April 2015
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
Focusing on
footwear
UTECH Europe:
Presenting our passion
for polyurethanes
Handling a luggage
upgrade for Samsonite
Driving greater comfort
in Mazda car seats
Computer modelling –
the science of simulation
www.huntsman.com/pu
PU briefing 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 polyurethanes
industry event which takes place every three years and which has sister events in America and China. I always find these
gatherings 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 is
not immune from macroeconomic or geopolitical developments, but I have to say that I see many encouraging signs for our
industry. When you look at the stories in this issue, you’ll read about some exciting innovations that are coming through the
pipeline 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 involved
with 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 to
introduce 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 of
MDI-based polyurethanes as ever. I hope that after reading this magazine, you do too.
Demonstrating our passion for PU
In mid April, Huntsman will be at UTECH Europe 2015, showcasing its
passion for polyurethanes and the ways in which its knowledge of this
specialist chemistry is helping to enrich the lives of people worldwide.
Polyurethanes surround our daily lives – having a
positive impact on the way we move around the
planet; how comfortable we feel; our ability to
save time and energy; and even the food that we
eat. Focusing on these four elements, products
on display at Huntsman’s stand (1210) – within a
special circle of innovation – will include:
• A flexible foam to help optimize comfort in
bedding, furniture and seating applications
• A hydrophilic substrate that can be used in
hydroponic greenhouses and commercial
food growing environments
• A resin to enhance the manufacture of
automotive carbon fiber composite panels
• A new polyurethane resin system that is a
viable alternative to other thermoset-based
tooling products
• Polyurethane additives and catalysts to
improve the performance properties of
polyurethane-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 and
drink-related applications.
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The team will also be taking part in the
UTECH Europe 2015 conference program.
Tony Hankins, President of Huntsman
Polyurethanes, will deliver the conference
keynote address, discussing the challenges
and opportunities facing the polyurethanes
sector in the medium term, in both Europe
and beyond. Wim Gilis will give a presentation
on the company’s new VITROX ® EST resin
tooling technology. And Geert Dries will
present a paper on emissions limits for
vehicle interiors and how next generation
polyurethane additives and catalysts are
helping original equipment manufacturers
comply with legislative measures. |
ilse_vanden_brande@huntsman.com
Samsonite picks
Huntsman to handle
luggage upgrade
Samsonite, the world’s largest travel
luggage company, has chosen
Huntsman’s TPU to enhance several
lines in its prestigious collection.
At its European manufacturing
headquarters in Oudenaarde, Belgium,
Samsonite is using grades from
Huntsman’s IROGRAN® range to
produce parts for its Lite-Locked,
Lite-Cube, Cosmolite, Firelite and
Chronolite luggage carriers.
In its relentless pursuit for innovation
and quality, Samsonite was keen to
start sourcing more of its raw materials
from Huntsman. Specifically it wanted
an extremely reliable new material
to bond to a polyamide handle.
Samsonite’s product development
experts were very clear about their
requirements. The material needed to
offer good tear strength that could
withstand cuts, abrasion and general
wear while being soft to touch and
aesthetically attractive.
Following recommendations by IMCD,
one of Huntsman’s key distribution
partners, Samsonite decided to run
trials with a plasticizer-free IROGRAN®
TPU that forms excellent bonds to
other materials.
The IROGRAN® TPU in question offered
all the processing properties Samsonite
required, including high shear rate
resistance in the tool during molding
and good strength at higher demolding
temperatures. As well as being soft to
touch with a matt, dry-feel surface
quality, the finished material has an
attractive appearance. It is also
resistant to scratching, marring and
doesn’t show sweat marks or residues.
Supported by Huntsman’s technical
development team, Samsonite ran
a series of product trials. Following
positive results, IROGRAN® TPU was
introduced for full-scale production of
handles for Samsonite’s premium
Lite-Locked and Lite-Cube models.
In addition, Samsonite has switched
to using the same IROGRAN® TPU
material for the production of hinges
on its Cosmolite, Firelite and
Chronolite models.
Rik Hillaert, Vice President,
Manufacturing and Development at
Samsonite, said: “Continual innovation
is key to Samsonite’s success. We are
constantly striving to improve our
products with new designs and
features, adapted to the needs of
consumers in different markets, while
staying true to the Group’s core values
of lightness, strength and functionality.
We have been very pleased with
Huntsman’s technical support and
delighted with the results achieved
with IROGRAN® TPU.” |
simone_richter@huntsman.com
New UV protected TPU grades developed for industrial cables
Huntsman has developed two ultraviolet (UV) protected grades of TPUs for use in offshore, oil and gas,
and mining wire and cable applications.
The polyether-based TPU materials – IROGRAN® A 85 P 4394 UV DP and IROGRAN® A 92 P 4637
UV DP – are part of Huntsman’s established IROGRAN® product range. Both are designed for
jacketing the cables of heavy duty pieces of equipment that have to function in harsh, abrasive and
outdoor environments, and are exposed to the elements.
Over time, exposure to UV light can cause cabling materials to degrade, losing performance in tensile
strength, 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 from
customers in the Americas, who were asking for increasingly demanding performance levels from
their cable jacketing materials.
Easily processed and offering a wide temperature window, Huntsman’s new IROGRAN® materials
contain a UV package that is not listed as a substance of very high concern (SVHC) under REACH
regulations. Designed to increase cable longevity, the inclusion of this additive is beneficial for wire
and cable manufacturers who are looking to improve performance and comply with stringent
environmental standards. |
simone_richter@huntsman.com
www.huntsman.com/pu
3
Improving end caps for
charging electric vehicles
Worldwide, the market for electric cars is growing rapidly
with many leading automotive brands now offering
plug-powered and hybrid vehicles. UK-based think-tank,
the Institute of Economic Affairs (IEA) predicts there will be
1.1 million electric and plug-in hybrid electric vehicle sales
globally by 2015; 6.9 million by 2020; and 106 million by 2050.
