2010 number 4 winter. ThemE: space & aerospace composites

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1 2010 number 4 winter ThemE: space & aerospace composites

2 Sustainability / Environment Space & Aerospace Composites TenCate Royal Ten Cate (TenCate) is a multinational company which combines textile technology with chemical processes in the development and production of functional materials. Various market applications have been created around this technological base. TenCate occupies leading positions worldwide in its core markets. TenCate s growth is based principally on global trends, namely, safety / protection and sustainability / the environment. TenCate materials are principally used for: personal safety and the protection of living and working environments; modernization of military and police equipment space and aerospace (reduction in fuel costs through lighter materials); water management and environmental protection; TenCate s strategy is based on the concept of value chain management. The four cornerstones of this policy are: cost leadership; product differentiation, focusing on specific applications and customer requirements; end-user marketing and an industrial intellectual property policy; technological innovation. These four cornerstones within the TenCate business model are related to market, product, process and technology, and their interaction. In txtures the trends, cornerstones and other essential elements of the business model are referred to as often as possible. In this winter edition, we portray in particular TenCate s performance in the field of sustainability and the environment. This winter edition gives pride of place to Space & Aerospace Composites. The use of advanced composites produces weight savings, fuel reduction and extension of the lifespan of aircraft, ships, vehicles and exploratory spacecraft. The development and production of these materials enables TenCate to make a contribution to global developments relating to sustainability and the environment. Production of carbon fabrics at TenCate Advanced Composites USA in Morgan Hill TenCate co Both the Space & Aerospace Composites market group and the Advanced Armour market group develop and produce composite materials; the former for applications primarily in the space and aerospace industry and the latter for antiballistic solutions. TenCate composite materials have proven themselves to be high flyers over many years. Advanced composites combine high strength and low weight; they reduce fuel consumption, extend the lifespan of aircraft and vehicles, have excellent formability and are also flame-retardant, and acid- and moisture-resistant. Through the development and production of these materials TenCate is responding to global trends relating to sustainability and the environment. 2 txtures number 4 winter

3 mposites light, strong, durable Composites are fibre-reinforced plastics made mostly of glass, carbon and aramid fibres. TenCate composite materials are based on textile technology combined with chemical processes. They consist of a composition of fibres or fabrics from which semi-manufactures are made with the addition of resin systems (see also framed text on page 9). TenCate Cetex for example is a series of thermoplastic composite materials, consisting of unidirectional, fabric-based prepregs and tapes, semipregs, laminates and sandwich inserts. The use of advanced composites ensures fuel reduction and considerable extension of the lifespan of aircraft, ships, vehicles and satellites. These are becoming lighter, stronger, safer, more economical and certainly in aviation more cost efficient. TenCate operates a pyramid model with material, process, design and sustainability as its cornerstones. At home in space and aerospace Advanced composites from the Space & Aerospace Composites group are primarily used in the world of space and aerospace: in commercial and military aircraft, satellites and exploration vehicles for Mars missions for example. Both the space and aerospace markets are conservative: safety and reliability are of the utmost importance. The costs of the development and qualification of materials are high. Once a certain material is used after qualification, not a single modification may be made for follow-up deliveries unless it relates to a proven improvement. This makes it financially unviable to seek out new materials unless there is a technical or business need for them and explains why specifications for certain parts dating from the 1970s still apply, even though better materials have since become available. Continued on page 4 3

4 Sustainability / Environment Space & Aerospace Composites To a great height Continued from page 3 In addition there is a multiplicity of defence and industrial applications. Examples include the extraction of oil and gas, the recreational market and mobility concepts (solar car and the Superbus). Unmanned aircraft (UAVs) represent a major growth market. In aircraft, composite materials such as TenCate Cetex are used in the secondary wing structure and in the primary flight structure and interior parts of the aircraft. Examples include flaps, access doors, pylons, radomes [the protective housing for radar antenna), the fixed wing leading edge, beams, luggage containers and floor panels. For these interior and structural parts TenCate works directly with its customers, the suppliers to aircraft manufacturers and especially experts in material and process technology. Examples of applications in space include solar arrays, antenna, reflectors, parts of the skin and the supporting structure for the solar cells, antenna, booms, trusses, communication dishes and heat shields. In the lead Space & Aerospace Composites is a major player in its niche markets when it comes to the development and production of composite materials for these demanding applications. The market group is the global market leader in radomes and materials for space. Many years of knowledge and experience relating to materials and technology, flexibility and continuity, and the reliability of quality and delivery underpin this position. This expertise is partly the result of cooperation with partners in the value chain (such as Fokker Aerostructures, the TU Delft and 4 txtures number 4 winter

5 In radomes and materials for space applications TenCate s Space & Aerospace Composites group is global market leader the University of Twente) and in development and innovation consortia like TAPAS and TPRC. There are, however, long lead times for the space and aerospace market and the time needed to recover investment costs is long. The market has, to a limited degree, product and design knowledge, particularly of thermoplastics. The market group itself does not produce any fibres or polymers and is consequently flexible in its choice of suppliers. The strengths of the group lie in its expertise, the technical performance of its materials and its throughput. Together with partners it is continuously working on improving products, processes and technologies. The group operates in markets that show growth. Cornerstones Its own PPS+ programme is focused on a new generation of TenCate Cetex thermoplastic composites. PPS (polyphenylene sulfide) can withstand temperatures of more than 200 C and is flame-retardant. The programme is aimed at delivering more efficient internal processes, new composite architectures and improved temperature resistance. Thanks to intensive product development, TenCate is now able to offer more new unitapes, resins and prepregs. This means cost efficiency, product differentiation and innovation. As far as end-user marketing is concerned, the group is doing its utmost to continue to point out to customers the advantages of composite use. This it does at trade shows, in personal contacts, in technical papers and datasets and on the Internet, and based on its proven record of service to the space and aerospace industry. [email protected] 5

6 Sustainability / Environment Space & Aerospace Composites in THe Us AND Europe In the US the emphasis is on applications in space, civil aviation, the market for business jets and defence 6 txtures number 4 winter

