastic than from raw materials – so using recycled content is a smart business decision, as well as environmentally responsible.
Les Yamato, Business Manager for TEROL Polyols at Huntsman, said: “Whereverpossible we try to use polyurethane raw materials that contain recycled andrenewable content. By incorporating recycled components into our TEROL polyols line we are doing our bit for the planet and contributing to the creation of moresustainable products. We are also meeting the purchasing protocols of our customers,who want to design their products confident in the knowledge that they containrecycled raw materials.”
PET is one of the world’s most widely produced plastics. It is used in fibers for textiles,bottles for drinks, films for packaging and other industrial and consumer uses. Anyform of PET can be used for the manufacture of aromatic polyester polyols via thetrans-esterification process. The most common sources are virgin, post-industrialscraps from extrusion applications, and post-consumer scraps from the recycling ofbottles obtained from municipal collection. |
As part of its commitment to sustainability, Huntsman triesto incorporate as much pre-consumer, post-consumer andrenewable plastic content as possible into its TEROL aromaticpolyester polyols manufacturing line in Houston, Texas.
TEROL®polyester polyol for insulation applications
TEROL 649 polyol offers enhanced solubility and compatibility with new blowing agents. It canalso reduce the amount of polyether polyols and flame retardants that insulation formulators needto use. Tests conducted by Huntsman show that the polyol can reduce and, in some instances,even completely eliminate the use of brominated flame retardants (BFRs).
Compatible with 3.5 and 4.0 generation blowing agents, TEROL 649 polyol can be used to thesame effect as HFC-245fa and other hydrofluorocarbon systems. It also allows for higher loadinglevels (up to 100% of the polyol requirement), which can improve SPF performance in an array oftesting protocols.
Huntsman offers one of the broadest ranges of aromatic polyester polyols for rigid foam thermalinsulation applications with hydroxyl values ranging from 120 to 350. Additionally, its polyolsolutions can be tailored to meet customer specifications across the insulation value chain,including boardstock, SPF, insulated metal panels, structural insulated panels, appliances andcommercial refrigeration. |
Huntsman has developed a high-functionality aromatic polyester polyol forrigid insulation systems and spray polyurethane foam (SPF) applications.
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PU Review (PU R): Thanks for showing usaround today. Can you start off by telling thereaders of PU Review what Tecnoelastomeriproduces here in Modena?Alessandro Gramellini (AG): Of course.Basically there are two core elements to ourbusiness. We produce high technologyelastomer systems. From these materials it ispossible to create a variety of everydayindustrial items, such as wheels, rollers, sealsand general technical parts. We also produce arange of CASTECH™ machines that can beused to efficiently cast compact polyurethaneelastomers and microcellular elastomer foamsfrom all types of isocyanate and chain extendercombinations – including our own systems.
PU R: Where are your elastomers used?AG: Think of any industrial application and it’s likely that you’ll find a high technologyelastomer in use somewhere within it. Typically,our elastomers are used in heavy-duty projects,where there is a need for rugged, durablematerials for example, in mining or offshoreenvironments. They are also used in roboticand hydraulic equipment. We also producematerials for the automotive industry, wherethere is a need for components that are toughenough to withstand extreme under-the-hood
conditions, such as the presence of heat, oil,grease and friction. There are many other usesfor our hot-cast elastomer systems too. Withmore than 1,000 different formulation optionsavailable there is a solution for almost everykind of polyurethane elastomer project. Our jobis to work with individual customers to identifytheir requirements and then recommendor tailor make a polymer that’s best suited totheir needs.
PU R: How long has Tecnoelastomeri beenin business?AG: Tecnoelastomeri has been active in theMDI elastomer market since 1985 when myfather founded the company. Initially, our focus was on the development of bespokepolyurethane systems that we marketed underthe TECNOTHANE™ brand – but over theyears our offering has grown. Today, alongsideTECNOTHANE, we also produce CASTECHmachines. Together, these elements create acomplete technology solution for producinghot-cast elastomers. Our work begins with scientific and technical discussions with customers to agree specific elastomermaterial requirements. We then move on tocover equipment decisions, plant set up andactual manufacturing.
Casting a wider net in the hightechnology elastomer market
Dr. Alessandro Gramellini, GlobalBusiness Director of Tecnoelastomeri.