Hand in hand with the growth of electric vehicles comes the
need to establish and manage an increasing number of
charging stations.
To improve the longevity of cables and
connectors used to charge electric and
plug-in hybrid vehicles, Mennekes, a leading
manufacturer of industrial plugs and sockets,
is using a TPU from Huntsman.
Headquartered in Kirchhundem, Germany,
Mennekes is employing an IROGRAN® TPU
grade to produce protective caps that fit on
the connector end of type 2 charging cables.
These coupling flexes are used to connect
cars to vehicle charging points, which are
now commonplace around city centres, in
municipal car parks, at petrol stations and by
the roadside. The end caps are put in place
when the cables are not in use, helping to
keep dirt and moisture out of the holes where
the sleeve contacts are inserted.
Mennekes specified IROGRAN® TPU for its end
cap application following recommendations
from Chemie Plast – one of Huntsman’s key
distribution partners. The product development
team at Mennekes were very clear about
their requirements. They needed to source
a material that would offer high wear and
abrasion resistance. The solution also had
to provide very good temperature flexibility.
Mennekes plugs and sockets for the electric
vehicle market have to withstand a range
of temperature extremes from sub-zero
conditions in Norwegian winters to hot and
humid Mediterranean summers.
Before approaching Chemie Plast, Mennekes
had tested other materials including rubber
and numerous thermoplastic elastomers (TPE).
However, they found that these moldings were
prone to leaving scuffmarks when they came
into contact with car paint. To overcome this
problem, Chemie Plast recommended a harder
grade of IROGRAN® TPU.
Mr Thomas Tigges, Plastic Technician at
Mennekes, said: “As ownership of electric
vehicles increases there will be a need for
more publicly accessible charging stations –
and of course more charging cables and end
caps. With new volumes coming through we
wanted to be sure that we were using the
very best material available for our cable caps.
The advice on offer from Chemie Plast,
combined with the quality of Huntsman’s
TPU, was a compelling proposition. We are
delighted with the support offered throughout
the decision making process and with the
end result.”
Mennekes is a family-run business with
subsidiaries and agencies in more than
90 countries, giving it global reach.
The business dates back to the 1930s
when Aloys Mennekes set up a small
electrical workshop. Today, the Mennekes
product portfolio comprises over 15,000
standardised CEE industrial plugs and
sockets in different shapes and designs
for multiple purposes. The business also
produces innovative components for the
increasing electric mobility market including
sockets, charging cables, vehicle plugs as
well as complete charging stations for
commercial and private use. |
simone_richter@huntsman.com
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New reactor installed
at TEROL®
Performance Polyols site
Huntsman has installed a new reactor at its
TEROL® Performance Polyols manufacturing
facility in Houston, Texas.
The new aromatic polyol reactor, which has
significantly increased the site’s annual
production capacity, is enabling Huntsman to
better serve its customers and meet growing
demand for specialty polyols.
Huntsman offers one of the broadest ranges
of aromatic polyester polyols for rigid foam
applications, with hydroxyl values ranging
from 120 to 350. Its customized polyol
solutions can meet the most demanding
insulation applications from spray
polyurethane foam, boardstock, insulated
metal panels, structural insulated panels to
appliances and commercial refrigeration.
Steve Burns, Vice President, Americas,
Huntsman Polyurethanes, said: “Our
investment in the TEROL® Performance
Polyols manufacturing site illustrates our
continuing commitment to support the
growth of these specialty polyols and the
overall global MDI urethanes sector. By
increasing the site’s production capabilities,
we can drive growth in our downstream MDI
insulation systems business and expand
into new markets.” |
eric_stebel@huntsman.com
TEROL® Performance Polyols
site receives UL
Environment certification
Huntsman has become the first U.S. manufacturer to receive the
Underwriters Laboratories (UL) Environment certification for a polyol.
TEROL® 563 modified aromatic polyester
polyol is primarily used in polyisocyanurate
(PIR) insulation applications. When
formulated and processed properly,
insulation panels produced with TEROL® 563
polyol can pass the Factory Mutual 4450
Calorimeter and ASTM E-84 Tunnel tests.
The UL certification demonstrates that
Huntsman’s TEROL® Performance Polyols
business has the technological expertise
and logistical capabilities to provide an
independent, third party certified range of
recycled content and renewable content
polyols. Huntsman’s aromatic polyester
polyols incorporate both pre-consumer and
post-consumer recycled content, allowing
customers to design their insulation
products with confidence and meet
preferred purchasing protocols.
Les Yamato, Business Manager, TEROL
Polyols, Huntsman Polyurethanes, said:
“Receiving the UL Environment Certification
illustrates Huntsman’s continued commitment
to environmental excellence and providing
high-quality, sustainable insulation products
to our customers. We strive to be an
industry leader in sustainability, and the UL
Environment certification represents another
step toward that goal.” |
eric_stebel@huntsman.com
Brazil machine hall inaugurated
Huntsman has inaugurated a new machine hall for its polyurethanes business, adjacent to the
company’s Advanced Technological Centre (ATC) in Taboão da Serra, Brazil.
Designed to support commercial and technical polyurethanes growth in the Brazilian region, the facility is
being used to develop new polyurethane applications, simulate customer processes and carry out
demonstrations of Huntsman’s specialty systems.