7 Production and products The Space & Aerospace group has production facilities in Europe (Nijverdal) and the United States (Morgan Hill and Benicia, California). The companies are: TenCate Advanced Composites, Phoenix, YLA and CCS Composites. Design techniques Benicia produces thermoset prepregs, chopped moulding compounds and compression-moulded aerospace parts for the aviation industry. In the US the emphasis is on applications in space, civil aviation, the market for business jets and defence. In Morgan Hill they make thermoset prepregs and thermoplastic unidirectional (UD) prepregs. This tape technology complements existing production processes for composites and produces extra savings in production, thanks to the possibility for automation that it provides. UD tape is especially suitable for fuselage and wings, due to it optimal mechanical properties: for example, stiffness, strength, thermal and electrical conductivity, chemical and UV resistance and fire safety. This technology will make it possible in the near future to build for instance a light fuselage made of thermoplastic composite. Fire safety is a key design criterion for fuselages. The development of UD tape technology has enabled TenCate to strengthen its position in the aviation sector. Read further on next page Thermoset mounting clip for the Boeing 787 7

8 Sustainability / Environment Space & Aerospace Composites in THe Us AND Europe Continued from previous page These last two design techniques offer greater formability or result in finished products, such as hydraulic and fuel line clamp assemblies for the Boeing 787. This is an example of forward integration in the manufacturing process. In the US TenCate also produces carbon composite prepregs. These are used by one of its customers to manufacture composite rotor tubes for a new method of uranium enrichment by supplier USEC in Piketon (Ohio). Mobility concepts In Europe production is mainly focused on commercial aviation and here primarily thermoplastic composites are manufactured. There is a strategic alliance with Fokker Aerostructures. Composite material is also supplied for innovative mobility concepts such as the Superbus and vehicles that are driven by solar and wind energy. In the world of sports too demand for composites is growing. TenCate Cetex is eminently suitable for sports in which weight plays a major role, such as cycling and skating. There is a significant degree of production, sales and technical support between the US and Europe. Thermoplastic prepregs and laminates (TenCate Cetex ) produced in Nijverdal are also sold in the US. In turn, thermoset prepregs from Benicia and Morgan Hill find their way to European producers in the space industry (for example radomes). 8 txtures number 4 winter

9 Advanced composites Advanced composites combine exceptionally high strength and low weight and offer a high degree of formability. Formability plays a major role in almost every application: composites can be processed relatively easily into complex shapes. They require far less maintenance than traditional materials, they can be tailored to the specific application, have good impact-retardant and flame-retardant properties. In addition depending in part on the resin system chosen they have excellent resistance to acids, chemicals and water, they can easily withstand numerous cycle loadings and are thermally insulating. Composites are developed mainly within the aviation industry. Here for the most part carbon composites are used to build structures that are light and strong. Glass and aramid fibre structures have become popular through their use in radomes, for which radar transparency is essential. Thanks to the great variety of fibres, resins and reinforcement shapes, the freedom of design of a composite product is exceptionally great. The choice of type of fibre, the fibre architecture and type of resin are crucial for its mechanical properties. A thermoplastic is a material made of plastic that softens when heated and can then easily be brought into the correct form. It is a physical process, and thus reversible. The characteristics of thermoplastics include low production costs, flame and toxic smoke resistance, unlimited and non-conditioned storage and higher toughness. Thermoplastics are used in the aviation industry, but are still limited in high load-bearing aircraft parts. All thermoplastics are in principle recyclable. A thermoset remains hard and eventually degrades when heated. This involves a chemical process and is thus irreversible. Thermoset composite materials offer resistance to extreme temperatures and are extremely strong, low-weight and durable. Thermoset is mainly used in military aviation and the space industry. With conditions such as those on Mars between -80º and +20º C all materials for exploration vehicles must be completely reliable and secure. A prepreg consists of a thin foil of a substrate (a thin layer of fabric of for example glass, carbon or aramid fibre) that is impregnated with an epoxy or flattened by rollers into thin sheets. Prepregs are used for the shaping of layered composite materials (laminates). 9

10 Sustainability / Environment Space & Aerospace Composites has impressive customer base Airworthy and reliable The major customers for civil aviation are Airbus, Boeing, Bombardier and Embraer and their direct suppliers. US companies account for 55% of the global market in aerospace, European companies, 25%. Airbus and Boeing together have a market share of 80%. The fixed wing leading edge (J-nose) and the engine inlet among other parts of the Airbus A380 are made of TenCate Cetex. Various parts of the A350 will also be based on thermoplastic materials from TenCate. The Boeing 787 Dreamliner too uses this material and TenCate supplies the composite materials for the floor panels and the moving horizontal and vertical parts of the tail for the Gulfstream G650 business jet. The Cirrus SR20 and SR22 business jets consist entirely of thermoset composite material. Other types of aircraft in which the material is used include the Airbus A320 (the workhorse of the Airbus fleet), the A400 M, the Boeing 737, Boeing 747-8, Boeing 777 and Boeing 767; the Embraer Lineage, Phenom 100 and Phenom 300, the Gulfstream G550 and the Apache AH64 helicopter. TenCate is currently going through a qualification programme that is aimed at the replacement of a metal loading ramp in helicopters with thermoplastic composite. This will produce a weight saving of 40%, greater strength and an increased lifespan. TenCate s customer base also includes the names of aircraft manufacturer Lockheed Martin, the defence and technology company Raytheon, Loral (satellite systems), BAE Systems (aviation), Cobham (aviation and defence), General Atomics (applications in nuclear energy, aviation and defence), ATK (space and aerospace, defence) and Astrium (space). Aircraft industry: cautious The aircraft industry is sometimes depicted as conservative, but cautious is a more fitting description at least that is the view of Frédérique Mutel, CEO of JEC Composites (see article on page 15). Safety and reliability are paramount and ensuring these takes a great deal of time. The major challenge here is to produce more aircraft using the same quality and to produce lighter parts for aircraft that can go faster at lower costs, while still retaining the same quality. The answer to all this is the automation of production processes (by robotization and simulation) and innovation of materials. Aerospace has no choice. Continued on page txtures number 4 winter

11 The Cirrus SR20 and SR22 consist entirely of composite material 11

12 Sustainability / Environment Space & Aerospace Composites has impressive customer base Continued from page 11 As an illustration she mentions the Boeing 787, where dozens of engineers are trying to work out how to save eight grams on a single part. The only solution for weight saving is composites. In order to be able to produce more composites and make them more competitive, automation is vital: it can speed up the production cycle, guarantee the reproducibility and quality of parts and reduce costs. JEC Composites supports the industry by providing an extensive information and training programme in automation. Europe, where 83% of the production processes are currently automated, acts as a driver for Asia (68%) for example. The entire composites industry must, however, move forward, as a sign that it is committed to the environment. TenCate supplies composite materials for the moving horizontal and vertical parts of the tail of the gulfstream G txtures number 4 winter