In June 2015, Huntsman announced the acquisition of its latest system house, Tecnoelastomeri – one of theworld’s leading manufacturers and marketers of MDI-based hot-cast elastomer systems and processingmachines. For this edition of PU Review, the editorial team travelled to Modena, Italy to find out more aboutthe business. Alessandro Gramellini, who heads up Tecnoelastomeri, took us on a tour of the facility, andexplained more about the company and what lays ahead now it is part of a global corporation.
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PU R: When did the business start producingCASTECH machines?AG: We branched out with the development ofCASTECH machines in 2002. After many yearsin the industry, we saw a gap in the marketand knew there was an opportunity to create a better kind of casting machine. Using ourknowledge of elastomer properties, wedesigned a piece of equipment that wouldwork in complete harmony with ourTECNOTHANE MDI systems – getting the verybest out of the material. Naturally, we werecareful to also design a solution that would be compatible with TDI, NDI and otherpolyurethane platform technologies, includingtechnical foam.
PU R: How are your CASTECH machinesdifferent to others available?AG: CASTECH machines were developedusing 30 years of chemical and material know-how and as a result are one of the mostadvanced equipment options available for theefficient manufacture of elastomers. Manythings set our machines apart from thecompetition. First and foremost, there is theflexibility that comes with a machine arm thatcan extend up to two meters in length. Thismakes it possible to cast directly in an oven,which can lead to productivity improvements.Then there is the fact that CASTECH machinesoffer very high levels of accuracy; typically adosing precision of 0.3%. They also haveexcellent shot strength – making it possible tosingle cast high quality elastomers successivelyand accurately with virtually no waste.Furthermore, our machines are very easy tooperate and look after. Less maintenance is
required thanks to the unique design of theCASTECH mixing head gasket. In addition, a clever automated system removes the needto recalibrate the machine when the hardnessof a material is changed.
PU R: What differentiates your elastomermaterials from other solutions available?AG: In short, it is the breadth of our offering and our business model that are different.Offering expertise in MDI systems, machineryand elastomer parts makes us unique – no oneelse provides this full end-to-end package.
PU R: How do the elastomer systems thatTecnoelastomeri produces differ from the TPU materials that Huntsman has beenmanufacturing for many years?AG: Following the acquisition of Tecnoelastomeri,Huntsman now offers one of largest portfolios of polyurethane elastomers based on MDI technology. The range includes ourTECNOTHANE MDI systems and Huntsman’sIROGRAN®TPUs. These materials are oftensold in the same markets and we have manycustomers that use both materials – but thereare clear differences between the product lines,which are actually complementary.
Customers typically begin new projects withcast MDI systems. The cost of molds and theeffectiveness of machines is better when lowproduction numbers are involved. Once a part’sdesign has been tried and tested, and largervolumes are required, some customers decideto switch to TPU. Between 15,000 and 20,000pieces, TPU becomes more cost effective.Another important parameter is part size.
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Over a certain weight there are clear materialdecisions to be made. In general, it is alwaysadvantageous to create small, thin parts usingTPU. Whereas, the manufacture of very big,thick parts is typically more suited to cast MDIsystems. Moving forward, we’ve made thedecision to offer products from both ranges toour customers. As and when an opportunityarises, and depending on their requirements,the relevant sales teams will liaise with thecustomer to validate specifics and move theproject forwards.
Huntsman now offers one of thelargest portfolios of polyurethaneelastomers based on MDI technology.
our elastomer department, where we canproduce any kind of elastomer part. Thisdepartment has the most direct interaction with customers. Some want small batches ofproduct. Others may come to us for advice onsetting up a new production line or developingan elastomer for pre-marketing.
PU R: How many people work on site inModena?AG: At present, around 40 people areemployed in Modena – almost half of who have a technical background.
PU R: Day to day, what has changed since the business became part of Huntsman?AG: When it comes to the production of our products, very little has changed sinceHuntsman acquired us. We remain committedto the manufacture of high technologyelastomers and we continue to offer end-to-end support to our customers – working with them to explore ideas for new elastomerapplications and produce materials for specificprojects. The biggest change is that we nowhave a much bigger network of scientists and polyurethane experts to draw upon. Thissignificantly boosts our capabilities – enablingus to produce our TECNOTHANE polyurethanesystems in other parts of the world. There isalso a bigger Huntsman networking and salesforce to increase awareness of our productsand the number of projects we are involved in.Furthermore, we have greater access to rawmaterials and the economies of scale andbuying power that comes from being part of a global corporation.