Specialized equipment in the hall includes a high-pressure spray machine for elastomers, polyurea and spray
polyurethane foam; a mix head, high-pressure, injection device for rigid and flexible foam; and a lab scale
batch 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 polyurethanes
business in Brazil grow strategically in automotive, insulated metal panels (IMPs), slabstock and ACE
(polyurea coatings) markets as well as other sectors. |
eric_stebel@huntsman.com
www.huntsman.com/pu
9
5
Focusing on footwear
Polyurethane chemistry touches all of our lives. Wherever
you are, whatever you are doing, this special material is
hard at work close by. Sometimes the presence of
polyurethanes is invisible. At other times, its benefits can
be clearly felt – for example in shoes and boots. To learn
more about one of the most tangible polyurethane
applications, PU Review spoke to Alfons Tremml,
Commercial Manager for Footwear in Europe at Huntsman.
PU Review (PU R): How long have
polyurethanes been used in the footwear
industry?
Alfons Treml (AT): Polyurethanes were first
introduced to the footwear industry in the late
1960s and have been a popular raw material
ever since – helping manufacturers make
lighter, more comfortable shoes and achieve
greater production efficiencies. Huntsman’s
involvement in the sector dates back to the
early 1970s and the launch of AVALON® TPU
– a range of premium materials developed
specifically for footwear applications.
PU Review (PU R): Is the AVALON® TPU
range still available today?
AT: Yes. More than forty years on, the
AVALON® TPU brand is still going strong.
Footwear manufacturers respect the caliber of
the material and the benefits it can bring to the
processing and performance of shoe soles,
and a variety of other footwear components.
Today, AVALON® TPUs are part of a much
wider portfolio of lightweight polyurethane
materials developed to meet the needs of the
footwear industry.
6
PU Review (PU R): How has the footwear
industry changed since the introduction
of polyurethanes?
AT: The footwear industry has changed
enormously since the 1970s. The last five
decades have been characterized by
tremendous growth. At the end of 2014, the
World Footwear Yearbook reported that more
than 22 billions pairs of shoes were produced
in 2013. While the last few years have been
tricky in some regions because of the global
downturn, industry revenue has continued to
grow overall thanks to continuing demand
from emerging markets such as India.
New fashions, modern manufacturing
techniques and more stringent environmental
standards have also brought about major
change across the industry. As styles have
shifted and production practices have
progressed, material providers have had to
keep pace. At Huntsman that’s meant evolving
our portfolio to create new polyurethanebased systems that continually raise the bar
in terms of material performance, comfort
and processability.
Feature
We’ve had to develop solutions for new
footwear applications that go beyond simply
soling, for example, gel liners and even film
coatings for shoe uppers. Expectations for
better performing materials in terms of
resistance to water, abrasion and static have
also increased.
PU Review (PU R): Can you give us some
specific examples of footwear innovation?
AT: There are many examples of innovation
but three achievements really stand out. In the
early 1990s, our footwear business – then part
of ICI – was the first company to introduce
water-blown polyether footwear systems,
eliminating the use of chlorofluorocarbons
(CFCs). Later that decade we broke new
ground with the first universal prepolymer
for use with both polyester- and polyetherbased systems. Around the millennium we
invented AVALON® Duo – a dual soling
solution that combines the benefits of TPU
and polyurethane.
PU Review (PU R): You mention three
different types of polyurethane: polyester,
polyether and TPU. What sets each apart?
AT: Polyester, polyether and thermoplastic
polyurethanes all have slightly different traits
and as such, lend themselves well to different
footwear applications. As a general rule,
polyester polyurethanes work well in safety
shoe applications. They have a high resistance
to chemicals, as well as substances such as
oil and petrol. They are also ideal for direct-on
processing and for casting unit soles – both
single and double density.
Polyether polyurethanes deliver good pattern
definition, whatever the processing technique
or desired density. They offer outstanding
flex-life properties and hydrolysis resistance.
With the ability to withstand moisture, they are
perfect for producing shoes and sandals worn
in humid, tropical climates where water ingress
and attack from microorganisms that thrive in
warm, damp environments is commonplace.
Then there are TPUs – one of the best
performing footwear materials available in
terms of abrasion and impact resistance, flexlife and optical stability. TPUs can be used to
create unit soles, which are stuck straight to
the upper of a shoe in the latter stages of
manufacture. They can be combined with a
polyurethane midsole to create a dual density
solution. TPUs can also be precision
engineered to create footwear components
including top pieces and molded heels for
ladies fashion shoes; sports plates for soccer,
golf and baseball shoes; plus skates and
ski boots.
PU Review (PU R): What materials do
polyurethanes compete with in the footwear
sector and how does the chemistry compare?
AT: Polyurethanes are one of the only
materials that can be used in almost every
footwear application from outsoles and
midsoles to liners and uppers. This means
they have to compete with all standard
substrates such as ethylene-vinyl acetate
(EVA), vulcanized rubber, thermoplastic
rubbers, polyvinyl chloride (PVC), nylon and
leather. Performance wise, polyurethanes offer
a number of advantages. They enable
footwear manufacturers to produce lighter,
more comfortable shoes. They are easy to
process, helping to improve production line
efficiencies. Polyurethanes can also be
engineered to overcome yellowing and
hydrolysis issues, which can affect footwear
aesthetics and longevity.
PU Review (PU R): How do you see the
footwear manufacturing market developing?
AT: The balance of power in footwear
manufacturing is unlikely to change in the
immediate future. According to the World
Footwear Yearbook, Asia is responsible for
manufacturing an estimated 87% of the
world’s footwear. China remains the
undisputed leader, making almost two out of
every three pairs of shoes sold globally.
