UTECH Europe:Presenting our passionfor polyurethanes
Handling a luggageupgrade for Samsonite
Driving greater comfortin Mazda car seats
Computer modelling –the science of simulation
Focusing onfootwear
R E P O R T I N G T H E W O R L D O F P O LY U R E T H A N E S F O R O U R C U S T O M E R S
April 2015
www.huntsman.com/pu
In mid April, Huntsman will be at UTECH Europe 2015, showcasing itspassion for polyurethanes and the ways in which its knowledge of thisspecialist chemistry is helping to enrich the lives of people worldwide.
Demonstrating our passion for PU
Polyurethanes surround our daily lives – having apositive impact on the way we move around theplanet; how comfortable we feel; our ability tosave time and energy; and even the food that weeat. Focusing on these four elements, productson display at Huntsman’s stand (1210) – within aspecial circle of innovation – will include:
• A flexible foam to help optimize comfort inbedding, furniture and seating applications
• A hydrophilic substrate that can be used inhydroponic greenhouses and commercialfood growing environments
• A resin to enhance the manufacture ofautomotive carbon fiber composite panels
• A new polyurethane resin system that is aviable alternative to other thermoset-basedtooling products
• Polyurethane additives and catalysts toimprove the performance properties ofpolyurethane-based systems
• TPU food contact materials (FCM) suitable for use in harvesting and picking equipment,processing and dispensing machinery,conveyor belts and many other food anddrink-related applications.
The team will also be taking part in theUTECH Europe 2015 conference program.Tony Hankins, President of HuntsmanPolyurethanes, will deliver the conferencekeynote address, discussing the challengesand opportunities facing the polyurethanessector in the medium term, in both Europeand beyond. Wim Gilis will give a presentationon the company’s new VITROX® EST resintooling technology. And Geert Dries willpresent a paper on emissions limits for vehicle interiors and how next generationpolyurethane additives and catalysts arehelping original equipment manufacturerscomply with legislative measures. |
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PUbriefing April 2015
Encouraging signs for our industry in Europe Tony Hankins, President, Huntsman Polyurethanes
This issue of PU review is being published to coincide with UTECH Europe 2015 in Maastricht, the prestigious polyurethanesindustry event which takes place every three years and which has sister events in America and China. I always find thesegatherings provide a good barometer of the industry mood and serve as a launch pad for new products and applications.And of course, they provide an excellent opportunity to catch up with our valued customers and make new contacts.
In recent times, there has been a great deal of negative news about the European economy. The polyurethanes industry isnot immune from macroeconomic or geopolitical developments, but I have to say that I see many encouraging signs for ourindustry. When you look at the stories in this issue, you’ll read about some exciting innovations that are coming through thepipeline and which complement the enormous creativity of our European customers.
There is a particular focus on thermoplastic polyurethanes (TPU) – that most versatile range of products. The main feature(pages 6 to 8) gives an interesting insight into footwear applications, which is a market that Huntsman first became involvedwith in the 1970s, when AVALON® TPU was launched. Having led our global footwear business back in the early 1990s,
I still have a special affinity for AVALON®, and it’s great to see our footwear products thriving and our customers continuing tointroduce such cutting-edge innovations.
Huntsman’s presence at UTECH Europe will showcase how we are helping to address global challenges related to food,energy and comfort. Twenty-five years after joining the industry, I remain as enthusiastic about the wide ranging benefits ofMDI-based polyurethanes as ever. I hope that after reading this magazine, you do too.
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At its European manufacturingheadquarters in Oudenaarde, Belgium,Samsonite is using grades fromHuntsman’s IROGRAN® range toproduce parts for its Lite-Locked, Lite-Cube, Cosmolite, Firelite andChronolite luggage carriers.
In its relentless pursuit for innovationand quality, Samsonite was keen tostart sourcing more of its raw materialsfrom Huntsman. Specifically it wantedan extremely reliable new material to bond to a polyamide handle.Samsonite’s product developmentexperts were very clear about theirrequirements. The material needed tooffer good tear strength that couldwithstand cuts, abrasion and generalwear while being soft to touch andaesthetically attractive.
Following recommendations by IMCD,one of Huntsman’s key distributionpartners, Samsonite decided to runtrials with a plasticizer-free IROGRAN®
TPU that forms excellent bonds to other materials.
The IROGRAN® TPU in question offeredall the processing properties Samsoniterequired, including high shear rateresistance in the tool during moldingand good strength at higher demoldingtemperatures. As well as being soft to
touch with a matt, dry-feel surfacequality, the finished material has anattractive appearance. It is alsoresistant to scratching, marring anddoesn’t show sweat marks or residues.
Supported by Huntsman’s technicaldevelopment team, Samsonite ran a series of product trials. Followingpositive results, IROGRAN® TPU wasintroduced for full-scale production ofhandles for Samsonite’s premium Lite-Locked and Lite-Cube models. In addition, Samsonite has switched to using the same IROGRAN® TPUmaterial for the production of hinges on its Cosmolite, Firelite and Chronolite models.
Rik Hillaert, Vice President,Manufacturing and Development atSamsonite, said: “Continual innovationis key to Samsonite’s success. We areconstantly striving to improve ourproducts with new designs andfeatures, adapted to the needs ofconsumers in different markets, whilestaying true to the Group’s core valuesof lightness, strength and functionality.We have been very pleased withHuntsman’s technical support anddelighted with the results achieved with IROGRAN® TPU.” |
The polyether-based TPU materials – IROGRAN® A 85 P 4394 UV DP and IROGRAN® A 92 P 4637UV DP – are part of Huntsman’s established IROGRAN® product range. Both are designed forjacketing the cables of heavy duty pieces of equipment that have to function in harsh, abrasive andoutdoor environments, and are exposed to the elements.
Over time, exposure to UV light can cause cabling materials to degrade, losing performance in tensilestrength, abrasion and elongation. On oil rigs, offshore wind farms and in underground applications,any form of deterioration in cable quality is unacceptable and could have costly consequences.