PU R: What lies ahead for the HuntsmanTecnoelastomeri business in 2016?AG: There are some exciting projects in thepipeline in the year ahead including an initiativewith RÄDER-VOGEL (see opposite) to createoutsize elastomer wheels for use in heavy-dutyconstruction, foundry and mining equipment. In collaboration with Huntsman’s global R&Dcenters, we are also busy improving MDIsystem processability to facilitate ourcustomers moving from TDI-Mboca to MDIsystems in offshore, mining, automotive andrailway applications. There will be more newson these developments at K2016 in October –where we’ll be exhibiting alongside theHuntsman TPU team. |
PU R: Is there a big market for high technologyelastomers?AG: Yes. At present, the majority of ourbusiness originates from central and northernEurope, but there is also a growing market inChina and South Korea. As part of Huntsman’sglobal operations, we are now looking at waysto expand the distribution of our materials and machines in North and South America, in Australia and in other APAC countries, such as Malaysia.
PU R: How many CASTECH machines havebeen produced since 2002? And where arethey in use?AG: To date, we’ve produced around 100machines, which are being used in multiplecountries across Europe, as well as in Turkey,Russia, China and South Korea.
PU R: What kind of equipment do you havehere in Modena?AG: Modena is the home of Tecnoelastomeriand is our technical headquarters. Here, weproduce our TECNOTHANE MDI systemsusing several reactors with up to 12 tescapacity. Our total capacity is around 10ktesper year. In Modena, we also have ourCASTECH machine department where we canproduce up to twenty machines per year; and
Using high technology elastomersystems it’s possible to create a varietyof everyday industrial items.
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After consulting Huntsman Tecnoelastomeriabout the best materials to use to supersize its range, RÄDER-VOGEL is now offering itscustomers tailor-made wheels with a diameter of more than 1500 mm. The wheels are beingoffered under RÄDER-VOGEL’s PEVOTEC®brand – an extensive family of wheels andcastors designed for use in extreme operatingconditions.
PEVOTEC wheels are based on TECNOTHANEhot-cast polyurethane MDI system fromTecnoelastomeri. Characterized by their flexibility,castors and wheels in the PEVOTEC range arerenowned for their ability to carry heavy loads,even where mounting space is tight. Wellequipped to handle extreme stress andtemperature variations, they are ideal for heavyduty tasks. In the metal processing industry for example, they are used to transport hefty,dirty raw materials between heat furnaces andforging units.
A new dimension to custom wheels Explaining more about the development of the new PEVOTEC wheel options, CarstenHenning, President and Managing Partner ofRÄDER-VOGEL, said: “Over recent years, we’veseen a significant uplift in requests for extra-largewheels for industrial applications. Producingbigger wheels to function in production andprocessing environments – where materialproperties are tested to the limits – soundsrelatively straightforward, but it’s actually reallycomplex. It’s not just a case of scaling up oursmaller designs. Each customer wants a differentsized wheel for a specialist task, so we need totailor what we offer each time. With years of
material know-how, Tecnoelastomeri has a widerange of TECNOTHANE hot-cast polyurethaneMDI systems that we can choose from and theskills to help us adapt their chemical and physicalproperties to meet the needs of our customers.”
The first extra-large PEVOTEC wheels developedby RÄDER-VOGEL are performing well.Customers putting them to good use includeDango & Dienenthal Maschinenbau GmbH – aleading manufacturer of machines for the filtrationand processing of raw materials. RÄDER-VOGELhas created wheels for Dango & Dienenthal thathave a diameter of 1450mm; a width of 500mm;and a load capacity of more than 50 tons. Thewheels are used in forging manipulators. Offeringtrouble-free transportation, the wheels are copingwith extreme stress and temperature challenges– consigning different types of damage, such ascracking or flattening, to the past.
Stefan Buch, Purchasing Manager at Dango &Dienenthal, said: "Thanks to PEVOTEC, we can ensure the highest performance for ourmachines. This in turn is helping us keepproduction losses to a minimum and increasecustomer satisfaction.”
Based on the market’s positive reaction to thelaunch of its new range of extra-large wheels,RÄDER-VOGEL is expecting further interest fromcompanies across the mining industry and othersectors where the use of heavy duty equipmentis essential. |
RÄDER-VOGEL, one of the world’s largestproducers of industrial wheels and castors,has expanded its product portfolio to includeextra-large custom-made wheels. The movefollows a technical development projectwith TECNOTHANE hot-cast polyurethaneMDI system experts from Tecnoelastomeri –the Italian system house purchased byHuntsman in 2015.
