Niagara Falls, NYOctober 2010
IMF FALL MEETING
Stollberg Overview
Kenneth Hashimoto and Michael Frazee, District Managers
STOLLBERG OVERVIEW
• S & B Industrial Minerals
• Stollberg Group Worldwide
• History of Stollberg, Inc.
• Stollberg Organization
• Production Capabilities
• Products and Process Flow
• Improvements and Future Projects
Welcome from
Kenneth Hashimoto and Michael Frazee, District Managers
S&B INDUSTRIAL MINERALSOVERVIEW
Kenneth Hashimoto and Michael Frazee, District Managers
S&B INDUSTRIAL MINERALSOVERVIEW
Kenneth Hashimoto and Michael Frazee, District Managers
S&B INDUSTRIAL MINERALSOVERVIEW
Kenneth Hashimoto and Michael Frazee, District Managers
STOLLBERG OVERVIEW
S&B North America
Kenneth Hashimoto and Michael Frazee, District Managers
THE GROUP
STOLLBERG GROUP
Kenneth Hashimoto and Michael Frazee, District Managers
STOLLBERG GROUP
Kenneth Hashimoto and Michael Frazee, District Managers
Stollberg Germany & France
Stollberg Brazil
Stollberg US
Stollberg India
Stollberg Korea & China
STOLLBERG GROUP: WORLDWIDE FACILITIES
STOLLBERG GROUP
The STOLLBERG Model
• Seven global manufacturing sites• Common Production Equipment• International technology base• Local technical sales and service personnel• Educational seminars and training services• Experienced product development laboratory and staff• Competitive pricing• Rapid response time• Short delivery time• ISO certification• Patented mold flux feeding equipment• SAP based software system• Engineered solutions to technical problems
Kenneth Hashimoto and Michael Frazee, District Managers
History of Stollberg, Inc.
STOLLBERG HISTORY
1982 Start-up of marketing activities for mold powders in North America.
1984 Foundation of Stollberg, Inc. with location in Niagara Falls, NY.
1985 Construction and start-up of production facilities in Niagara Falls with a 4,000 ton mixingand packaging operation.
1986 Start-up of laboratory with X-ray, carbon, fluorine and moisture analyzer, hot stagemicroscope, viscometer, and other sample preparation and melting equipment.
1989 Acquisition of Mobay’s Mold Flux business.
1990 Completion of bulk bag unloading stations and second packaging line with a capacityincrease to over 6,000 tons.
1993 Increase in Share Capital to $1.8 million. $7 million investment into fully automatedmold powder plant including spray drying facilities for the production of granular(spherical) product, with a total capacity of over 20,000 tons per year.
STOLLBERG HISTORY
1994 Acquisition of TAM Ceramics’ Mold Flux business.Continuation of License Agreement for Mold Fluxes with Nippon Thermochemical.
1997 ISO-9002 Certification.
1998 $4 million investment for plant expansion including second spray dryer for theproduction of granular (spherical) mold powders, new lab facilities including labequipment, and additional warehouse space.
1998 Acquisition of Latimer Co.’s mold flux business.
1999 Acquisition of CV Materials (CVM) mold flux business.
2003 Acquisition of NATCO mold flux business.
2004 Stollberg Group purchased by S&B Industrial Minerals S.A.
2009 ISO 9001-2008 Certification
STOLLBERG HISTORY
Plant Construction1992-1993
Plant Expansion1998-1999
Kenneth Hashimoto and Michael Frazee, District Managers
Stollberg, Inc.• Organization
• Capabilities
• Products
• Process Flow
• Process Improvements – Past and Future
STOLLBERG OVERVIEW
STOLLBERG ORGANIZATION
The STOLLBERG TEAM
• 41 Full Time Production Employees• 8 QC and Innovation Team Employees• 4 Purchasing, Logistics and Office Employees• 13 Technical Sales Engineers
(Geographically Located)
Kenneth Hashimoto and Michael Frazee, District Managers
• 2 Spray Dry process lines
Capacity of 30000 MT/year
• 3 Dry Mixing Process Lines
2 Plow Mixers, 1 Air Mixer
• 3 Pneumatic Transporters
Batching, Bulk Bag Unloading,Small Bag Unloading
• Packaging Lines
Bulk Filling, Automatic PolyBaggers, Impeller Packagers
• 36 Raw Material Silos
• PLC Controlled Batching Car
STOLLBERG PRODUCTION CAPABILITIES
Kenneth Hashimoto and Michael Frazee, District Managers
STOLLBERG PRODUCT MIX:Granular conversion for continuous casting
• Granular materialAccounts for 98% ofcontinuous castingfluxes
– Better flowability
– Superior Homogenation from slurrypreparation
– Large batch sizes
– Dust free
– Automatic feeding
– Improved quality
Kenneth Hashimoto and Michael Frazee, District Managers
STOLLBERG PRODUCT MIX 2010
For continuous casting, the product mix is nearly all granular forenvironmental and performance benefits.