Huntsman’s latest wire and cable innovations were developed in response to requests fromcustomers in the Americas, who were asking for increasingly demanding performance levels fromtheir cable jacketing materials.
Easily processed and offering a wide temperature window, Huntsman’s new IROGRAN® materialscontain a UV package that is not listed as a substance of very high concern (SVHC) under REACHregulations. Designed to increase cable longevity, the inclusion of this additive is beneficial for wireand cable manufacturers who are looking to improve performance and comply with stringentenvironmental standards. |
Samsonite picksHuntsman to handleluggage upgradeSamsonite, the world’s largest travelluggage company, has chosenHuntsman’s TPU to enhance severallines in its prestigious collection.
New UV protected TPU grades developed for industrial cablesHuntsman has developed two ultraviolet (UV) protected grades of TPUs for use in offshore, oil and gas,and mining wire and cable applications.
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To improve the longevity of cables andconnectors used to charge electric andplug-in hybrid vehicles, Mennekes, a leadingmanufacturer of industrial plugs and sockets,is using a TPU from Huntsman.
Headquartered in Kirchhundem, Germany,Mennekes is employing an IROGRAN® TPUgrade to produce protective caps that fit onthe connector end of type 2 charging cables.These coupling flexes are used to connectcars to vehicle charging points, which arenow commonplace around city centres, inmunicipal car parks, at petrol stations and bythe roadside. The end caps are put in placewhen the cables are not in use, helping tokeep dirt and moisture out of the holes wherethe sleeve contacts are inserted.
Mennekes specified IROGRAN® TPU for its endcap application following recommendations
from Chemie Plast – one of Huntsman’s keydistribution partners. The product developmentteam at Mennekes were very clear about their requirements. They needed to source a material that would offer high wear andabrasion resistance. The solution also had to provide very good temperature flexibility.Mennekes plugs and sockets for the electricvehicle market have to withstand a range of temperature extremes from sub-zeroconditions in Norwegian winters to hot andhumid Mediterranean summers.
Before approaching Chemie Plast, Mennekeshad tested other materials including rubber and numerous thermoplastic elastomers (TPE).However, they found that these moldings wereprone to leaving scuffmarks when they cameinto contact with car paint. To overcome thisproblem, Chemie Plast recommended a hardergrade of IROGRAN® TPU.
Mr Thomas Tigges, Plastic Technician atMennekes, said: “As ownership of electricvehicles increases there will be a need formore publicly accessible charging stations –and of course more charging cables and endcaps. With new volumes coming through wewanted to be sure that we were using thevery best material available for our cable caps.The advice on offer from Chemie Plast,combined with the quality of Huntsman’sTPU, was a compelling proposition. We aredelighted with the support offered throughoutthe decision making process and with theend result.”
Mennekes is a family-run business withsubsidiaries and agencies in more than 90 countries, giving it global reach. The business dates back to the 1930s when Aloys Mennekes set up a smallelectrical workshop. Today, the Mennekesproduct portfolio comprises over 15,000standardised CEE industrial plugs andsockets in different shapes and designs for multiple purposes. The business alsoproduces innovative components for theincreasing electric mobility market includingsockets, charging cables, vehicle plugs aswell as complete charging stations forcommercial and private use. |
Improving end caps forcharging electric vehicles Worldwide, the market for electric cars is growing rapidlywith many leading automotive brands now offeringplug-powered and hybrid vehicles. UK-based think-tank,the Institute of Economic Affairs (IEA) predicts there will be1.1 million electric and plug-in hybrid electric vehicle salesglobally by 2015; 6.9 million by 2020; and 106 million by 2050.Hand in hand with the growth of electric vehicles comes theneed to establish and manage an increasing number ofcharging stations.
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Brazil machine hall inaugurated
Huntsman has become the first U.S. manufacturer to receive theUnderwriters Laboratories (UL) Environment certification for a polyol.
TEROL® Performance Polyolssite receives ULEnvironment certification
TEROL® 563 modified aromatic polyesterpolyol is primarily used in polyisocyanurate(PIR) insulation applications. Whenformulated and processed properly,insulation panels produced with TEROL® 563polyol can pass the Factory Mutual 4450Calorimeter and ASTM E-84 Tunnel tests.
The UL certification demonstrates thatHuntsman’s TEROL® Performance Polyolsbusiness has the technological expertiseand logistical capabilities to provide anindependent, third party certified range ofrecycled content and renewable contentpolyols. Huntsman’s aromatic polyesterpolyols incorporate both pre-consumer andpost-consumer recycled content, allowing
customers to design their insulationproducts with confidence and meetpreferred purchasing protocols.
Les Yamato, Business Manager, TEROLPolyols, Huntsman Polyurethanes, said:“Receiving the UL Environment Certificationillustrates Huntsman’s continued commitmentto environmental excellence and providinghigh-quality, sustainable insulation productsto our customers. We strive to be anindustry leader in sustainability, and the ULEnvironment certification represents anotherstep toward that goal.” |
Huntsman has inaugurated a new machine hall for its polyurethanes business, adjacent to thecompany’s Advanced Technological Centre (ATC) in Taboão da Serra, Brazil.
Designed to support commercial and technical polyurethanes growth in the Brazilian region, the facility isbeing used to develop new polyurethane applications, simulate customer processes and carry outdemonstrations of Huntsman’s specialty systems.
Specialized equipment in the hall includes a high-pressure spray machine for elastomers, polyurea and spraypolyurethane foam; a mix head, high-pressure, injection device for rigid and flexible foam; and a lab scalebatch block machine for slab viscoelastic, high resiliency and rebound applications.
Alongside the new ATC (16,100 sqft.), the instruments in the machine hall will help Huntsman’s polyurethanesbusiness in Brazil grow strategically in automotive, insulated metal panels (IMPs), slabstock and ACE(polyurea coatings) markets as well as other sectors. |
New reactor installedat TEROL®
Performance Polyols siteHuntsman has installed a new reactor at itsTEROL® Performance Polyols manufacturingfacility in Houston, Texas.