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RÄDER-VOGEL supersizes wheelswith help from Huntsman
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After years of general wear and tear, the aging PVC roof on Building One was approachingthe end of its life. To protect the expensive equipment housed within its laboratories, and toobtain the highest levels of certification from insurers, Huntsman decided to completelyreplace the existing roof.
To modernize the L-shaped, 70,000-square-foot facility, Huntsman decided to utilize the verylatest roofing material. A long-lasting thermoplastic polyolefin, UltraPly™ TPO roofing systemfrom Firestone Building Products was chosen. Firestone is a long-term Huntsman customerand some of the components used in its TPO roof system were developed at HATC.
Peak Roofing Inc., a highly regarded Firestone contractor based in Houston, installed the roofsystem in 60 days. Throughout the project, Huntsman worked hand-in-hand with commercialproperty insurer FM Global to ensure the roof system exceeded requirements for wind class,R-value and other key building criteria. Following completion, FM Global awarded Huntsmanthe ‘Highly Protected Risk’ designation, which is given to facilities with a lower than normalprobability of loss. The new energy efficient roof has an expected lifespan exceeding 20 yearsand has achieved a combined R-value of 21 – exceeding local, state and internationalenergy codes. |
Huntsman celebrated ten years of its Advanced Technology Center(HATC) in The Woodlands, Texas in 2015. To mark this milestone, thebusiness made a number of improvements to the four facilities oncampus, including the installation of a brand new polyurethane-basedroof on one of its buildings.
TPO single-ply roofing membranesare among the fastest growingcommercial roofing products and havegained broad industry acceptance,mainly for their performance andinstallation advantages.
Huntsman was dedicated to selecting amaterial with a long lifespan, therebyreducing the roof’s environmental impact.TPO single-ply roofing membranes provideresistance to ultraviolet, ozone andchemical exposure, helping to ensure theirlongevity. In laboratory testing, FirestoneUltraPly TPO lasted three times longer than PVC and 12.5% longer than itsclosest TPO competitor. Furthermore,TPO is recyclable.
Long lasting and recyclable
The increased level of insulation and thehighly reflective white TPO membrane canhelp lower roof temperatures, leading togreater indoor comfort. Firestone UltraPlyTPO is ENERGY STAR®certified and manyof the components of this roofing systemcontribute to points for LEED®certification.
Increased indoor comfort
Huntsman’s new roof is virtuallymaintenance-free and TPO is also lesssusceptible to the mold, mildew anddiscoloration that can affect PVC roofs.
Low-maintenance
Huntsman’s Global Technology HQ retrofittedwith Firestone Building Products
Installation of the new roof at HATC in The Woodlands.
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Synthetic roof tiles help to battle elements
In 1981, a U.S. Department of Agriculturestudy concluded that wood shake roofs werethe single most influential factor in whether a house, caught in a wildfire, would survive.Fast-forward eight years to 1989, when theLos Angeles City Council outlawed the fitting of new wood-shingled roofs – becoming thefirst major city to veto this popular roofingmaterial. In 2015, additional cities and countiesundertook similar measures following a seriesof wildfires that wreaked havoc.
Faced with increasingly restrictive buildingcodes, roofing companies across NorthAmerica are searching for alternatives to traditional wooden tiles. For theseorganizations, new composite polyurethanematerials offer a solution, providing greaterdurability and fire resistance, without sacrificingthe aesthetic appeal of wood.
One company producing just such a substituteis Colorado Roofing Products, LLC., basedoutside Denver, Colorado. Assisted byHuntsman, the company has developedsynthetic CeDUR™ roofing shakes that canstand up to wind, hail, snow, and of course,fire. Indistinguishable from natural cedar, andbased on high-strength polyurethane, CeDURshakes are incredibly durable – combining allthe physical properties required for long-termperformance with a natural looking elegance.
To create CeDUR shakes, molds are designedfrom a number of different natural cedarshingle parts. A formulated polyol blend andmethylene diphenyl diisocyanate (MDI) are thenmixed together with a pigment and fillerpackage and subsequently injection moldedinto the final shape. The resulting product
looks like natural cedar, but is far moredurable. Colorado Roofing Products offers a50-year warranty on its synthetic cedar roofingtiles. The cedar composite has also earned aClass A fire rating from the International CodeCouncil (ICC) and does not require a specialfire-resistant underlay. Class A is the highestfire resistance rating ICC offers.