In China, it’s very much a numbers game.
Local manufacturers make millions of pairs of
shoes every year so unit prices can be kept
low, which is hard for manufacturers elsewhere
to compete with. Other regions are slowly
becoming more attractive again but this will
take time. Within Asia for example, footwear
companies are slowly starting to shift
production from China to Vietnam, Indonesia
and Taiwan. There is also growing interest in
manufacturing in Cambodia and Myanmar.
In Europe, where it’s more difficult to compete
on cost, the market is largely dominated by
small to medium sized companies making
shoes for niche applications such as safety
footwear – where material performance is
paramount.
It’s largely the same story in America.
According to the American Apparel and
Footwear Association, domestic footwear
companies manufactured just 1.4% of shoes
purchased in the U.S in 2011. Like Europe,
footwear production in the U.S is generally
more specialist, primarily safety footwear but
also military combat boots.
In terms of future growth, India is definitely
a market to watch. There is a big domestic
market for sandals and casual shoes,
which is growing quickly and the industry
is starting to wake up to what’s possible
with polyurethanes.
PU Review (PU R): You mentioned that other
regions are becoming more attractive again as
manufacturing locations – what’s driving this?
AT: There are two key factors. Import
procedures are becoming increasingly
complex – which means domestic
manufacturing is starting to have more
appeal. Processing techniques are also
becoming more automated – making
manufacture in other regions, outside of Asia,
more competitive.
www.huntsman.com/pu
7
Feature
PU Review (PU R): Are there any other
regional differences of note?
AT: Yes. The difference in regional production
levels is reflected in the use of materials and
manufacturing techniques employed around
the world. Polyurethanes and TPUs have a
global share of the footwear market of around
8%. In Europe this rises to approximately 18%
– echoing the emphasis on high quality,
specialist footwear applications.
We also offer customers practical advice to
reduce manufacturing costs and improve staff
training. In recent years we’ve worked with a
number of European manufacturers, helping
them to get new production lines up and
running. This kind of work will remain of high
value as the drive for automation continues as
mainstream footwear manufacturers consider
a return to production in Europe and the U.S,
and need to train more people locally.
In terms of techniques, unit sole casting is
widely used in Asia, South Europe and the
Middle East, where labour costs are generally
lower. While in central Europe and the U.S.,
where employment costs are typically higher,
and there is a move towards more automated
methods, which are far less labour intensive.
PU Review (PU R): Finally, can you tell
PU Review readers what Huntsman
does to support sustainability in footwear
manufacturing?
AT: In a fast paced industry, where so much
is in flux, making a positive sustainability
contribution is not just about making products
that have less environmental impact. That’s
important of course and something we take
very seriously. But sustainability in footwear
manufacturing is also about creating stability.
The footwear industry is highly pressurised, it’s
dominated by seismic seasonal shifts.
Manufacturers need to respond rapidly to
consumer demands. For big manufacturers
this can mean churning out thousands of
new styles every year. For smaller companies
it’s about keeping production sustainable
from a cost perspective so they can
remain competitive.
PU Review (PU R): In such a competitive
sector, how does Huntsman differentiate itself?
AT: We have many strengths; our time in the
market place, the breadth of our portfolio, and
our global capabilities. Customers tell us that
the quality of our technical partnerships also
help us stand out from the competition. From
our dedicated footwear development center in
Belgium, we undertake long-term research
projects into emerging footwear applications.
Liaising with customers we assess future
market trends and develop new materials –
producing samples in house on industry
standard machines that we’ve invested in.
8
We support sustainability by looking at
innovation and people alongside the planet.
It’s our duty to keep a pipeline of new
products coming through that enable
manufacturers to make high quality shoes
and boots at an acceptable cost and with
minimal environmental impact. DALTOPED®
Lite polyether material is one such
example. Launched three years ago, this
ultra-lightweight, cost-effective and highly
versatile alternative to ethyl vinyl acetate
(EVA) makes it possible to produce extremely
lightweight unit soles on existing polyurethane
machinery at a lower production cost
with less wastage.
Huntsman is also involved in corporate social
responsibility initiatives in countries such as
India, which are designed to make the local
footwear industry more sustainable over time.
In Kerala we work with the Footwear Design
and Development Center (FDDC) – a local
charity that helps equip people in rural
communities with the skills they need to enter
the footwear profession – helping to grow
the sector and improve prospects for
people locally.
These are just two examples of how we
are helping to improve sustainability in the
footwear sector. Countless other instances
exist and it’s this well-rounded approach
to supporting sustainability in the footwear
sector that our customers value and
which has given us such a high share of
the market worldwide. |
alfons_tremml@huntsman.com
The PU Review team would also like to thank
the following individuals for their editorial
contribution:
• Leon Chou, Technical Manager for
Elastomers and Regional Footwear Industry
Coordinator at Huntsman’s Asia
Technology Center
• Mark Kwek, Strategic Marketing Manager,
Great Asia
• Memphis Wei, Commercial Manager
Footwear, China
• Colin Tan, Sales Manager, TPU, Great Asia
• Jim McCloud, Senior Sales
Representative, PU
Huntsman TPU is sole choice for Panter
Huntsman’s footwear experts
have been working closely
with Panter (Industrial
Zapatera) – one of the largest
producers of safety shoes
and boots in Iberia.
The two companies have been collaborating on a series of soling projects that have helped
to improve productivity on Panter’s production lines and enhance the performance of its
technical workwear.