The new aromatic polyol reactor, which hassignificantly increased the site’s annualproduction capacity, is enabling Huntsman tobetter serve its customers and meet growingdemand for specialty polyols.
Huntsman offers one of the broadest rangesof aromatic polyester polyols for rigid foamapplications, with hydroxyl values rangingfrom 120 to 350. Its customized polyolsolutions can meet the most demandinginsulation applications from spraypolyurethane foam, boardstock, insulatedmetal panels, structural insulated panels toappliances and commercial refrigeration.
Steve Burns, Vice President, Americas,Huntsman Polyurethanes, said: “Ourinvestment in the TEROL® PerformancePolyols manufacturing site illustrates ourcontinuing commitment to support thegrowth of these specialty polyols and theoverall global MDI urethanes sector. Byincreasing the site’s production capabilities,we can drive growth in our downstream MDIinsulation systems business and expandinto new markets.” |
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Focusing on footwear
PU Review (PU R): How long havepolyurethanes been used in the footwearindustry?Alfons Treml (AT): Polyurethanes were firstintroduced to the footwear industry in the late1960s and have been a popular raw materialever since – helping manufacturers makelighter, more comfortable shoes and achievegreater production efficiencies. Huntsman’sinvolvement in the sector dates back to theearly 1970s and the launch of AVALON® TPU– a range of premium materials developedspecifically for footwear applications.
PU Review (PU R): Is the AVALON® TPUrange still available today?AT: Yes. More than forty years on, theAVALON® TPU brand is still going strong.Footwear manufacturers respect the caliber ofthe material and the benefits it can bring to theprocessing and performance of shoe soles,and a variety of other footwear components.Today, AVALON® TPUs are part of a muchwider portfolio of lightweight polyurethanematerials developed to meet the needs of thefootwear industry.
PU Review (PU R): How has the footwearindustry changed since the introductionof polyurethanes?AT: The footwear industry has changedenormously since the 1970s. The last fivedecades have been characterized bytremendous growth. At the end of 2014, theWorld Footwear Yearbook reported that morethan 22 billions pairs of shoes were producedin 2013. While the last few years have beentricky in some regions because of the globaldownturn, industry revenue has continued togrow overall thanks to continuing demandfrom emerging markets such as India.
New fashions, modern manufacturingtechniques and more stringent environmentalstandards have also brought about majorchange across the industry. As styles haveshifted and production practices haveprogressed, material providers have had tokeep pace. At Huntsman that’s meant evolvingour portfolio to create new polyurethane-based systems that continually raise the barin terms of material performance, comfortand processability.
Polyurethane chemistry touches all of our lives. Whereveryou are, whatever you are doing, this special material ishard at work close by. Sometimes the presence ofpolyurethanes is invisible. At other times, its benefits canbe clearly felt – for example in shoes and boots. To learnmore about one of the most tangible polyurethaneapplications, PU Review spoke to Alfons Tremml,Commercial Manager for Footwear in Europe at Huntsman.
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We’ve had to develop solutions for newfootwear applications that go beyond simplysoling, for example, gel liners and even filmcoatings for shoe uppers. Expectations forbetter performing materials in terms ofresistance to water, abrasion and static havealso increased.
PU Review (PU R): Can you give us somespecific examples of footwear innovation?AT: There are many examples of innovationbut three achievements really stand out. In theearly 1990s, our footwear business – then partof ICI – was the first company to introducewater-blown polyether footwear systems,eliminating the use of chlorofluorocarbons(CFCs). Later that decade we broke newground with the first universal prepolymerfor use with both polyester- and polyether-based systems. Around the millennium weinvented AVALON® Duo – a dual solingsolution that combines the benefits of TPUand polyurethane.
PU Review (PU R): You mention threedifferent types of polyurethane: polyester,polyether and TPU. What sets each apart?AT: Polyester, polyether and thermoplasticpolyurethanes all have slightly different traitsand as such, lend themselves well to differentfootwear applications. As a general rule,polyester polyurethanes work well in safetyshoe applications. They have a high resistanceto chemicals, as well as substances such asoil and petrol. They are also ideal for direct-onprocessing and for casting unit soles – bothsingle and double density.
Polyether polyurethanes deliver good patterndefinition, whatever the processing techniqueor desired density. They offer outstandingflex-life properties and hydrolysis resistance.
With the ability to withstand moisture, they areperfect for producing shoes and sandals wornin humid, tropical climates where water ingressand attack from microorganisms that thrive inwarm, damp environments is commonplace.
Then there are TPUs – one of the bestperforming footwear materials available interms of abrasion and impact resistance, flex-life and optical stability. TPUs can be used tocreate unit soles, which are stuck straight tothe upper of a shoe in the latter stages ofmanufacture. They can be combined with apolyurethane midsole to create a dual densitysolution. TPUs can also be precisionengineered to create footwear componentsincluding top pieces and molded heels forladies fashion shoes; sports plates for soccer,golf and baseball shoes; plus skates and ski boots.
PU Review (PU R): What materials dopolyurethanes compete with in the footwearsector and how does the chemistry compare?AT: Polyurethanes are one of the onlymaterials that can be used in almost everyfootwear application from outsoles andmidsoles to liners and uppers. This meansthey have to compete with all standardsubstrates such as ethylene-vinyl acetate(EVA), vulcanized rubber, thermoplasticrubbers, polyvinyl chloride (PVC), nylon andleather. Performance wise, polyurethanes offera number of advantages. They enablefootwear manufacturers to produce lighter,more comfortable shoes. They are easy toprocess, helping to improve production lineefficiencies. Polyurethanes can also beengineered to overcome yellowing andhydrolysis issues, which can affect footwearaesthetics and longevity.
PU Review (PU R): How do you see thefootwear manufacturing market developing?AT: The balance of power in footwearmanufacturing is unlikely to change in theimmediate future. According to the WorldFootwear Yearbook, Asia is responsible formanufacturing an estimated 87% of theworld’s footwear. China remains theundisputed leader, making almost two out ofevery three pairs of shoes sold globally.