2010 PROJECTED TONNAGE (MT) VOLUME %
GRANULAR 23,00066%
TUNDISH 5,00014%
BOTTOM POUR 1,5004%
HOT TOPPING 1,0003%
POWDER 6002%
INSULATING COVERS 4,00011%
35,100
Kenneth Hashimoto and Michael Frazee, District Managers
• Continuous Casting Mold Flux
• Synthetic Blends and Granulated
• Tundish Covering
• Synthetic Blends and Granulated
• Bottom Pour Flux
• Synthetic Blends and Granulated
• Hot Topping Compounds
• Synthetic Blends
• Insulating Covers
STOLLBERG PRODUCTS
Kenneth Hashimoto and Michael Frazee, District Managers
RawMaterials
ToProcess
QC
QC
QC
RawMaterials
IntoPlant
w
w
w w
STOLLBERG PRODUCTION: PROCESS FLOW
Powder Production
Kenneth Hashimoto and Michael Frazee, District Managers
QC
QC
QC
QC
QC
QC
QC
QC
w
FinishedGoods toWarehouse
RawMaterials
To PowderProduction
STOLLBERG PRODUCTION: PROCESS FLOW
Powder Production
Kenneth Hashimoto and Michael Frazee, District Managers
ToPackaging
RawMaterials
To GranularProduction w
w
w
w
w
QC
QC
QC
QC
STOLLBERG PRODUCTION: PROCESS FLOW
Granular Production
Kenneth Hashimoto and Michael Frazee, District Managers
From Spray DrierProduction
ToWarehouse
QC
QC
QC
QC
QC
QC
QC
QC
STOLLBERG PRODUCTION: PROCESS FLOW
Granular Production
Kenneth Hashimoto and Michael Frazee, District Managers
2001WinCCSCADAsystem
Siloproject
2005-6
2003-4Productivityimprovement
NetTonsGranularProducedPerProductionDay(2Spraytowers)
(2002- present)
50
60
70
80
90
100
110
120
130
140
Se
p-0
2
De
c-0
2
Ma
r-03
Ju
n-0
3
Oc
t-03
Ja
n-0
4
Ap
r-04
Au
g-0
4
No
v-0
4
Fe
b-0
5
Ma
y-0
5
Se
p-0
5
De
c-0
5
Ma
r-06
Ju
l-06
Oc
t-06
Ja
n-0
7
metr
icto
ns/d
ay
SprayTowertons/hr Output
2.002.102.202.302.402.502.602.702.802.903.003.103.203.303.403.50
20
03
20
04
Ja
n-0
5
Feb
-05
Ma
r-05
Ap
r-05
Ma
y-0
5
Ju
n-0
5
Ju
l-05
Au
g-0
5
Sep
-05
Oc
t-05
No
v-0
5
STOLLBERG: PROCESS IMPROVEMENTS
Kenneth Hashimoto and Michael Frazee, District Managers
2007-8AutomaticPackagingEquipment
2008-9Viscometers,AutomaticPumpPressureControl
-5
-3
-1
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
12:00:00 AM 2:24:00 AM 4:48:00 AM 7:12:00 AM 9:36:00 AM 12:00:00 PM 2:24:00 PM
Ba
gC
ou
nt,
Tre
eP
res
su
re,P
um
pP
res
su
re
-50
0
50
100
150
200
250
300
350
400
Flo
wR
ate
(/1
0),
YV
isc
os
ity
Bag Count OSPump1 G13852
OSTrPrAvg G13852 OSSlurryFlow/10 G13852
OSViscosity G13852
Rejected
Bags 17 and
18 made
here
Rejected
bag 8
made here
Rejected
bag 16
made here
STOLLBERG: PROCESS IMPROVEMENTS
Kenneth Hashimoto and Michael Frazee, District Managers
• 2011 - Replacement of Impeller Packers
– Improved efficiency, filling, sealing, andrecording of weight, bag identification
• 2012-2015- Mixer upgrade and spray dry towerreplacement
– Larger batch sizes, replacing older equipment
– Replacement of tower due to age
STOLLBERG: FUTURE PROCESS IMPROVEMENTSHIGHLIGHTS
Kenneth Hashimoto and Michael Frazee, District Managers
WELCOME TO STOLLBERG
We look forward to havingyou visit our facilitiestomorrow.
If you need safety glasses ora hard hat, let us know andwe will supply them.
Thank You!
WELCOME IMFMEMBERS