Composite shakes also offer a solution forhomeowners worried about the impact of hailand wind. Significant hail events can causeless durable roofing materials to crack andgive, representing a significant safety and costrisk. ICC has given CeDUR a Class 4 hailresistance rating – meaning it can stand up tothe tough storms that often ravage states likeColorado. To achieve this rating – ICC’shighest – a material must be able to withstanddamage from a two-inch steel ball beingdropped from 20 feet on to multiple surfacepoints. CeDUR shakes are also certified toresist wind speeds of up to 110 mph andabsorb a minimal amount of water comparedto other roofing materials. These factors givethe composite shingles superior freeze/thawcycle performance.
The response from homeowners to CeDURshakes has been overwhelmingly positive, as the market for synthetic roof productscontinues to outpace growth in the overallroofing industry. As the sector evolves,consumers are looking for products that donot look like plastic. CeDUR is the mostauthentic representation of real cedar woodthat is available on the market and comes withthe highest toughness ratings in the industry. |
Cedar shake roofs are a hallmark of home design in the WesternUnited States, lending a classiclook to new construction projects.However, many municipalities in states, such as Colorado andCalifornia, have now outlawed the use of cedar roof tiles onresidential properties due to theharsh environmental conditionsthose areas face.
Cedar shake roofs – a hallmark of homedesign in the Western United States.
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Louisiana-Pacific (LP) Building Products is one such company. A global leader inengineered wood products for framing, paneland siding applications, LP continuallydevelops new solutions to help its customersimprove their offering.
For over 30 years, Huntsman and LP haveworked together to meet the evolving needs of builders and the construction industry.Supplying LP with RUBINATE®MDI bindingsystems, Huntsman has played an integral rolein helping LP increase the performance of itscomposite wood products and keep up withbuilding and energy codes, while maintainingthe highest levels of product stewardship and sustainability.
From its Geismar manufacturing complex,Huntsman supplies MDI to all 16 LP OSB and siding mills throughout North and SouthAmerica. Mark Hutnik, Senior Account Managerat Huntsman Polyurethanes, explains more.
Offering engineered wood products for avariety of applications, LP is committed tofinding new ways to bring energy efficiency and fire resistance to its core wood strandtechnologies. Our job is to support theseefforts. Over the years, we’ve fostered strongties with personnel at all levels within LP – and helped create products that fulfill buildingindustry needs. TechShield®is a great exampleof the innovative forward looking culture thatexists at LP.
Energy efficiencyIn response to market demand and U.S.-based energy codes, LP pioneered thecategory of radiant barrier sheathing with itsTechShield product line. Designed to lower a home’s attic temperature by as much as 30 degrees Fahrenheit, TechShield works byblocking radiant heat in the roof panel. Theproduct is made by laminating a thin piece ofaluminum to the underside of OSB sheathing.The OSB found in TechShield uses Huntsman’sMDI (as an adhesive). TechShield sheathingcan help residential homes lower Home EnergyRating System (HERS) scores and radiantbarrier panels based on the technology havenow been installed in more than 1.5 millionhomes in the United States.
Fire protectionFire protection is another area of buildingcodes that has seen dramatic change. To keeppace, LP has enhanced its wood sheathingtechnology so that it fits with more restrictivefire codes. LP’s FlameBlock®product line isfocused on fire resistance and can be used insingle-family, multi-family and commercialbuildings. This Class A, flame spread rated,OSB sheathing, combines fire resistance andstructural performance in a single panel.FlameBlock OSB sheathing provides a one- totwo-hour fire wall assembly component inresidential and commercial buildings, and hasthree times longer burn-through resistancethan standard wood sheathing.
Product stewardshipWhile developing novel engineered woodsystems, LP and Huntsman always prioritizeprotecting the environment and maintaining asafe working environment. Huntsman’s productstewardship activities begin well before itsproducts arrive at LP’s manufacturinglocations. Delivery vessels are maintained tothe highest standards and training of selectedcarriers is provided. Mill personnel also receivetraining that encompasses Department ofTransportation (DOT) requirements.
SustainabilitySustainability is also important with bothcompanies sharing a commitment to minimizingLP’s environmental footprint. LP is certified tothe Sustainable Forestry Initiative®(SFI) FiberSourcing Standard which sets mandatorypractice requirements for the responsibleprocurement of all fiber obtained directly fromthe forest and includes measures to enhancebiodiversity. To give back to the environment,LP also invests in reforestation projects andhelps landowners manage the acres of landand operations that produce its wood supply.