In China, it’s very much a numbers game.Local manufacturers make millions of pairs ofshoes every year so unit prices can be keptlow, which is hard for manufacturers elsewhereto compete with. Other regions are slowlybecoming more attractive again but this willtake time. Within Asia for example, footwearcompanies are slowly starting to shiftproduction from China to Vietnam, Indonesiaand Taiwan. There is also growing interest inmanufacturing in Cambodia and Myanmar.
In Europe, where it’s more difficult to competeon cost, the market is largely dominated bysmall to medium sized companies makingshoes for niche applications such as safetyfootwear – where material performance isparamount.
It’s largely the same story in America.According to the American Apparel andFootwear Association, domestic footwearcompanies manufactured just 1.4% of shoespurchased in the U.S in 2011. Like Europe,footwear production in the U.S is generallymore specialist, primarily safety footwear butalso military combat boots.
In terms of future growth, India is definitelya market to watch. There is a big domesticmarket for sandals and casual shoes,which is growing quickly and the industryis starting to wake up to what’s possiblewith polyurethanes.
PU Review (PU R): You mentioned that otherregions are becoming more attractive again asmanufacturing locations – what’s driving this?AT: There are two key factors. Importprocedures are becoming increasinglycomplex – which means domesticmanufacturing is starting to have moreappeal. Processing techniques are alsobecoming more automated – makingmanufacture in other regions, outside of Asia,more competitive.
Huntsman is also involved in corporate socialresponsibility initiatives in countries such asIndia, which are designed to make the localfootwear industry more sustainable over time.In Kerala we work with the Footwear Designand Development Center (FDDC) – a localcharity that helps equip people in ruralcommunities with the skills they need to enterthe footwear profession – helping to growthe sector and improve prospects forpeople locally.
These are just two examples of how we are helping to improve sustainability in thefootwear sector. Countless other instancesexist and it’s this well-rounded approach to supporting sustainability in the footwearsector that our customers value and which has given us such a high share of the market worldwide. |
The PU Review team would also like to thankthe following individuals for their editorialcontribution:
• Leon Chou, Technical Manager forElastomers and Regional Footwear IndustryCoordinator at Huntsman’s Asia Technology Center
• Mark Kwek, Strategic Marketing Manager,Great Asia
• Memphis Wei, Commercial ManagerFootwear, China
• Colin Tan, Sales Manager, TPU, Great Asia
• Jim McCloud, Senior Sales Representative, PU
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We also offer customers practical advice toreduce manufacturing costs and improve stafftraining. In recent years we’ve worked with anumber of European manufacturers, helpingthem to get new production lines up andrunning. This kind of work will remain of highvalue as the drive for automation continues asmainstream footwear manufacturers considera return to production in Europe and the U.S,and need to train more people locally.
PU Review (PU R): Finally, can you tellPU Review readers what Huntsmandoes to support sustainability in footwearmanufacturing?AT: In a fast paced industry, where so muchis in flux, making a positive sustainabilitycontribution is not just about making productsthat have less environmental impact. That’simportant of course and something we takevery seriously. But sustainability in footwearmanufacturing is also about creating stability.The footwear industry is highly pressurised, it’sdominated by seismic seasonal shifts.Manufacturers need to respond rapidly toconsumer demands. For big manufacturersthis can mean churning out thousands ofnew styles every year. For smaller companiesit’s about keeping production sustainablefrom a cost perspective so they canremain competitive.
We support sustainability by looking atinnovation and people alongside the planet.It’s our duty to keep a pipeline of newproducts coming through that enablemanufacturers to make high quality shoesand boots at an acceptable cost and withminimal environmental impact. DALTOPED®
Lite polyether material is one such example. Launched three years ago, thisultra-lightweight, cost-effective and highlyversatile alternative to ethyl vinyl acetate(EVA) makes it possible to produce extremelylightweight unit soles on existing polyurethanemachinery at a lower production costwith less wastage.
PU Review (PU R): Are there any otherregional differences of note?AT: Yes. The difference in regional productionlevels is reflected in the use of materials andmanufacturing techniques employed aroundthe world. Polyurethanes and TPUs have aglobal share of the footwear market of around8%. In Europe this rises to approximately 18%– echoing the emphasis on high quality,specialist footwear applications.
In terms of techniques, unit sole casting iswidely used in Asia, South Europe and theMiddle East, where labour costs are generallylower. While in central Europe and the U.S.,where employment costs are typically higher,and there is a move towards more automatedmethods, which are far less labour intensive.
PU Review (PU R): In such a competitivesector, how does Huntsman differentiate itself?AT: We have many strengths; our time in themarket place, the breadth of our portfolio, andour global capabilities. Customers tell us thatthe quality of our technical partnerships alsohelp us stand out from the competition. Fromour dedicated footwear development center inBelgium, we undertake long-term researchprojects into emerging footwear applications.Liaising with customers we assess futuremarket trends and develop new materials –producing samples in house on industrystandard machines that we’ve invested in.
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The two companies have been collaborating on a series of soling projects that have helpedto improve productivity on Panter’s production lines and enhance the performance of itstechnical workwear.
Panter has the capacity to produce thousands of pairs of safety shoes every day. Its manufacturingfacility in Alicante, Spain is operational 24 hours a day, six days a week, and employs only the verybest footwear materials.
With help from Huntsman, Panter has switched to using TPU to create soles for a range of itsprofessional safety boots, which are used in meat processing and butchery environments. Panteremploys Huntsman’s TPU to form a blue transparent outsole with a white mid sole. The materialalso offers Panter higher cycle times and good abrasion and slip resistance – a winning combinationover conventional soling options.
Panter has also been working with Huntsman to improve the design of a wellington boot that itmanufactures for a leading Spanish supermarket chain. Employees who work in the supermarket’sfish / seafood department and distribution depots used to wear boots made from other materials.However, high levels of humidity and the fact that the boots were heavy and uncomfortable to wear,meant employees’ feet were prone to sweat.