Panter has the capacity to produce thousands of pairs of safety shoes every day. Its manufacturing
facility in Alicante, Spain is operational 24 hours a day, six days a week, and employs only the very
best footwear materials.
With help from Huntsman, Panter has switched to using TPU to create soles for a range of its
professional safety boots, which are used in meat processing and butchery environments. Panter
employs Huntsman’s TPU to form a blue transparent outsole with a white mid sole. The material
also offers Panter higher cycle times and good abrasion and slip resistance – a winning combination
over conventional soling options.
Panter has also been working with Huntsman to improve the design of a wellington boot that it
manufactures for a leading Spanish supermarket chain. Employees who work in the supermarket’s
fish / 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 environments
for a long period of time. Lightweight and offering good anti-slip resistance, excellent hydrolysis
resistance and decent cold temperature protection for the wearer – this has been a major step
forward in terms of the safety, comfort and wellbeing of the supermarket’s workers. |
footwear@huntsman.com
Stepping up safety
shoe production
Using a specialist polyurethane material from Huntsman, SCHÜTZE-SCHUHE – an Austrian manufacturer of
premium 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.
SCHÜTZE-SCHUHE is a family-run business,
best known for making hardwearing boots that
enable construction employees to work on hot
asphalt for more than an hour. The organization
also has an established range of roofing shoes
that offer exceptional grip.
When SCHÜTZE-SCHUHE decided to diversify
and create a range of ESD safety shoes, the
business began looking for a new polyurethane
supplier to work flexibly with. The ideal partner
had to be located in central Europe; willing to
develop a double-density soling solution
tailored to specific requirements; and capable
of providing hands-on technical support.
SCHÜTZE-SCHUHE contacted Huntsman and
together the two companies embarked on the
development of a bespoke soling solution
based on Huntsman’s DALTOPED® DUAL
DENSITY technology. Following a period of
rapid product development and successful
trials at Huntsman’s footwear technology
center in Belgium, SCHÜTZE-SCHUHE began
using the DALTOPED®-based material to
create a compact polyurethane outsole with
a foamed, soft polyurethane midsole.
Thomas Schützeneder, CEO of SCHÜTZESCHUHE, said: “Our business is renowned for
making shoes and boots that are tough and
have a long working life but are comfortable
enough to be worn eight hours a day, week
after week. We only pick the very best
materials and never compromise quality – two
values we carried through to our work with
Huntsman. Forging new supplier relationships
can be daunting but the transition to working
with Huntsman was a really positive
experience. They took a flexible approach
to innovation, provided exactly the kind of
material we needed and the technical support
they gave was invaluable.”
Following completion of its dual density soling
project for SCHÜTZE-SCHUHE, Huntsman
is now supplying the business with additional
products for other aspects of its production
set up – including the lines where its
highly insulated asphalt boots and slip
resistant roofing shoes are manufactured. |
footwear@huntsman.com
www.huntsman.com/pu
9
Polyurethane shows different
side to exterior cladding
Polyurethane chemistry is used extensively across the
construction industry. Typically it’s found in insulation to make
buildings more energy efficient and in adhesive, coating and
elastomer products, where it can help enhance durability,
toughness and overall aesthetics.
Now, polyurethanes are also proving their
benefits in siding, cladding and exterior trim
applications thanks to the efforts of Boral –
an international building and construction
materials group.
Combining a proprietary polyurethane
chemistry that utilizes Huntsman products with
fly ash (a by-product of coal-fired electric
generating plants), Boral has developed
TruExterior™ Siding and Trim – a new category
of products for exterior building applications
such as cladding, sofits, fascias, door casings
and window surrounds, which have historically
employed wood.
Less susceptible to the elements
Described by Boral as a poly-ash structure,
TruExterior™ products are engineered to look
like traditional wood-based siding and trim
solutions. Similar in weight but far less
susceptible to degradation from insects or
exposure to the elements, TruExterior™ requires
very little maintenance. It can be painted
any color and is easy to cut, route, drill and
mill using traditional woodworking tools
and methods.
Unlike other exterior trim solutions such as
wood, wood composites, fiber cement, or
vinyl/PVC, TruExterior™ products maintain a
high level of dimensional stability during periods
of moisture and temperature change. They are
also suitable for ground contact and do not
require end-sealing, special adhesives or other
costly installation techniques.
More than 70% recycled content
Furthermore, the TruExterior™ material has
excellent sustainability credentials. Consisting
of more than 70% recycled content blended
with a relatively low level of polyurethane
component, TruExterior™ is manufactured in
a LEED® Silver facility using a proprietary low
emission and low energy usage production
process. As a result, the products can
contribute 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 the
construction market towards man-made
materials that are more resource efficient
and have greater potential to reduce energy
consumption and environmental impact.
Brian Below, President of Light Building
Products at Boral, said: “Across the
construction industry, the last two decades
have seen enormous change in the use of
building materials. Government mandates
and legislative measures, designed to boost
the energy efficiency of buildings, have led
to the evolution of existing technologies and
the development of many new alternative
products. Several years ago we spotted a
gap in the exterior trim market for a new type
of material. Industry feedback told us that
engineered wood, PVC and fiber cement
solutions were working well as wood
substitutes – but still had their drawbacks.
Moisture resistance, stability during
temperature fluctuations, and workability
challenges were just some of the issues
raised by users.”
10
“Realizing that no single material offered exactly
the right mix of attributes we decided to
develop a solution that would work as a true
replacement for wood trim. With builders and
homeowners accustomed to the workability
of wood we knew we needed to develop
a product that would look good, and offer
excellent durability, but be easy to cut and
fasten. We did just that, testing and trialing
all aspects of the TruExterior™ material over a
six year period and creating a product unlike
anything else available.”