13 Lightweight composites, which meet the requirements of the aircraft manufacturers in terms of strength and stiffness, can also be used to make cars and ships lighter. To achieve this, however, faster, automated production techniques must become available. Biding one s time Participation in the aviation market is a question of biding one s time. Even now designers are already getting down to work on planes that will not take to the air before The requirements made by the aviation industry change rapidly and the use of composites in this sector is increasing markedly. Composite is both stronger and lighter than aluminium and other metals. Each successive generation of aircraft as a rule contains yet more composite material, as it is a matter of being able to carry more passengers over greater distances, with reduced fuel consumption and lower production and maintenance costs. New commercial aircraft that will be delivered in 2010 and the following years will have fuselages and wings in which yet more aluminium has been replaced by (carbon fibre) composites. The same also applies to the structural parts. In 2014, 11% more composites will be used in aircraft than in The Airbus A320 (1986) consists of 20% composite material, the A380 (2005), 35%. The new Boeing 787 and Airbus A350 XWB will consist of approximately 50% composites and only 20% aluminium. The use of composites makes aircraft lighter and increases their lifespan. As this will also enable the air pressure and atmospheric humidity to be increased, passenger comfort too will be enhanced. With aluminium the atmospheric humidity is kept artificially low, as corrosion would otherwise occur (for example in the rivet joints). This keeps the air in the aircraft dry. At an altitude of ten kilometres the plane must be kept pressurized; in an average lifespan a plane is pumped up approximately 150,000 times. Composites thus have an advantage because, unlike aluminium, absolutely no material fatigue will occur. Opting for TenCate Customers have their own reasons for opting for composite materials from TenCate: reliability and continuity, for example. TenCate offers excellent technical service, very short lead times and a wide selection of specialty products for key segments like radomes and satellites. Manufacturers of satellite systems value the benefits of the very high modulus fibres and resin systems from TenCate, which are extremely dimensionally stable. Radome manufacturers want composites that are dielectrically very pure: glass and quartz fabrics with no carbon fibre contamination. In the Morgan Hill facility the group has carbon-free areas. TenCate has wide-ranging technology in resins, both thermoset and thermoplastics, and can also manufacture parts itself. Space & Aerospace Composites is also a good technical partner, being able to develop and qualify new materials for specific end-use applications. In both Nijverdal amd Morgan Hill, TenCate possesses some of the very latest production equipment in both thermoset and thermoplastic prepregs and unitape. 13

14 Sustainability / Environment TenCate working on new materials AND processes UD tape technology will make it possible in the future to build a light fuselage of thermoplastic composite 14 txtures number 4 winter

15 Innovations and trends As a technology partner, TenCate works with both end-users and suppliers in the development of composite materials and their use in existing and new aircraft. In this way concepts and products can be customized as required. the traditional trade-off between toughness/ flexibility and stiffness/hardness. The TenCate Advanced Composites PPS+ programme is directed at a new generation of TenCate Cetex thermoplastic composites, the basis being a new generation of polyphenylene sulfide (PPS) semipregs. PPS powder is applied directly to the carbon fabric and melted. This saves a number of steps in the processing and is thus cheaper, meaning that the material can compete on price with traditional thermoset composites. The programme thus provides more efficient internal processes, new composite architectures and better temperature resistance. TenCate can now offer new products in thermoplastic unitapes, new resins for high-temperature applications like the Orion heat shield, new prepregs for the satellite structure and a new generation of thermoset prepregs focused on aircraft for out of autoclave processing. The adhesion of layers and hardening of the material in autoclaves is an expensive process and is therefore not feasible for example for the automotive industry. The most recent product introductions are a prepreg for industrial and recreational applications and a new composite surfacing film to provide a cosmetically superior surface to composite structure. CCS Composites supplies thermoset clamps for the hydraulic and fuel lines of the Boeing 787 Dreamliner. Ten Cate Advanced Composites USA has entered into an agreement with 3M for the supply to TenCate of 3M Matrix Resin for the creation of customized TenCate prepregs. The 3M Matrix Resin is a proprietary resin technology that can produce stronger, lighter and more durable composites. The resin makes it possible for manufacturers to avoid Global trends TenCate s PPS+programme enables the company to respond to a number of trends that are emerging in the world of composites. The major trend in the aircraft industry is interest in improving the productivity of composite fabrication through automation and in new materials. There is also a shift towards composite aircraft fuselage and wings in new commercial planes, which is driving overall composite usage and the demand for thermoplastic composites in interior applications. In other applications customers are seeking productivity savings from the use of automation and the elimination of very high pressure curing cycles. TenCate thermoset materials can be cured in ovens instead of autoclaves, thereby reducing the time and capital investment. With thermoplastic UD tape the automation from thermoplastic unitapes provides productivity savings along with the ability to store these materials at ambient temperatures. 15

16 Sustainability / Environment TenCate working on new materials AND processes Frédérique Mutel, Chairman and CEO of JEC Composites From open to closed A development is taking place in injection processes, which goes hand-in-hand with the shift from open-moulding techniques to closed-moulding, such as resin transfer moulding (RTM). This is a low-pressure design process with two resins that are injected into a mould, after which they are cured. This technique is clean, energy efficient and enables large and relatively complex products to be made and to have an extremely smooth surface on both sides. This is a significant improvement from the point of view of quality, environment and health. It produces a more constant quality end-product and helps to significantly reduce the emission of gases (solvents) in production. Here too there is a challenge, particularly for the emerging economies. Traditional manual processing (hand lamination in an open mould) can be harmful to humans and the environment. This development fits in with the strong growth in the share of thermoplastics, which are lending themselves more for closed-mould processes and can be more easily recycled. Moreover, unlike thermosets, they do not produce any inventory problems. The share of thermoplastics in the value chain amounted to 30% in 2002; this is currently 37%. Tailwind Another trend is the growth of applications in wind energy. In Frédérique Mutel s view we will not be able to avoid having a variety of forms of energy. We shan t be able to continue with just one or two forms of energy. Rapid growth is occurring chiefly in the United States. Here they realized eight years ago that the US could face problems in many markets and it was decided to enter new markets, such as wind turbines. The US is traditionally strong in automotive and space systems; however, knowledge of nuclear energy is still limited there. With the production of wind turbine blades you have to be close to your customer and to the place where the wind turbines are. Growth in Asia There is also undeniably strong growth in the use of composites in Asia. Of the worldwide growth from 5.9 million ton (Mt) in 1999 to 10.3 Mt in 2013, Asia s share rose from 24% to 36%. Large composite companies now have production facilities all over Asia, not so much due to the wages as to the fact that the market and the demand are large there. Western players too want their share of the cake and the same applies to raw materials suppliers. These are companies with advanced technology and full control of their emissions. Environmental awareness in emerging countries is growing rapidly. Frédérique Mutel knows from her own experience. From time immemorial there has been a culture there of reuse and recycling. They have a long tradition of care for water and nature. They feel involved with the quality of the natural environment - that is one of the greatest values. That s why you don t just throw things away. TenCate remains principally focused on space and aerospace. There is a growing potential for aircraft interiors for thermoplastics, radomes for military ships, oil and gas applications for weight reduction and composite use in commercial aviation and the market segment for business aircraft. 16 txtures number 4 winter