Together, Panter and Huntsman developed a solution that would perform well in harsh environmentsfor a long period of time. Lightweight and offering good anti-slip resistance, excellent hydrolysisresistance and decent cold temperature protection for the wearer – this has been a major stepforward in terms of the safety, comfort and wellbeing of the supermarket’s workers. |
SCHÜTZE-SCHUHE is a family-run business,best known for making hardwearing boots thatenable construction employees to work on hotasphalt for more than an hour. The organizationalso has an established range of roofing shoesthat offer exceptional grip.
When SCHÜTZE-SCHUHE decided to diversifyand create a range of ESD safety shoes, thebusiness began looking for a new polyurethanesupplier to work flexibly with. The ideal partnerhad to be located in central Europe; willing todevelop a double-density soling solutiontailored to specific requirements; and capableof providing hands-on technical support.
SCHÜTZE-SCHUHE contacted Huntsman andtogether the two companies embarked on the
development of a bespoke soling solutionbased on Huntsman’s DALTOPED® DUALDENSITY technology. Following a period ofrapid product development and successfultrials at Huntsman’s footwear technologycenter in Belgium, SCHÜTZE-SCHUHE beganusing the DALTOPED®-based material to create a compact polyurethane outsole with a foamed, soft polyurethane midsole.
Thomas Schützeneder, CEO of SCHÜTZE-SCHUHE, said: “Our business is renowned formaking shoes and boots that are tough andhave a long working life but are comfortableenough to be worn eight hours a day, weekafter week. We only pick the very bestmaterials and never compromise quality – twovalues we carried through to our work with
Huntsman. Forging new supplier relationshipscan be daunting but the transition to workingwith Huntsman was a really positiveexperience. They took a flexible approach to innovation, provided exactly the kind ofmaterial we needed and the technical supportthey gave was invaluable.”
Following completion of its dual density solingproject for SCHÜTZE-SCHUHE, Huntsmanis now supplying the business with additionalproducts for other aspects of its productionset up – including the lines where itshighly insulated asphalt boots and slipresistant roofing shoes are manufactured. |
Huntsman’s footwear expertshave been working closelywith Panter (IndustrialZapatera) – one of the largestproducers of safety shoesand boots in Iberia.
Huntsman TPU is sole choice for Panter
Stepping up safetyshoe production
Using a specialist polyurethane material from Huntsman, SCHÜTZE-SCHUHE – an Austrian manufacturer ofpremium quality, professional footwear – has developed a next generation soling solution for a new range of light, fashionable, safety shoes that have electric static discharge (ESD) properties.
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Polyurethane shows differentside to exterior cladding
Now, polyurethanes are also proving theirbenefits in siding, cladding and exterior trimapplications thanks to the efforts of Boral – an international building and constructionmaterials group.
Combining a proprietary polyurethanechemistry that utilizes Huntsman products withfly ash (a by-product of coal-fired electricgenerating plants), Boral has developedTruExterior™ Siding and Trim – a new categoryof products for exterior building applicationssuch as cladding, sofits, fascias, door casingsand window surrounds, which have historicallyemployed wood.
Less susceptible to the elementsDescribed by Boral as a poly-ash structure,TruExterior™ products are engineered to looklike traditional wood-based siding and trimsolutions. Similar in weight but far lesssusceptible to degradation from insects orexposure to the elements, TruExterior™ requiresvery little maintenance. It can be paintedany color and is easy to cut, route, drill andmill using traditional woodworking toolsand methods.
Unlike other exterior trim solutions such aswood, wood composites, fiber cement, orvinyl/PVC, TruExterior™ products maintain ahigh level of dimensional stability during periodsof moisture and temperature change. They arealso suitable for ground contact and do notrequire end-sealing, special adhesives or othercostly installation techniques.
More than 70% recycled contentFurthermore, the TruExterior™ material hasexcellent sustainability credentials. Consistingof more than 70% recycled content blendedwith a relatively low level of polyurethanecomponent, TruExterior™ is manufactured in a LEED® Silver facility using a proprietary lowemission and low energy usage productionprocess. As a result, the products cancontribute to a building’s LEED® pursuits. It can also help reduce lifecycle costs.
Boral’s development of TruExterior™ Siding and Trim is indicative of a wider shift in theconstruction market towards man-madematerials that are more resource efficient and have greater potential to reduce energyconsumption and environmental impact.
Brian Below, President of Light BuildingProducts at Boral, said: “Across theconstruction industry, the last two decadeshave seen enormous change in the use ofbuilding materials. Government mandates and legislative measures, designed to boostthe energy efficiency of buildings, have led to the evolution of existing technologies andthe development of many new alternativeproducts. Several years ago we spotted agap in the exterior trim market for a new typeof material. Industry feedback told us thatengineered wood, PVC and fiber cementsolutions were working well as woodsubstitutes – but still had their drawbacks.Moisture resistance, stability duringtemperature fluctuations, and workabilitychallenges were just some of the issuesraised by users.”
“Realizing that no single material offered exactlythe right mix of attributes we decided todevelop a solution that would work as a truereplacement for wood trim. With builders andhomeowners accustomed to the workability of wood we knew we needed to develop a product that would look good, and offerexcellent durability, but be easy to cut andfasten. We did just that, testing and trialing all aspects of the TruExterior™ material over asix year period and creating a product unlikeanything else available.”
Proven performanceBefore its launch, the TruExterior™ materialunderwent rigorous internal and third partytests to verify its performance and durability,even in the harshest of climates. Third-partycertification group MBDC has assessedTruExterior™ Siding and Trim for its overallimpact to health and the environment andcertified it with a Cradle to Cradle™ Silver rating.Scientific Certification Systems (SCS) Globalhave also certified that the products havegreater than 70% recycled content. |
For more information:www.BoralAmerica.com/TruExterior [email protected]
Polyurethane chemistry is used extensively across theconstruction industry. Typically it’s found in insulation to makebuildings more energy efficient and in adhesive, coating andelastomer products, where it can help enhance durability,toughness and overall aesthetics.