Proven performance
Before its launch, the TruExterior™ material
underwent rigorous internal and third party
tests to verify its performance and durability,
even in the harshest of climates. Third-party
certification group MBDC has assessed
TruExterior™ Siding and Trim for its overall
impact to health and the environment and
certified it with a Cradle to Cradle™ Silver rating.
Scientific Certification Systems (SCS) Global
have also certified that the products have
greater than 70% recycled content. |
eric_stebel@huntsman.com
For more information:
www.BoralAmerica.com/TruExterior or
Nadine.sizemore@boral.com
Automotive
focuses on reducing
A
growingteam
technology
noise, vibration and ride harshness
In the food industry, demand for fresh crops, all year round, is
increasing. Consumers are now accustomed to having ready access to
fruit and vegetables, regardless of season. With the global population
booming – and estimated to surpass nine billion by 2050 – pressure on
food supplies is set to intensify.
In the Netherlands there is a mature, high tech, hydroponics industry continually growing food to
meet national and international demand. To support this sector, Huntsman has developed a
special hydrophilic material. With a special affinity for water, the technology has been designed for
use 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 with
BVB Substrates – a Dutch specialist in greenhouse horticulture. Clean, inert and easy to use it has
a high pore volume that gives it an excellent water holding capacity. A well balanced water /air ratio
enables 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, as
well 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 circulates
past the bare roots of plants. A continuous supply of oxygen is also provided, encouraging the
root 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 soil
eliminated, greenhouse drains can be kept clear. In addition, the roots of salad plants such as
lettuce 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 ensure
that BVB SUBLIME® substrate complies with food safety standards. Tested by numerous growers
and research stations, the material is now used in commercial greenhouses worldwide and
interest in this ‘next generation substrate’ is increasing.
As well as commercial hydroponic growing mats, BVB SUBLIME® substrate can be shaped into
grow 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. |
dave_burge@huntsman.com
For further information about BVB SUBLIME® substrate, contact: psonneveld@bvb-substrates.nl
www.huntsman.com/pu
11
Bio-based foam chosen for car headrest
In the March 2014 edition of PU
Review we announced Huntsman’s
successful development of a
special polyurethane prepolymer
based on rapeseed oil. This major
achievement* was instigated to
enable the production of more
sustainable polyurethane materials
for the automotive sector, where
there is a major drive for resources
with a strong renewable element.
Image for illustration only.
This issue we can announce that the Windsor
Machine Group (WMG) is now creating
headrests for a leading automotive
manufacturer using a fully formulated,
polyurethane foam from Huntsman, based on
this novel chemistry.
The bio-based headrests are the first of their
kind to be produced in Europe and employ
RUBIFLEX® H Bio – the name given to
Huntsman’s rapeseed oil /MDI-based
foam system.
WMG works with some of the world’s bestknown automotive brands. Its design engineers
have a reputation for developing creative
solutions that can significantly improve the fuel
efficiency of cars and the manufacturing
processes used to create them. The headrests
are being manufactured by WMG in Slovakia,
at a facility that opened in 2014.
Rob Purves, Windsor Machine and Stamping
Supplier Quality Manager at WMG, said:
“It’s hard to believe that the foam system
developed by Huntsman is bio-based. Its
quality is excellent, outperforming many of the
other materials we’ve tested. Crucially, the
percentage of bio-based content it contains
is also significantly higher. When we first
contacted Huntsman we wanted to find a foam
with a minimum bio content of 5% – to meet
OEM requirements. Huntsman recommended
RUBIFLEX® H Bio foam system. With 9% bio
content; no adverse effects on performance
properties; and a better process window;
we knew instantly that it represented a major
leap forward in foam technology.”
12
Incorporating bio polyols into foam production
has proved complicated in the past. The
presence of sustainable ingredients has
negatively impacted on both the processing
and performance capabilities of the resulting
material. Bio polyols are typically incompatible
with standard polyether-polyol combinations
used in the manufacture of flexible molded
polyurethanes. As a result the bio polyol can
separate very quickly. If this occurs, re-mixing
with a different storage tank and pump is
needed – which can be costly and time
consuming. Some bio polyols can also have
a detrimental effect on curing and final
mechanical properties.
Huntsman’s innovation team worked to
overcome this problem, developing a bio polyol
that has been pre-polymerized with specific
MDI isomers. As a result, RUBIFLEX® H Bio
foam system offers a better process window –
enabling the production of different foam parts
of a different hardness, density and shape.
Demold times are also short. The complete
cycle time is around three minutes.
Huntsman and WMG began discussions in
November 2013. The conversation was timely.
Huntsman had just initiated conversations with
Oleon about its bio prepolymer development
project. Impressed by what it heard,
WMG decided to work with Huntsman in
February 2014.
Huntsman’s first task was to define the right
prepolymer / polyol formulation based on
WMG’s specification and process conditions.
With parameters agreed, Huntsman created
foam prototypes at its technical development
center in Deggendorf, Germany. Once WMG
were happy, Huntsman offered additional
support, performing quality checks including
PPAP (Production Part Approval Process) –
a common standard developed by the
Automotive Industry Action Group (AIAG) that
establishes confidence in component suppliers
and their production processes. As production
commenced, Huntsman helped WMG further,
carrying out an audit of its health and safety
practices and delivering the polyurethane
industry’s Walk the Talk training program.