Ben Skoog, Vice President, Growth andInnovation, LP Building Products, said:“Huntsman works with us to upgrade ourproducts and keep up with what builders wantand need. This allows us to stay current in themarket but better serve our customers too.” |
LP Building Products’ TechShield OSBbeing installed on a house.
As building codes grow more stringent, and as the use of sustainable buildingmaterials becomes increasingly important to both residential and commercialcontractors, providers of engineered wood products, such as oriented strandboard (OSB) must work hard to keep up with customers’ demands.
Long-term bond over innovativeengineered wood products
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Clogs have long been associated with Dutchnational identity and remain very popular in The Netherlands; both for work and leisurewear. A pioneer of innovative footwearmanufacturing techniques, Gerla has evolvedthe traditional Dutch wooden clog, creatingcontemporary versions that comprise awooden insert, polyurethane sole and leatherupper. Gerla has been in business for morethan 100 years and its updated take on theclassic clog has attracted a loyal customerbase, including Dutch royalty.
Gerla’s brief to Huntsman’s footwear team was to investigate how to improve the comfortof its clogs, especially for people wearing them all day. Lighter weight, good grip, shockabsorbency and anti-slip properties combinedwith durability and visual appeal were allkey requirements. Gerla was particularlyinterested in how the use of different solingmaterials, specifically polyether-based systems,could help achieve added performancebenefits, including enhanced resistance toabrasion and water. In addition to Huntsman’sextensive portfolio of specialist polyurethanefootwear products, Gerla also wantedto explore the technical support on offerfrom the chemical company at its Europeanfootwear development center in Belgium –including its capacity to manage productperformance trials.
Critiquing clog constructionTaking a collaborative approach to the project,Huntsman worked closely with Gerla to analyzeall aspects of clog construction. Together, theyevaluated the design of Gerla’s existing soles tosee what improvements would optimizeperformance – a more in-depth, holisticapproach than Gerla had previouslyexperienced. Huntsman’s solution was todevelop a tailor made, fully formulated,polyether-based polyurethane product. With alower density than Gerla’s existing solingmaterial, and a higher level of robustness
during manufacture, the material offered verygood flow properties when injection molded.This enabled the creation of a seamless solewith no air bubbles that could be joined directlyto the wooden part of the clog without the useof an additional adhesive.
Following rigorous tests (managed byHuntsman), Gerla put the solution intoproduction, leading to a number of immediatebenefits. As well as enabling the production oflighter, more comfortable clogs, the companyboosted its productivity by reducing wastageand scrap rates during manufacture.
Mr. Joost Pijnenburg, Managing Director atGerla, said: “With a much-loved classic like the Dutch clog, our challenge was to introduceinnovative new materials while upholding theshoe’s heritage and tradition. Huntsman did farmore than recommend a new soling product.They took a refreshingly holistic approach,meaning we could explore all possibilities toimprove our clogs. What’s more, Huntsman’sability to road test different soling materialsunder trial conditions gave us completeconfidence that choices made in the laboratorywould translate to full-scale production. This enabled us to get a better product tomarket faster and with minimal risk.”
Gerla produces around 600 pairs of clogs aday – all of which now incorporate HuntsmanPolyurethanes’ products in the soles. Inaddition to clogs, Gerla also produces differenttypes of footwear for various markets, mostnotably safety and work shoes. |
Huntsman helps Dutchclog manufacturer keeppace with innovation
When Netherlands-based footwear manufacturerGerla Products wanted to improve the comfortand performance of its iconic Dutch clogs,it called on Huntsman to help deliver a rangeof enhancements.
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Forestali uses TPU in composite materialfor leather goods manufacture
Forestali is a leading producer of adhesivesfor the leather goods market, as well as forfootwear, sailing and furniture applications.The business also manufactures a wide rangeof impregnated fabrics and textiles.
After spotting a gap in the leather goodsmarket, Forestali contacted Huntsman.Forestali wanted Huntsman to help develop a durable material that could be wrapped inleather to form structural components forbags, for example, weight-bearing handlesand shoulder straps. Specifically, Forestaliwanted Huntsman’s advice on a polyurethane-based solution that could be used to coat anon-woven polyester and create inserts thatwere strong and robust yet incredibly flexibleand soft to touch.