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Automotive team focuses on reducingnoise, vibration and ride harshness
In the Netherlands there is a mature, high tech, hydroponics industry continually growing food tomeet national and international demand. To support this sector, Huntsman has developed aspecial hydrophilic material. With a special affinity for water, the technology has been designed foruse in commercial greenhouses and food-growing environments, in the production of tomatoes,peppers, cucumbers, eggplants and salad leaves.
The material, marketed as BVB SUBLIME® substrate, is produced in conjunction withBVB Substrates – a Dutch specialist in greenhouse horticulture. Clean, inert and easy to use it hasa high pore volume that gives it an excellent water holding capacity. A well balanced water /air ratioenables it to release moisture to plant roots slowly, over time.
Delivering a comparable performance to existing plant growing substrates, BVB SUBLIME®
substrate is ideal for use in greenhouses employing traditional hydroponics growing systems, aswell as NFT – the nutrient film technique. Via this method, salad leaves grow in a watertight gully.At the bottom of the channel, a shallow stream of water containing dissolved nutrients circulatespast the bare roots of plants. A continuous supply of oxygen is also provided, encouraging theroot system to establish on a substrate at the base of the waterway.
Growing plants using BVB SUBLIME® substrate has further advantages. With the need for soileliminated, greenhouse drains can be kept clear. In addition, the roots of salad plants such aslettuce are kept clean – and require less preparation before distribution to retail outlets.
Huntsman and BVB Substrates have worked together for five years undertaking trials to ensurethat BVB SUBLIME® substrate complies with food safety standards. Tested by numerous growersand research stations, the material is now used in commercial greenhouses worldwide andinterest in this ‘next generation substrate’ is increasing.
As well as commercial hydroponic growing mats, BVB SUBLIME® substrate can be shaped intogrow plugs and propagation blocks, supporting the different stages of the plant growth cycle –and a growing industry with the potential to benefit everyone on the planet. |
For further information about BVB SUBLIME® substrate, contact: [email protected]
In the food industry, demand for fresh crops, all year round, isincreasing. Consumers are now accustomed to having ready access tofruit and vegetables, regardless of season. With the global populationbooming – and estimated to surpass nine billion by 2050 – pressure onfood supplies is set to intensify.
A growing technology
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This issue we can announce that the WindsorMachine Group (WMG) is now creatingheadrests for a leading automotivemanufacturer using a fully formulated,polyurethane foam from Huntsman, based onthis novel chemistry.
The bio-based headrests are the first of theirkind to be produced in Europe and employRUBIFLEX® H Bio – the name given toHuntsman’s rapeseed oil /MDI-basedfoam system.
WMG works with some of the world’s best-known automotive brands. Its design engineershave a reputation for developing creativesolutions that can significantly improve the fuelefficiency of cars and the manufacturingprocesses used to create them. The headrestsare being manufactured by WMG in Slovakia,at a facility that opened in 2014.
Rob Purves, Windsor Machine and StampingSupplier Quality Manager at WMG, said: “It’s hard to believe that the foam systemdeveloped by Huntsman is bio-based. Itsquality is excellent, outperforming many of theother materials we’ve tested. Crucially, thepercentage of bio-based content it contains is also significantly higher. When we firstcontacted Huntsman we wanted to find a foamwith a minimum bio content of 5% – to meetOEM requirements. Huntsman recommendedRUBIFLEX® H Bio foam system. With 9% biocontent; no adverse effects on performanceproperties; and a better process window; we knew instantly that it represented a majorleap forward in foam technology.”
Incorporating bio polyols into foam productionhas proved complicated in the past. Thepresence of sustainable ingredients hasnegatively impacted on both the processingand performance capabilities of the resultingmaterial. Bio polyols are typically incompatiblewith standard polyether-polyol combinationsused in the manufacture of flexible moldedpolyurethanes. As a result the bio polyol canseparate very quickly. If this occurs, re-mixingwith a different storage tank and pump isneeded – which can be costly and timeconsuming. Some bio polyols can also have a detrimental effect on curing and finalmechanical properties.
Huntsman’s innovation team worked toovercome this problem, developing a bio polyolthat has been pre-polymerized with specificMDI isomers. As a result, RUBIFLEX® H Biofoam system offers a better process window –enabling the production of different foam partsof a different hardness, density and shape.Demold times are also short. The completecycle time is around three minutes.
Huntsman and WMG began discussions inNovember 2013. The conversation was timely.Huntsman had just initiated conversations withOleon about its bio prepolymer developmentproject. Impressed by what it heard,WMG decided to work with Huntsman inFebruary 2014.
Huntsman’s first task was to define the rightprepolymer / polyol formulation based onWMG’s specification and process conditions.With parameters agreed, Huntsman created
foam prototypes at its technical developmentcenter in Deggendorf, Germany. Once WMGwere happy, Huntsman offered additionalsupport, performing quality checks includingPPAP (Production Part Approval Process) – a common standard developed by theAutomotive Industry Action Group (AIAG) thatestablishes confidence in component suppliersand their production processes. As productioncommenced, Huntsman helped WMG further,carrying out an audit of its health and safetypractices and delivering the polyurethaneindustry’s Walk the Talk training program.
Continuing, Rob from WMG, said: “In additionto supplying a top quality bio-based foam,Huntsman’s full service package had strongappeal. We’ve been producing headrests inother parts of the world for many years but asa relative newcomer to Europe, we needed anMDI partner that was prepared to offer morethan just materials. With a new site to bringonline, equipment to install and people to train,Huntsman’s development, prototyping andtechnical support was invaluable – and anadded bonus alongside its bio-based system.”
WMG commenced production of the newheadrests in Q4 2014 (October). At the time of going to press, Huntsman was the only MDI supplier offering a bio-based prepolymertechnology to automotive OEMs in Europe. |
* Huntsman’s bio-based prepolymerwas realized with support from Frenchagribusiness Sofiproteol)
In the March 2014 edition of PUReview we announced Huntsman’ssuccessful development of aspecial polyurethane prepolymerbased on rapeseed oil. This majorachievement* was instigated toenable the production of moresustainable polyurethane materialsfor the automotive sector, wherethere is a major drive for resourceswith a strong renewable element.