Continuing, Rob from WMG, said: “In addition
to supplying a top quality bio-based foam,
Huntsman’s full service package had strong
appeal. We’ve been producing headrests in
other parts of the world for many years but as
a relative newcomer to Europe, we needed an
MDI partner that was prepared to offer more
than just materials. With a new site to bring
online, equipment to install and people to train,
Huntsman’s development, prototyping and
technical support was invaluable – and an
added bonus alongside its bio-based system.”
WMG commenced production of the new
headrests in Q4 2014 (October). At the time
of going to press, Huntsman was the only
MDI supplier offering a bio-based prepolymer
technology to automotive OEMs in Europe. |
christophe_ponce@huntsman.com
* Huntsman’s bio-based prepolymer
was realized with support from French
agribusiness Sofiproteol)
Driving comfort in the new Mazda2
An all-MDI automotive seating system based on Huntsman’s
polyurethane chemistry is being used to drive greater comfort
levels in the brand new Mazda2, also known as the Mazda Demio.
Developed for Mazda by Huntsman and Toyo
Seat & Takaya – a Japanese car seat and
headrest supplier – the automotive seating
system is being used in the cushion and back
panel of the vehicle’s front seats.
The Mazda2 is a sporty, 1.3 liter, compact car.
Voted World Car of the Year in 2008, the
vehicle has exceptional fuel economy and is
widely regarded as sleek, stylish and fun to
drive. Awarded five stars in the Euro NCAP
safety ratings, the latest model of the Mazda2
is lighter than previous versions and has CO2
emission levels as low as 115g/km. It has a
carefully considered interior and according to
claims on the Mazda website, the company
has perfected the ergonomics of the car’s
seats and steering wheel.
Takaya introduced Huntsman to Mazda in
2013. Following a series of meetings to discuss
the benefits of using Huntsman’s polyurethanes
in automotive seating systems, Mazda agreed
that Takaya and Huntsman could work
together to develop a brand new system for
the latest Mazda2 model.
Over the following year, a team lead by Sansan
Wu, Technical Manager, at Huntsman’s Asia
Technical Center (ATC) in Shanghai, worked to
develop the system. Supported by Huntsman’s
automotive experts in the EAIME region, and
working closely alongside the Takaya team,
Huntsman ran a number of evaluations and
demonstrations at Takaya’s production line
in Japan.
Mazda sign off was secured in early 2014
and mass production of the system began
in October 2014. Today, Huntsman, Toyo
Seat & Takaya and Mazda are continuing
towork closely together to evaluate how
Huntsman’s all-MDI system could be
employed in other vehicles in the automotive
manufacturer’s range.
Julian Young, Japanese Transplant Manager,
Automotive and Flexible Industry at Huntsman
said: “The use of our all-MDI seating system in
the Mazda2 is a huge achievement for our
automotive team and represents a major
milestone for our Japanese business. Mazda
is one of the world’s major automotive
manufacturers. It has been a real honor to
work on a project that is so central to the
experience of people driving one of its most
popular vehicles. For most people, buying
a car is a major financial and emotional
investment, so ride quality can be a deciding
factor in the purchasing process. Polyurethanes
have been used across the automotive industry
for many years to help improve vehicle
performance and comfort. We are delighted
that Mazda has recognized the benefits of this
chemistry and is realizing the value it can add
to its vehicles worldwide.” |
ada_xu@huntsman.com
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 the
services 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 team
management, 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 chain
management; 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 seating
businesses 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. |
eric_stebel@huntsman.com
www.huntsman.com/pu
13
New PU tooling technology breaks the mold
Huntsman has made a major tooling technology breakthrough. The business has
developed a new polyurethane resin system that cures extremely quickly and allows
the production of high heat stable modeling, tooling and rapid prototyping boards.
The availability for the first time of an effective, high temperature stable polyurethane will open up a world of
new 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 offers
product designers, tooling manufacturers and mold-makers a viable polyurethane alternative to other
thermoset-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 demolding
and manufacturing cycle times. This can help manufacturers increase productivity, reduce energy costs and
cut carbon emissions. The VITROX® EST system can also be precisely formulated to suit specific
requirements – offering added flexibility and broadening scope for innovation.
VITROX® EST system’s high Tg properties mean a constant coefficient of thermal expansion (CTE) from room
temperature to 200°C is achievable. This enables the creation of products and tooling boards with improved
long-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 a
long, tunable pot life (5-20 minutes) and a low viscosity. Furthermore, the system is processable on low
pressure casting machines. |
wim_gilis@huntsman.com
Encouraging model behavior
Using computer-modeling techniques to understand how a material,
object or structure will behave over time, or when exposed to different
environments or circumstances, is now a fundamental part of the product
design process – regardless of application or end market.
Employing established modeling methods –
adapted for its own purposes – Huntsman
uses the science of simulation to gain a deeper
understanding of what it is possible to achieve
with polyurethanes. This strategic approach is
delivering major benefits for Huntsman
customers across a range of sectors, inspiring
innovation. PU Review spoke to Jan
Vandenbroeck to discover more.
“Architects and structural engineers would
never dream of constructing a high-rise
building without investigating how it would
cope in an adverse weather event or natural
disaster. Similarly, automotive manufacturers
would never approve new car concepts
without exploring every aspect of its design,
from aerodynamics to its performance on
different surfaces.
Diving deeper into polyurethane chemistry
“When it comes to road testing polyurethanes
and creating new MDI-based systems for
specific applications, we apply the same rules.
Several years ago we decided to invest in
computer modeling and dive deeper into
polyurethane chemistry.
“At our R&D headquarters in Belgium we
formed a dedicated computer modeling team
14
to study how polyurethanes perform in certain
scenarios. This five-strong group applies
algorithms and equations to help fine tune
chemical formulations and achieve the product
properties our customers want. Sometimes the
projects we work on are customer specific.