Huntsman recommended the use of apolyester-based TPU from its IROGRAN®range. Originally developed for hot meltcalendaring applications, the grade inquestion is also suitable for multilayerextruding. Offering outstanding batch-to-batch consistency, the TPU is low in colorand can be easily pigmented. It is alsocompatible with a variety of adhesives basedon natural and synthetic lattices.
Satisfied with Huntsman’s suggestion andsupported by the company’s technical team,Forestali developed TINTORETTO. The endresult is a material that is easy to produce and can be cut in any direction withoutcompromising dimensional stability. Thanks toIROGRAN TPU, TINTORETTO is also resistantto humidity, heat and cold, and can withstandrepeated mechanical actions such as bending.
Emiliano Bozzato, R&D Manager at Forestali,said: “Huntsman quickly understood wherewe wanted to get to with TINTORETTO andrecommended a TPU that was perfect for thetask. Using IROGRAN TPU, we’ve created ahardwearing, but flexible product that appealsto decision makers across the global leathergoods market.”
TINTORETTO is now available worldwide andis proving particularly popular with Forestalicustomers in Italy, a country renowned forquality leather goods. |
Italian company Industrie ChimicheForestali S.p.A (Forestali) hasdeveloped an innovative compositematerial for the leather goodsindustry using one of Huntsman’sspecial TPU grades. The material,which features a durable layer ofTPU, is called TINTORETTO andis designed to improve thestructural integrity of high-endleather goods, such as designerhandbags and belts.
Nayati phases out HCFC usewith Huntsman’s help
A successful cooperation betweenHuntsman and Nayati Indonesia – a leading manufacturer of professionalcatering equipment – resulted in Huntsman developing and supplying Nayati with DALTOFOAM®MP 52095.
Working with Huntsman, Nayati’s aim was to produce an insulation panel for use in its chiller and refrigerator units withoutemploying an HCFC-141B blowing agent.HCFC blowing agents are being phased out under the Montreal Protocol.
First trialed in February 2015, DALTOFOAMMP 52095 was subsequently refined andcommercialized in August 2015. Using
DALTOFOAM MP 52095 to createpolyurethane insulation, Nayati estimatesthat it has achieved a 30% reduction ininvestment costs. It has also reduced the in-house risk of storing cyclopentane; as part of its work, Huntsman delivered a product stewardship presentation thathelped to upgrade safety awareness atNayati prior to product commissioning.
Aldo J Susanto, R&D Manager at NayatiIndonesia, said: “The advantages of using a cyclopentane, such as DALTOFOAM MP52095 are two-fold: we can deliver a farbetter service to our customers and we canalso give them a quality product that is fullycompliant with industry requirements.”
Nayati Indonesia was first established almost30 years ago, and today is a well-known,international kitchen equipment brand. Key customers include hotel groups, suchas Best Western, Sheraton, Grand Aston,Swiss Bell and F&B, plus chain restaurants,such as KFC and McDonalds. |
Huntsman’s systems house in Indonesia has become the first in thecountry to produce a fully blended cyclopentane polyol to supportStage One HCFC phase out across the country.
Forthcoming events and technical presentations
For more information on the subjects covered in PU Reviewmagazine, please contact the editor:Eric Stebel, [email protected], +1 281-719-4602
While all the information and recommendations in this publication are to the best of ourknowledge, information and belief accurate at the date of publication, nothing herein is to be construed as a warranty, express or otherwise.SUPRASEC®, VITROX®, RIMLINE®, TEROL®, IROGRAN®, RUBINATE® andDALTOFOAM® are registered trademarks of Huntsman Corporation or an affiliatethereof in one or more, but not all, countries. CASTECH™ and TECNOTHANE™ are trademarks of Huntsman Corporation or an affiliate thereof in one or more, butnot all, countries. iPad® and iPhone® are registered trademarks of Apple Inc. PEVOTEC® is a registeredtrademark of RÄDER-VOGEL. UltraPly™ is a trademark of Firestone BuildingProducts. ENERGY STAR® is a registered trademark of the U.S. EnvironmentalProtection Agency. LEED® is a registered trademark of U.S. Green Building Council(USGBC). CeDUR™ is a trademark of Colorado Roofing Products, LLC. TechShield®and FlameBlock® are registered trademarks of Louisiana-Pacific Corporation.Sustainable Forestry Initiative® is a registered trademark of SFI Inc. Solstice® is aregistered trademark of Honeywell International Inc.Copyright © 2016 Huntsman Corporation. All rights reserved.Designed and produced by: Chris Pearson creative communications.