Bio-based foam chosen for car headrest
Image for illustration only.
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Huntsman wins Johnson Controls performance award Huntsman has received a bronze Supplier Performance Award from Johnson Controls, Inc.(JCI) for demonstrating excellence in all aspects of its supplier /customer relationship.
Every year, JCI – the largest global supplier of automotive interiors and seating in terms of market share – evaluates theservices it receives from its suppliers via a comprehensive review and sustainability survey.
The award is judged on six categories: quality, commercial (which includes cost-saving objectives), supply teammanagement, service and general expectations, social and environmental sustainability, and general performance.
The top performers are subsequently awarded prizes in categories that focus on quality; commercial activity; supply chainmanagement; service and general expectations; social and environmental sustainability; and general performance.
Huntsman has been supplying its MDI RUBINATE® products to JCI’s automotive interiors and seatingbusinesses for many years. The business received its prize – one of just twenty-four trophies given out –at JCI’s annual North American Supplier Performance Awards ceremony in Plymouth, Michigan. |
Developed for Mazda by Huntsman and ToyoSeat & Takaya – a Japanese car seat andheadrest supplier – the automotive seatingsystem is being used in the cushion and backpanel of the vehicle’s front seats.
The Mazda2 is a sporty, 1.3 liter, compact car.Voted World Car of the Year in 2008, thevehicle has exceptional fuel economy and iswidely regarded as sleek, stylish and fun todrive. Awarded five stars in the Euro NCAPsafety ratings, the latest model of the Mazda2is lighter than previous versions and has CO2
emission levels as low as 115g/km. It has acarefully considered interior and according toclaims on the Mazda website, the companyhas perfected the ergonomics of the car’sseats and steering wheel.
Takaya introduced Huntsman to Mazda in2013. Following a series of meetings to discussthe benefits of using Huntsman’s polyurethanesin automotive seating systems, Mazda agreedthat Takaya and Huntsman could worktogether to develop a brand new system forthe latest Mazda2 model.
Over the following year, a team lead by SansanWu, Technical Manager, at Huntsman’s AsiaTechnical Center (ATC) in Shanghai, worked todevelop the system. Supported by Huntsman’sautomotive experts in the EAIME region, andworking closely alongside the Takaya team,Huntsman ran a number of evaluations and
demonstrations at Takaya’s production linein Japan.
Mazda sign off was secured in early 2014and mass production of the system beganin October 2014. Today, Huntsman, ToyoSeat & Takaya and Mazda are continuingtowork closely together to evaluate howHuntsman’s all-MDI system could beemployed in other vehicles in the automotivemanufacturer’s range.
Julian Young, Japanese Transplant Manager,Automotive and Flexible Industry at Huntsmansaid: “The use of our all-MDI seating system inthe Mazda2 is a huge achievement for ourautomotive team and represents a majormilestone for our Japanese business. Mazda is one of the world’s major automotivemanufacturers. It has been a real honor towork on a project that is so central to theexperience of people driving one of its mostpopular vehicles. For most people, buying a car is a major financial and emotionalinvestment, so ride quality can be a decidingfactor in the purchasing process. Polyurethaneshave been used across the automotive industryfor many years to help improve vehicleperformance and comfort. We are delightedthat Mazda has recognized the benefits of thischemistry and is realizing the value it can addto its vehicles worldwide.” |
Driving comfort in the new Mazda2An all-MDI automotive seating system based on Huntsman’spolyurethane chemistry is being used to drive greater comfortlevels in the brand new Mazda2, also known as the Mazda Demio.
New PU tooling technology breaks the mold
Encouraging model behavior
The availability for the first time of an effective, high temperature stable polyurethane will open up a world ofnew opportunities in a wide range of sectors including aerospace, automotive, marine and shipbuilding.
With a glass transition temperature (Tg) of 200°C and higher, the new generation VITROX® EST system offersproduct designers, tooling manufacturers and mold-makers a viable polyurethane alternative to otherthermoset-based tooling products – with a number of additional advantages.
The fast cure features of Huntsman’s VITROX® EST system make it possible to significantly reduce demoldingand manufacturing cycle times. This can help manufacturers increase productivity, reduce energy costs andcut carbon emissions. The VITROX® EST system can also be precisely formulated to suit specificrequirements – offering added flexibility and broadening scope for innovation.
VITROX® EST system’s high Tg properties mean a constant coefficient of thermal expansion (CTE) from roomtemperature to 200°C is achievable. This enables the creation of products and tooling boards with improvedlong-term stability when exposed to high temperatures. Products and tooling boards made with the VITROX®
EST system also demonstrate better impact resistance and good machinability. Processing benefits include along, tunable pot life (5-20 minutes) and a low viscosity. Furthermore, the system is processable on lowpressure casting machines. |
Huntsman has made a major tooling technology breakthrough. The business hasdeveloped a new polyurethane resin system that cures extremely quickly and allowsthe production of high heat stable modeling, tooling and rapid prototyping boards.
Using computer-modeling techniques to understand how a material,object or structure will behave over time, or when exposed to differentenvironments or circumstances, is now a fundamental part of the productdesign process – regardless of application or end market.
Employing established modeling methods –adapted for its own purposes – Huntsmanuses the science of simulation to gain a deeperunderstanding of what it is possible to achievewith polyurethanes. This strategic approach isdelivering major benefits for Huntsmancustomers across a range of sectors, inspiringinnovation. PU Review spoke to JanVandenbroeck to discover more.
“Architects and structural engineers wouldnever dream of constructing a high-risebuilding without investigating how it wouldcope in an adverse weather event or naturaldisaster. Similarly, automotive manufacturerswould never approve new car conceptswithout exploring every aspect of its design,from aerodynamics to its performance ondifferent surfaces.
Diving deeper into polyurethane chemistry“When it comes to road testing polyurethanesand creating new MDI-based systems forspecific applications, we apply the same rules.Several years ago we decided to invest incomputer modeling and dive deeper intopolyurethane chemistry.