Some are driven by our own ideas. Others are
run in conjunction with world-renowned
universities and institutions including the
Belgian and Dutch governments, and the
European Union.
Layering additional information
“Computer modeling in the polyurethanes
industry has been around for a while but we’re
taking it a step further. Take flexible foams as
an example. In the past, computer modeling
helped define the structure of a polyurethane
foam. Today, we can simulate what the perfect
foam would look like and layer that information
with data about external influences and their
impact on processing and performance
properties. These extra insights are helping us
create innovative polyurethane-based products
that are truly fit for purpose.
“In recent years, we helped develop
ACOUSTIFLEX® S – a special form of sound
insulation. Going beyond conventional R&D
techniques, we explored the chemical /
acoustic relationship of the system to maximize
its ability to muffle sound. To help improve
building energy efficiency, we are using our
computer modeling capabilities to investigate
how the thermal properties of insulation can be
improved to develop super insulating materials.
And in the automotive industry, we are helping
vehicle manufacturers define what comfort –
delivered by polyurethane foams – should feel
like. Many manufacturers already run their own
tests to help quantify what is ultimately a
subjective area. Our work builds on this,
translating their requirements into specific
product parameters. We’ve also recently
introduced a CT scanner to our research lab,
enabling the 3D analysis of foam and
composite structures.” |
jan_vandenbroeck@huntsman.com
RUBIFLEX® Cocoon technology
creates cool comfort
RUBIFLEX® Cocoon technology is a new technology from Huntsman that’s been
developed with human wellbeing top of mind. Used to manufacture cool,
breathable, flexible foams, RUBIFLEX® Cocoon technology can significantly
enhance comfort in bedding, furniture and seating applications by reducing the
build up of heat and moisture that transfers from the body when it is at rest.
The availability of RUBIFLEX® Cocoon
technology makes it possible to fabricate
foams that combine the very best attributes of
existing memory and high resilience foam
solutions, with a number of additional benefits.
The resulting foam slabs provide excellent
support and good pressure distribution – gently
cradling the body and minimizing pressure
points to maximize blood flow and promote
quality sleep and relaxation.
With an open cell structure, the natural
increase in humidity produced by the body is
dispersed very effectively. Airflow permeability is
also high – helping to transport heat way from
the body’s surface. Tests show that the
temperature build up in a RUBIFLEX® Cocoonbased foam is more than 1.5°c lower than in a
comparable memory foam solution. Combined,
these qualities help support the body’s natural
thermoregulation mechanisms.
With RUBIFLEX® Cocoon technology, comfort
is heightened further still thanks to the unique
moisture management properties of the
system. Special hygrothermal attributes help
dissipate the natural accumulation of heat and
moisture generated by the body when it comes
into contact with mattresses, pillows, toppers,
armchairs, sofas and car seats.
RUBIFLEX® Cocoon technology is now in
commercial use. Spanish company Colchones
y Componentes Aspol is using it to produce
a range of mattresses for one of the
biggest department store chains in Europe,
El Corte Inglés.
The polymer structure of RUBIFLEX® Cocoon
technology offers a good balance of hydrophilic
and hydrophobic segments – enabling water
vapor permeability and moisture transmission.
foams also have an excellent wet compression
set and good tear strength. Conforming to
LGA and CertiPUR standards they meet low
VOC requirements. Furthermore, they can be
vacuum packed and are suitable for use in
adjustable mattresses.
andy_walton@huntsman.com
Foams based on RUBIFLEX® Cocoon
technology have a dry yet silky feeling and
work well in all climates. They are durable and
resilient, retaining their original feel, thickness
and shape over time – despite changes in
temperature conditions. RUBIFLEX® Cocoon
Forthcoming events and
technical presentations
List of forthcoming events:
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)
Find us on:
Facebook: www.facebook.com/huntsmancorp
Twitter: www.twitter.com/Huntsman_Corp
LinkedIn: www.linkedin.com/company/huntsman
Google Plus: www.plus.google.com/106818920361803832093
YouTube: www.youtube.com/user/HuntsmanCorp
For more information on the subjects covered in PU Review
magazine, please contact the editor:
Ilse Vanden Brande, ilse_vanden_brande@huntsman.com,
+32 (0) 2 7589420
While all the information and recommendations in this publication are to the best of
our knowledge, information and belief accurate at the date of publication, nothing
herein is to be construed as a warranty, express or otherwise.
ACOUSTIFLEX®, AVALON®, DALTOPED®, IROGRAN®, RUBIFLEX®,
RUBINATE®, TEROL® and VITROX® are registered trademarks of Huntsman or
an affiliate thereof in one or more, but not all, countries. BVB SUBLIME® is a
registered trademark of Bas van Buuren B.V. LEED® is a registered trademark of
U.S. Green Building Council (ISGBC). Boral TruExterior ® Trim boards is a
registered trademark of Boral Composites Inc.
Copyright © 2015 Huntsman Corporation. All rights reserved.
Designed and produced by: Chris Pearson creative communications.
www.huntsman.com/pu
15
We create better comfort and durability.
Together.
At Huntsman Polyurethanes, we believe that working in true collaboration with customers is
the 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 our
customers 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 different
polyurethane chemistries. From fully formulated grades and tailor-made polyesters to
polyether-based systems and TPU grades, we give footwear companies the freedom to
design innovative shoes, boots and sandals in step with the latest fashion trends,
manufacturing techniques and environmental concerns. Combine our knowledge of
polyurethanes with your expertise, and we'll create better footwear… together.
www.huntsman.com/pu