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Zero ozone depletion blowing agentsused for water heater insulation project
Across the polyurethanes sector, there isgrowing pressure to reduce the use of blowingagents that have GWP or ozone depletingpotential (ODP). Since the phase out ofchlorofluorocarbons (CFCs) in the 1990s,hydrochlorofluorocarbons (HCFCs) andhydrofluorocarbons (HFCs) have been thedominant chemistries used in blowing agentproduction. However, these compounds arenow starting to face scrutiny, so a shift towardshydrofluoroolefins (HFOs) is beginning.
Derived from alkenes rather than alkanes,HFOs have much lower GWP than HCFCs andHFCs. They also have zero ozone-depletingeffects. Solstice LBA from Honeywell is onesuch product. Listed as a suitable replacementfor Class I and Class II ozone-depletingsubstances in foam applications, Solstice LBAhas a GWP of one; more than two orders ofmagnitude (99.9%) lower than current HFCs. It is also non-flammable, VOC exempt andavailable at a low system cost.
In New Zealand, interest in HFOs is increasingrapidly, driven by pending legislation. The New
Zealand government has plans to outlaw theimport of HCFCs. For Rheem NZ, this newsmeant a change in strategy, so they contactedHuntsman to discuss their options.
Rheem NZ has a reputation for developingtanks insulated with high quality materials. The energy efficiency of its heaters exceedNew Zealand performance standards anddeliver long-term reliability, enabling consumersto reduce heating bill costs. For Rheem NZ,maintaining a market-leading position meansembracing new technologies as they emerge.When CFC-based blowing agents werephased out, Rheem NZ quickly adopted HCFCalternatives and today it is the same story. With new HCFC legislation timetabled, RheemNZ wanted to explore the benefits associatedwith next generation blowing agents.
Together, Huntsman and Rheem NZ discussedthe pros and cons of choosing either HFC orHFO-based blowing agents. With HFOsperforming better than HFCs for both ODP andGWP, the two companies agreed that adoptinga HFO-based system would be the best
long-term option – giving the business asignificant advantage in the market place.Once the decision was made, a period ofrefinement followed with Huntsman tailoringSolstice LBA to the needs of Rheem NZ.
A series of new HFO-based formulations werethen trialed with great results. Tests showedthat the new insulation matched the existingHCFC-based system for energy loss and wasstable enough for Rheem NZ to use over itsnormal manufacturing cycle. With Huntsman’shelp, Rheem NZ is now manufacturing all of its water heaters with insulation that employs a HFO-based blowing agent – a move thatgives its products a real environmental boost.With one next generation blowing agent projectsuccessfully under its belt, Huntsman’s team in Australia is now exploring how the use ofHFO-based systems in other market sectorscould benefit polyurethane users worldwide. |
Huntsman has become one of the first companies to use a next generationblowing agent from Honeywell in a commercial application. The company’spolyurethanes team in Australia used Honeywell’s Solstice®Liquid BlowingAgent (LBA) technology – which has very low global warming potential (GWP)– in a project with Rheem New Zealand (NZ), part of Rheem USA, one of thelargest water heater manufacturers in the world.
List of forthcoming events:
Utech Asia 2016 Shanghai, China (2-4 August)
SPE Automotive Composites Conference & Exhibition (ACCE),Novi, Michigan (7-9 September)
CPI 2016 Polyurethanes Technical Conference, Baltimore, Maryland (26-28 September)
K 2016, Dusseldorf, Germany (19-26 October)
Lesdrevmash 2016, Moscow, Russia (24-27 October)
We create better energy efficiency and comfort. Together.
www.huntsman.com/pu
At Huntsman Polyurethanes, we believe that working in true collaboration with customers isthe only way to solve complex problems and find the solutions that will deliver real innovation.
So, we strive with a passion and determination to build the deep understanding of ourcustomers that’s required to get to the heart of their needs and establish lasting partnerships.
Our MDI-based polyurethanes and TPU technologies are used to meet the exactingneeds of the major automotive OEMs, providing superior seating comfort and durability,advanced acoustic absorbtion and high performance components, which optimizeweight and enhance safety. Combine our knowledge of polyurethanes systems with yourexpertise, and we’ll create better cars… together.