“At our R&D headquarters in Belgium weformed a dedicated computer modeling team
to study how polyurethanes perform in certainscenarios. This five-strong group appliesalgorithms and equations to help fine tunechemical formulations and achieve the productproperties our customers want. Sometimes theprojects we work on are customer specific.Some are driven by our own ideas. Others arerun in conjunction with world-renowneduniversities and institutions including theBelgian and Dutch governments, and theEuropean Union.
Layering additional information“Computer modeling in the polyurethanesindustry has been around for a while but we’retaking it a step further. Take flexible foams asan example. In the past, computer modelinghelped define the structure of a polyurethanefoam. Today, we can simulate what the perfectfoam would look like and layer that informationwith data about external influences and theirimpact on processing and performanceproperties. These extra insights are helping uscreate innovative polyurethane-based productsthat are truly fit for purpose.
“In recent years, we helped developACOUSTIFLEX® S – a special form of soundinsulation. Going beyond conventional R&Dtechniques, we explored the chemical /
acoustic relationship of the system to maximizeits ability to muffle sound. To help improvebuilding energy efficiency, we are using ourcomputer modeling capabilities to investigatehow the thermal properties of insulation can beimproved to develop super insulating materials.And in the automotive industry, we are helpingvehicle manufacturers define what comfort –delivered by polyurethane foams – should feellike. Many manufacturers already run their owntests to help quantify what is ultimately asubjective area. Our work builds on this,translating their requirements into specificproduct parameters. We’ve also recentlyintroduced a CT scanner to our research lab,enabling the 3D analysis of foam andcomposite structures.” |
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Forthcoming events andtechnical presentations
European Coatings Show, Nürnberg, Germany (21-23 April)
Ligna, Hannover, Germany (11-15 May)
Chinaplas, Guangzhou, China (20-23 May)
2015 Polyurethanes Technical Conference, Orlando, Florida(5-7 October)
Fakuma, Friedrichshafen, Germany (13-17 October)
WoodEx, Moscow, Russia (24-27 November)
Leathertech, Dhaka, Bangladesh (26-28 November)
List of forthcoming events:For more information on the subjects covered in PU Reviewmagazine, please contact the editor:Ilse Vanden Brande, [email protected],+32 (0) 2 7589420
While all the information and recommendations in this publication are to the best ofour knowledge, information and belief accurate at the date of publication, nothingherein is to be construed as a warranty, express or otherwise.
ACOUSTIFLEX®, AVALON®, DALTOPED®, IROGRAN®, RUBIFLEX®,RUBINATE®, TEROL® and VITROX® are registered trademarks of Huntsman oran affiliate thereof in one or more, but not all, countries. BVB SUBLIME® is aregistered trademark of Bas van Buuren B.V. LEED® is a registered trademark ofU.S. Green Building Council (ISGBC). Boral TruExterior® Trim boards is aregistered trademark of Boral Composites Inc.
Copyright © 2015 Huntsman Corporation. All rights reserved.
Designed and produced by: Chris Pearson creative communications.
RUBIFLEX® Cocoon technologycreates cool comfort
The availability of RUBIFLEX® Cocoontechnology makes it possible to fabricatefoams that combine the very best attributes ofexisting memory and high resilience foamsolutions, with a number of additional benefits.The resulting foam slabs provide excellentsupport and good pressure distribution – gentlycradling the body and minimizing pressurepoints to maximize blood flow and promotequality sleep and relaxation.
With RUBIFLEX® Cocoon technology, comfortis heightened further still thanks to the uniquemoisture management properties of thesystem. Special hygrothermal attributes helpdissipate the natural accumulation of heat andmoisture generated by the body when it comesinto contact with mattresses, pillows, toppers,armchairs, sofas and car seats.
The polymer structure of RUBIFLEX® Cocoontechnology offers a good balance of hydrophilicand hydrophobic segments – enabling watervapor permeability and moisture transmission.
With an open cell structure, the naturalincrease in humidity produced by the body isdispersed very effectively. Airflow permeability isalso high – helping to transport heat way fromthe body’s surface. Tests show that thetemperature build up in a RUBIFLEX® Cocoon-based foam is more than 1.5°c lower than in acomparable memory foam solution. Combined,these qualities help support the body’s naturalthermoregulation mechanisms.
RUBIFLEX® Cocoon technology is now incommercial use. Spanish company Colchonesy Componentes Aspol is using it to producea range of mattresses for one of thebiggest department store chains in Europe,El Corte Inglés.
Foams based on RUBIFLEX® Cocoontechnology have a dry yet silky feeling andwork well in all climates. They are durable andresilient, retaining their original feel, thicknessand shape over time – despite changes intemperature conditions. RUBIFLEX® Cocoon
foams also have an excellent wet compressionset and good tear strength. Conforming toLGA and CertiPUR standards they meet lowVOC requirements. Furthermore, they can bevacuum packed and are suitable for use inadjustable mattresses.
RUBIFLEX® Cocoon technology is a new technology from Huntsman that’s beendeveloped with human wellbeing top of mind. Used to manufacture cool,breathable, flexible foams, RUBIFLEX® Cocoon technology can significantlyenhance comfort in bedding, furniture and seating applications by reducing thebuild up of heat and moisture that transfers from the body when it is at rest.
Find us on:
Facebook: www.facebook.com/huntsmancorpTwitter: www.twitter.com/Huntsman_CorpLinkedIn: www.linkedin.com/company/huntsmanGoogle Plus: www.plus.google.com/106818920361803832093 YouTube: www.youtube.com/user/HuntsmanCorp
www.huntsman.com/pu 15
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.
We provide customers with a wide choice of footwear solutions, based on many differentpolyurethane chemistries. From fully formulated grades and tailor-made polyesters topolyether-based systems and TPU grades, we give footwear companies the freedom todesign innovative shoes, boots and sandals in step with the latest fashion trends,manufacturing techniques and environmental concerns. Combine our knowledge ofpolyurethanes with your expertise, and we'll create better footwear… together.
We create better comfort and durability. Together.
www.huntsman.com/pu