17 Sustainability / Environment TenCate player in rapidly growing market A world of composites The Space & Aerospace Composites market group develops and produces composite materials primarily for space and aerospace. These are markets that are showing growth, and in which there is a major role for automation, recycling and innovation of raw materials, materials and processes. The market is dominated by the transport sector (see illustration p. 18) and the construction industry. In the transport sector weight reduction results in fuel savings. In the construction industry building light means that fewer raw materials are required. In building, roofing, spanning and infrastructure many traditional materials lend themselves to replacement by composites. The maintenance of structures such as bridges is subject to strict regulation in the EU. Supporting structures made of composites can consequently compete with metal structures. By placing a greater emphasis on promoting itself in civil engineering and the construction industry, there is still a great deal of ground to be gained here by the industry. The aerospace market share amounts to 4%, although this sector has the highest growth and greatest profitability (21% of the market value). The market for wind energy accounts for 3% of the total volume (6% of the total value). In the United States and Europe these two high-tech sectors are far more developed than in the rest of the world. The shipbuilding, pipelines & tanks, consumer products and electricity & electronics sectors occupy a midway position as regards market share. Space & Aerospace Composites supplies 80% of High strength and low weight, extreme formability, excellent resistance to acids, chemicals, moisture, impact and heat: these are just a few of the many advantages that advanced composites offer and which are recognized in many sectors. Worldwide the composites industry serves many sectors, supplying both high-tech materials and low-value volume products. Production of carbon prepregs in Morgan Hill. The demand for carbon fibre will double between 2009 and 2012 its composites to the space and aerospace industry and 20% for industrial applications. Market volume and market value The market volume of the worldwide composites industry amounts to eight million tons and has a value of 60 billion. Of this, the US accounts for 35% (value 36%), the European Union (EU) 22% (33%) and Asia 43% (31%). The relatively high value of the EU can be ascribed to the high standard of composites technology. Asia is focused mainly on low-value composite materials in large volumes. Outside China the market is looking to an increasing extent to high-tech materials. Not only Asia, but India and South America too are emerging markets. They need new solutions for obsolete infrastructure and transport networks. Transport and construction are the major markets there. In the US and the EU, both mature economies, the market is already saturated. Improvement On average the global market is growing by 4% a year. This growth is accelerating as a result of the 17

18 Sustainability / Environment TenCate player in rapidly growing market increasing use of composites and improvements in production processes. Across the world some 550,000 people earn their living in the composites industry. These figures were provided by JEC Composites, which has extensively charted the rich and complex world of composites. JEC (Journals, Exhibitions & Composites) has set itself the task of promoting composite materials worldwide. JEC s global network connects more than 250,000 people who are professionally involved in composites. The composites industry is highly innovative. This innovative attitude is also essential, as the composites industry faces a number of challenging tasks, including automation (making production processes faster and cheaper through for example robotization) and the development of new raw materials, resins, and glass and carbon fibres. Each link in the value chain has a contribution to make to this, Frédérique Mutel (Chairman and EO of JEC Composites) told us. This makes all the players in the value chain mutually dependent. Innovations The demand for carbon fibre will increase between 2009 and Aerospace and industrial applications are showing the strongest growth. The innovation of resins and additives involves for example low-emission resins, bio-resins, improved prepregs and carbon and glass fibres with greater strength. When it comes to process innovation, the terms simulation and prototyping are often heard. Computers allow you to simulate anything. You can design a product on a computer; you don t need to build a scale model to do it. After rapid prototyping you can immediately start on serial production. Also, you can simulate the ageing process of composites. Apart from the focus on new raw materials and materials, attention is also given to obsolete products: recycling. Who does the collecting, who, the removal and who, the recycling? As far as regulations are concerned, Japan and the EU are to date the most progressive in this process. EU legislation for the recycling of cars and electrical equipment provides opportunities for the composites industry. In the US regulations relating to materials, chemicals and recycling are continually improving. Recycling is a great challenge for the industry and will become ever more important. Collective One of the specific qualities of the composites industry is its collective knowledge. The market wants products that don t rust and require little or no maintenance. Companies in the value chain are constantly working together to find the best solution. There is also internal competition within the sector: between thermosets and thermoplastics for example, whereas the real competition is taking place outside, in other materials. She feels that not all the companies can see the big picture. JEC Composites plays an important role in this by uniting all the families, representing the sector and coming up with various solutions. The collective challenge is to expand the composites markets and you can t do that with forty different families and poor arguments and resources. Following on from that, JEC Composites wants to increase the visibility of composites and communications about them. There are too many expressions for the same sorts of materials. All the links in the value chain talk about composites, and as a result there are too many confusing terms. The industry is relatively young so we must present ourselves far more clearly and, with the backing of a strong industry, show end-users and markets what you can do with composites and be efficient in conveying their advantages. 18 txtures number 4 winter

19 Concentration Another challenge is the concentration of companies. There are too many small and medium-sized companies in the composites industry. They all have expertise and knowledge. It would be good to form alliances and clusters of companies, so you have to consolidate, buying up other companies or forming clusters of small companies in technology or on a regional basis. This will mean the end of many such companies if they don t have the means to invest or to set up elsewhere. If you re small and aren t open to change, you won t stand a chance. There are some companies that are conservative. They behave in a very protective way and are not open to the outside world. Spirit of cooperation When it comes to TenCate, Frédérique Mutel is positive. TenCate is a company that works with partners in a spirit of cooperation and believes that alliances are very important. When I got to know TenCate in the US, and then in Asia, I saw the company s dynamism. Its people are open and very innovative. So it s no small wonder that the company won the JEC Innovation Award 2010 in Paris. Mr De Vries has vision. When I met him, he stressed that TenCate is a company that makes a difference. TenCate is important to us as JEC for our references. Space & Aerospace Composites contacts are limited for the time being to the JEC organization. Frédérique Mutel believes that TenCate could benefit even more from its network of experts and decision-makers. We could be partners to get our message across more clearly and to make the brand more visible. Composites industry is an innovative sector within which a great deal of knowledge is shared. There is an important role for automation, recycling and innovation of raw materials, materials and processes. JEC appreciates TenCate s open and innovative attitude [email protected] 19

20 Sustainability / Environment Ten Cate Advanced Composites signs supply contract Laminates for Airbus A350 XWB An enabled material contract has been signed to supply TenCate Cetex carbon fabric laminates for use in the new Airbus A350 XWB among other EADS applications. Based on this award TenCate Advanced Composites Europe will start the delivery of TenCate Cetex towards several Tier 1 and Tier 2 partners of Airbus that produce fuselage panels and components for the Airbus A350 XWB. TenCate Cetex material which can be characterized as high strength and low weight will be applied to the stiffening structure of the body of the Airbus A350 XWB. The thermoplastic material is already used in existing Airbus programs, including the Airbus A380. These advanced fabric reinforced thermoplastic composite materials are already used for many structural and semi-structural exterior as well as interior applications in aircraft. The supply of TenCate Cetex material to the Airbus A350 XWB program once again underlines the importance of light and moldable thermoplastic material. One of the advantages of the application of thermoplastic composite is the posibility for the serial production in large numbers. [email protected] 20 txtures number 4 winter

21 Sustainability / Environment Ten Cate Advanced Composites reduces waste streams Carbon composite for reprocessing Ten Cate Advanced Composites is realizing considerable savings in the costs of its waste streams. The high-grade composite waste that is offered pre-eminently lends itself for reprocessing a win-win situation in terms of material and environment. More and more companies are realizing that the raw and auxiliary materials used in the industry will not be endlessly available. Through smart design and production and through selecting reprocessable basic materials and green suppliers, it is possible to give many costly waste materials a new life. Ten Cate Advanced Composites has a multiyear contract with CFK Valley Recycling in Stade. CFK is the German designation for plastics reinforced with carbon fibre. With small logistic adjustments to the collection system for carbon woven edges, thermoplastic prepregs and sawing waste from laminates, the company in Nijverdal is managing to realize considerable savings in the costs of its waste streams. In addition the company is a frontrunner when it comes to providing high-grade composite waste that is particularly suitable for recycling. Ten Cate Advanced Composites is also a member of the CFK Valley consortium. Rules The European Union is working on rules regarding the reprocessing of discarded aeroplanes comparable to those applicable to cars. Making the disposal of these aircraft more efficient and profitable is also of great importance to the aviation industry itself. So it is working together with the waste processing industry to develop new forms of reprocessing carbon material. End products based on milled carbon fibres are used, among other things, for reinforcing injection moulding components for industrial or possibly automotive applications. They can also be used to make carbon fleece a sort of non-woven mat that serves as cost-effective, high-grade reinforcement in composites and laminates. Knowledge network The aim of CFK Valley in Stade (North Germany) is to develop a leading international knowledge network for the technology and production of carbon fibre-reinforced polymers. The focus lies on the application of (recycled) materials in aircraft building, ship building, railways, commercial vehicles and car engineering The best partners in the world in the field of carbon fibre-reinforced polymers are brought together in this network. With approximately 1,900 employees, this is the most important knowledge centre for large carbon fibre-reinforced plastic aircraft components, such as wings. CFK Valley is closely connected with the Airbus production plant 50 km away. Airbus itself produces the tail of the Airbus A380 aircraft in Stade. [email protected] The high-grade carbon selvages are collected and offered for recycling 21

22 Safety & Protection TenCate Liba COMES THROUGH FIRING TEST with FLYING COLOURS Setting sights on advanced armour Ballistic experts inspect the impact of heavy artillery on TenCate Liba 22 txtures number 4 winter

23 NATO and US soldiers in Iraq and Afghanistan are frequently exposed to multiple threats, such as roadside bombs. One of the possible ways of protecting them is through Market advanced armour (personal and vehicle protection). Product TenCate Liba. Technology ceramic and polymer technology. Process inserts are fitted into bulletproof vests and vehicle armouring. the development of lightweight protection solutions with TenCate Liba. TenCate Advanced Armour and Dynamit Nobel Defence invited a number of business relations to become better acquainted with the antiballistic properties of these solutions. The heavy artillery was brought in, which was comparable to that used on the scene of battle. TenCate Liba came through the test with flying colours. The demonstrations were held on 13 and 14 October in one of the bunkers on the vast, heavily protected complex of Dynamit Nobel Defence among the wooded hills near Burbach (Germany). An international gathering was assembled there, including technicians and designers from ministries of defence, other government agencies and weapon and vehicle manufacturers. This contact directly reached among others five of TenCate Advanced Armour s major customers. Effective systems TenCate Advanced Armour develops protective solutions based on lightweight armour composites. These effective systems are used in personal equipment, light and armoured vehicles, ships, aircraft, helicopters and installations. They incorporate the most advanced ceramic and composite technology that is currently available. TenCate Liba is a proprietary lightweight protection solution based on ceramic pellets embedded in an elastic polymer matrix, and from this panels are made. There is a wide range of solutions in both modular products and systems. Work is being carried out together with partners on product differentiation and innovation. This is a matter of pure necessity as the number and level of threats are increasing and soldiers in the field are regularly the target of explosively formed projectiles (EFP), improvised explosive devices (IEDs or roadside bombs) and portable rocket-propelled grenades. High level of threat Some seven tests were conducted in Burbach. Sights were set on lightweight repaired protection solutions using TenCate Liba. It was decided to reproduce a high level of threat in accordance with STANAG This NATO standard covers the levels of protection for occupants of logistic and light armoured vehicles. A damaged TenCate Liba insert can be quickly and easily repaired. One of the firing tests showed that an insert that has been repaired and once again shot at provides excellent protection. Moreover, TenCate Liba is also considerably lighter in weight than traditional steel, which makes a substantial difference to the weight, fuel consumption, speed and manoeuvrability of the armoured vehicle. Optimum solution Ulrich Rasmussen and Kenn Jensen (Sales Managers TenCate Advanced Armour) were two of the hosts. They too look back on the two-day event with a feeling of satisfaction. Our goal was to show that TenCate Advanced Armour can provide protection against many different threats, that we are the only company that offers a fully repairable solution and that we can work together with suppliers of other protection solutions to provide the customer with the optimum solution. In this aim they appear to have succeeded. The fitted TenCate Liba inserts proved to be sufficiently impactresistant. The same applied to an insert that had previously been shot at and then repaired. The visitors accepted the waiting time between the assembly and disassembly of the installations as a necessary part of the procedure. Different customers told us that they had found it extremely interesting. In particular, all customers, wherever they may be in the world, are experiencing a great demand for protection against EFPs. Knowledge and experience Both inside and outside TenCate a great deal of knowledge and experience has been gained relating to projectiles and the consequences for armouring when they are ignited. And yet the behaviour and results of heavy explosives remain difficult to calculate. At such a high level of threat we leave the field of science and enter the domain of the unpredictable, as Dynamit Nobel Defence s Herbert Weisshaupt put it. This underlines the importance of the protection of people and vehicles using lightweight solutions which incorporate TenCate Liba. Simulation of conditions in Iraq and Afghanistan at the demonstration of lightweight protection solutions TenCate Liba offers advanced armour protection in accordance with high STANAG level [email protected] 23

24 TenCate n 47% in thi Trading update Third quarter FIGURES FOR 2010 TenCate s results in the third quarter, with 47% growth, demonstrate that the recovery is continuing. Qualification of the profit growth is, however, called for. The underlying operational trend is more positive than is shown by the reported profit growth. This can also be seen from the sharp rise in sales in the third quarter to the level of the top year Loek de Vries, Chairman and CEO Sales in third quarter of 273 million at the level of the top year 2008 Profit growth of 47% Profit trend in third quarter affected by non-recurring high costs for the coordination of downstreaming of synthetic turf operations 24 txtures number 4 winter

25 et profit up rd quarter of 2010 In the first place, the direct consequence of the pick-up in some markets is that shortages have occurred in certain types of fibre. TenCate has contributed to this to a significant extent through the success of TenCate Tecasafe Plus and TenCate Defender M. Although TenCate, as global market leader in protective fabrics, is relatively well served by its suppliers, this has resulted in some delays and has led to somewhat higher costs, which will be of a temporary nature. Reorganization A second effect comes from the synthetic turf markets. As market leader, TenCate heads the field in the reorganization of the synthetic turf market, which is entering a new phase. This development was accelerated by the financial crisis of The financing of seasonal sales may produce problems for some parties. Other market-related developments are, however, also playing a role in this. In this development phase there will be a consolidation of the markets; market parties will start to work together more in the chain. The main demands of end-users relate to quality and durability. Local authorities are often the owner of sports complexes, and environmental aspects are also playing an ever greater role here. Cooperation is necessary in order to pool specific knowledge. TenCate is seeking to enter into this cooperation through alliances with companies that operate close to the end markets. This process will initially require the appropriate investments and management focus. Positive outlook There is also a more positive outlook for the aerospace market, although this is as yet not fully reflected in the current figures. TenCate with its composite materials occupies a prominent position in this market. It has already been announced through a press release that the sale of TenCate Defender M to the US Army will be substantial in the fourth quarter. Cautious We repeat the profit outlook for the second half of the year referred to above. The financial markets have, however, reacted cautiously so far. TenCate announced its expectation of achieving this outlook as a minimum. The trends observed also express confidence about a number of key future developments that will support the further growth of TenCate. 25

26 Sustainability / Environment TenCate Cetex in mobility concept superbus Safe flexible sustainable Superbus is nearing completion and this innovative mobility concept will be officially launched in just a few months time. Everything within the Superbus concept is geared to sustainability. Ten Cate Advanced Composites is involved in the project as material supplier. The TenCate Cetex materials are used in the body and the eight doors of the vehicle. Safety, flexibility and sustainability are the characteristics of Superbus, and safety, lightness and strength were the demands and therefore the reasons for choosing TenCate. On 22 September Superbus was unveiled to the press and public at the International Motor Show (IAA) in Hannover. Amazing!, Wow!, exclaimed Wubbo Ockels in regard to the reactions to his brainchild. The general public thought it was super and wondered why it hadn t been thought of before. But it came as quite a shock to the professional market, such as Daimler Benz and Mercedes, because for them it s such a great leap. It goes much further than anything they re working on or can devise. In how far the market will ultimately be interested is a process of the market itself. We will demonstrate Superbus more and more frequently, until it claims political attention. An opportunity is being organized for the Dutch press to ride in it, on the RDW test track in Lelystad or somewhere in Germany. Afterwards the campaigns will begin but not before Superbus is in tiptop condition. Basic principles Superbus is an innovative mobility concept where the basic principles include mobility, flexibility, energy efficiency, safety and reliability. Superbus delivers comfortable, demand-dependent and point-to-point transport. The luxury vehicle can reach a speed of 250 km an hour on dedicated Superbus lanes and run at a normal speed on existing roads. The vehicle has the same length as an average city bus but looks longer because it is not so high. Thanks to the rear-axle steering, Superbus has a modest turning circle. Wubbo Ockels is justly proud of his brainchild naturally, and of the team of people from Delft University of Technology led by Antonia Terzi that he manages and that is working on the realization. Moreover the 26 txtures number 4 winter

27 Market aerospace, industrial applications. Product TenCate Cetex. Technology weaving and impregnation technology. Process materials installed as pre-shaped panels in the body parts. number of members has now been reduced to five, who together compose the test team. It was an extraordinary experience to ride in Superbus for the first time. It s like a combination of a sportscar and a jet aeroplane. Relationship with TenCate Impact-resistant, strong, light in weight, and the combination of these qualities such were the requirements and for Wubbo Ockels the reasons to choose TenCate. TenCate makes these materials. The relationship dates back to the development of the Nuna, the car powered by solar energy, so I automatically landed up at TenCate again. Nor is it likely to be the last time. Wubbo Ockels still has many ideas and dreams. The most advanced is sky sailing, a sort of pioneering stunt with two planes on one line, one flying in the jet stream and the other outside. You need TenCate for these lightweight constructions. Sustainability as basis For TenCate, sustainability is the basis and reverberation of its pursuit of continuity. TenCate products and systems make an essential contribution to a world where themes such as safety, protection and sustainability have become self-evident. The related trends include personal safety, protection of the everyday world, restriction of energy consumption and CO2 emissions, water management and care for the environment. It is an important task of TenCate to formulate answers to these trends, devise solutions and thus compel developments. Thanks to composite materials, TenCate has a series of sustainable solutions available. The Earth as spaceship The interest of the professor of Sustainable Engineering and Technology at Delft University in sustainability was awakened during his time as an astronaut. The Earth is really a space ship with a thin layer of protection. This is no laughing matter; every process can damage it. And the exhaustibility of fossil fuels also plays a role. These are threats that, according to him, are still insufficiently recognized. He himself attempts in different ways to stimulate the enthusiasm of young people for sustainability and a sustainable society. As far as sustainability is concerned, the Netherlands is a vacillating country. It s shameful that what we produce in terms of sustainable energy lags so far behind. This is a problem for the young people coming later. They are taking no action and that worries me. I think it s important for young people to develop initiatives in this respect. Material demands for Superbus determine choice for TenCate composite materials Efforts of the Netherlands as far as sustainability concerned shameful tencateaerospacecomposites.europe.com [email protected] 27

28 Safety & Protection TenCate Advanced Armour strengthens its position Ballistic protection TenCate Advanced Armor USA received additional contracts in September for vehicle armouring, worth $18.5 million. The materials will be delivered to two major manufacturers of military vehicles and to the US Army before the end of This order will enable the company to cement its strong position in the market for vehicle armouring in the United States. TenCate is a specialist in the production of lightweight, protective ceramic and composite armour systems for use in vehicles, aircraft, ships and personal protection. These materials replace traditional ones such as steel and aluminium and ensure weight saving and improved functional properties. 28 txtures number 4 winter

29 Producing modern ballistic protective solutions requires advanced weaving and pressing technology and specially designed cutting technology. TenCate Advanced Armour elects to use the most advanced ceramic and composite technology available and it provides the lightest, most efficient armouring possible for these demanding applications. Access The American market for ballistic protection is by far the largest worldwide, while in Europe the UK is a dominant market. As a result of the acquisition of the British armour company AML UK in Swindon (UK), TenCate now has unlimited access to the British market for lightweight composite armour solutions, which are used in vehicles, aircraft and ships. Customers for these products are mainly large industrial conglomerates in the defence industry, manufacturers of trucks, aircraft, helicopters, etc. or related suppliers. Governments (ministries of defence) lay down the specifications for these. System approach TenCate Advanced Armour focuses on a system approach by working together with manufacturers of vehicle, ships and aircraft (and their customers) in order to achieve the best possible configuration for protection. In the design of armoured vehicles for example the balance between protection and mobility is a key factor: the weight of the armoured protection must be as low as possible, while providing the highest level of protection. During the design and development stages consideration is given to such factors as the level of threat of the weapons and the cost of the entire lifespan of the application. All the solutions are tailor-made for customers and end-users, whether they are for permanent integration into the structure of new vehicles and ships or for carrying out improvements to existing vehicles and ships. TenCate Advanced Armour can provide support for its customers worldwide. [email protected] 29

30 Sustainability / Environment TenCate Geotube in Portugal Environmentally responsible dewatering method TenCate Geosynthetics has supplied TenCate Geotube containers for a dewatering project in Almeirim (Portugal), which involves the removal and dewatering of 12,500 m³ of organic sludge. This first project in Portugal is the result of cooperation between TenCate Geosynthetics, Ashland Hercules Water Technologies and Geosin, the local partner. POLYMER DOSING UNIT 30 txtures number 4 winter

31 Market environment and infrastructure (bank protection, dewatering etc.). Product TenCate Geotube. Technology extrusion, weaving and coating technology. Process storage and dewatering of (polluted) sludge. TenCate Geosynthetics and Ashland Hercules Water Technologies are working closely together to bring integrated dewatering solutions based on TenCate Geotube and polymers on to the market. TenCate supplies the dewatering system and supports customers at home and abroad in setting up the installation. Fired by enthusiasm for TenCate Geotube during a workshop in November 2009, Geosin, the TenCate distributor in Portugal, went in search of a suitable partner for the project in Almeirim. Egeo, an important player in the waste industry in Portugal, showed interest. Thanks also in part to the assistance of Ashland Portugal, the first steps could be taken on Portuguese soil with a dewatering project using TenCate Geotube. Fruit juices The project related to the removal and dewatering of 12,500 m³ of organic sludge from two storage basins for a major producer of fruit juices. The production process releases residual water with organic waste, and this sludge is stored in two basins. For years TenCate Geosynthetics has been world leader when it comes to dewatering sludge from lagoons, but the dewatering of 100% organic sludge is a different story, as Gerben van den Berg (market manager TenCate Geotube Dewatering) well knows. It s no easy matter to dewater this using conventional techniques, but the TenCate Geotube technology offers various advantages for such a process. It is a cost-effective solution with minimal impact on the environment; large quantities can be processed in a relatively short time; and minimal manpower is required. Satisfied faces That the project led to highly satisfied faces is thanks to TenCate Geotube, the polymer technology, the selected approach (training local people) and the sound choice of partner to secure small-scale projects of this kind and see them through to a good conclusion. We re in the forefront of other suppliers in this respect, as it requires much more applied knowledge. It s a question of polluted organic sludge and you have to know exactly what you can and can t do. The right dose of polymers in combination with the selected TenCate Geotube container is crucial. This solution offers the customer the greatest certainty and reliability and that we speak the language of the local market is also a distinguishing factor. Whoever can do this well has considerable market potential. Environmental dredging is an attractive niche in the dredging market. With the right partners in the chain, who can benefit from our know-how and experience, we can identify work of this kind and make it profitable. The project in Portugal is not an isolated case. A project of the same kind is being set up in Hungary with UTB Hungary and Ashland. In addition projects are slowly getting off the ground in various other European countries. This is a good development. Success means that customers are gaining even greater confidence in us. TenCate Geosynthetics realizes first dewatering project with TenCate Geotube in Portugal TenCate Geotube technology is costeffective, environment-friendly, rapid and reliable solution Cooperation with chain partners offers good prospects in environmental dredging [email protected] Organic sludge is dewatered in an environmentally responsible manner 31

32 Information Technology TenCate realizes own global network Connected worldwide The process to realize the Global TenCate Network consists, among other things, of concentrating the IT services by means of three IT shared service centres: EMEA (Europe and Dubai), USA and Asia. Within this network all companies are being standardized in terms of IT infrastructure (Microsoft Exchange), which brings numerous advantages. Employees worldwide will have at their disposal besides the traditional telephone system internet, intranet, and Office Communicator, which serves for audio communication, video conferencing and the exchange of documents and other data. Sharing the systems, IT know-how and costs means saving costs for external consultants, as well as promoting internal cooperation. The project applies to the generic (applicable to all market groups) systems, and concentration will only occur if it makes sense. Company-specific systems are being standardized within the groups. Successful The process started in 2008 with the TenCate companies in Europe and Dubai (EMEA). After a successful start, the pace eased off in the course of 2009 because of the economic circumstances. The corporate IT department was tasked with bringing costs into line with the sales. Through a partial reorganization, the postponement of projects and new techniques, the consolidation and standardization of systems, and through server virtualization, operational costs could by reduced by 20%. Thanks to the virtualization of servers, several applications can run on one server, which means fewer servers are necessary, and therefore less power and lower costs. This then is process innovation and it fits in nicely with TenCate s Green IT objective. In America By the end of 2010 TenCate Grass in Dayton (Tennessee) and TenCate Advanced Armour 32 txtures number 4 winter

33 TenCate is putting the finishing touches to realizing the Global TenCate Network. All the TenCate companies across the world will be interconnected within this global IT network. A process of over three years will then be complete. Result: rapid, reliable communication and IT support accessible to all, as well as cost efficiency and a contribution to a clearcut presentation of the company. (Newark, Ohio) will be connected up with the IT shared service centre USA according to plan. The IT department of TenCate Protective Fabrics USA is responsible for the IT shared service centre USA. With this, 90% of all TenCate companies will be standardized. The shared service centre USA will be operational from January Just as in the Netherlands, the hosting will fall under an external partner that will provide IT services. Next year all the remaining TenCate companies in the United States will likewise be connected up. For the time being this does not apply to TenCate Geosynthetics. The IT systems of this group are based on IBM technology. Given the investment involved in the migration to the Global TenCate Network, this work is on hold until a natural time slot arises. Hitching a ride At the moment the Asian companies are hitching a ride on the SSC EMEA, but in 2011 the SSC Asia will be realized. TenCate has facilities in Singapore, Hong Kong, Malaysia and China (Zhuhai), and an investigation is being carried out to see which of these four is the best location for the shared service centre. It will examine such aspects as languages, reliability of the infrastructure, and restrictions imposed by government authorities on, for example, internet traffic. When this unit has also been completed, TenCate will have a worldwide network that can rival the best in terms of process optimalization and cost efficiency. Global TenCate Network has three IT shared service centres worldwide and ensures optimal communication and cost efficiency Project fits in with the pursuit of sustainable IT Middle of 2011 will see choice of location for IT centre in Asia 33

34 Sustainability / Environment TenCate composites in climate-neutral vehicle In January 2012 mountaineer and adventurer Wilco van Rooijen and co-pilot Fokke van Velzen are embarking on a trip to the South Pole with a CO2-neutral vehicle running on solar energy. Part of the bodywork consists of TenCate composites. With this expedition, Team Wilco wants to highlight the importance of sustainable energy and draw attention to the fact that in 2048 this continent will no longer enjoy protected status. Sustainable driving to Antarctica The vehicle is designed by Team Antarctica, students at the Faculty of Natural Sciences and Technology of the University of Applied Sciences Utrecht. The climate-neutral vehicle that they are now building is powered by solar energy. It seats two people, can drive on granular snow as well as hard ice waves, has a speed of 15 to 20 km an hour, and can cover a distance of 2300 km. Because it is equipped with solar cells, it is sturdy in build and TenCate Cetex has been selected to limit the weight. This composite laminate based on carbon fibre is manufactured by Ten Cate Advanced Composites in Nijverdal. TenCate Cetex can withstand the low temperatures during this period in Antarctica. Reinforcement Panels of TenCate Cetex are processed for reinforcement purposes in the lid of the boot (where the solar cells are installed), in the interior of the bonnet and the doors, as well as in the climate box. This is the electronic component that contains sensors and other parts that cannot withstand the extreme cold. The material was deliberately chosen: We were looking for a reliable partner who is big enough and is based in the Netherlands, explains Emma Recter (product design & engineering). TenCate seemed to be the right place to find the desired materials, and we re very pleased that we can use this material. Besides materials, TenCate is delivering technical support. With this expedition the team wants to demonstrate that it is possible to travel CO2-neutrally across Antarctica to the South Pole. Wilco van Rooijen and Fokke van Velzen hope to cover the distance of 2300 km in 30 days. Protected Antarctica is the coldest place on Earth. Once a temperature of C was registered some 1000 km from the South Pole. The continent is almost completely covered with ice. Currently this continent is still protected by the Environmental Protocol, part of the Antarctic Treaty, against drilling for minerals. The protection by this protocol ends in This project is intended to provoke dialogue with the pundits and government leaders of the future. By making the youngsters of today aware of this virgin continent and the possibilities of sustainable energy, they can later protect Antarctica txtures number 4 winter

35 Innovation TenCate sponsors Kanja UltraLight Glider Glider with composites TenCate composite materials are used in large and small aircraft, but application in gliders is rather less common. Carbon composites from Ten Cate Advanced Composites in Nijverdal are used in the wing ribs of the lightweight Kanja glider. This a project carried out by eight students at INHolland University of Applied Sciences. The wing of the glider spans 11 metres, with a surface area of m². Through sponsoring in kind, TenCate wants to familiarize students here too with the processing and possibilities of strong and lightweight composites. In the realm of gliding there is considerable demand for high-grade, ultralight aircraft. The Kanja was exhibited at the Composites Europe Fair in Essen, the biggest trade fair for composites in Europe. At the exhibition the team members were clothed in overalls based on protective materials sponsored by TenCate Protective Fabrics

36 Sustainability / Environment TenCate Outdoor Fabrics unveils vision Tents of the future The future of the camping world will be determined by new designs and innovative functionalities. When it comes to design, manufacturers of tents and awnings will be making increasing use of young designers. As far as functionalities are concerned, the developments are focused on self-cleaning and insulating capabilities, high visibility, glow in the dark, and an anti-mosquito finish. The glow-in-the-dark finish will afford night visibility thanks to the sunlight absorbed during the day. This ensures that the tents are clearly visible at any time of the day or night for emergency services and the army. A special finish smelling of lemon can keep mosquitoes away. [email protected] Self-cleaning Insulating Anti-mosquito 36 txtures number 4 winter

37 In 2010 TenCate Outdoor Fabrics was again present at the Camping and Caravan Show with a digital stand. At the company presented its vision on existing and future functionalities of fabrics for tents. Moreover the digital presentation underlined the fact that TenCate Outdoor Fabrics is technologically driven and works on product differentiation and innovation. High-visibility Glow in the Dark (night visibility thanks to sunlight absorbed during the day) 37

38 Sponsoring TenCate Grass at world expo txtures number 4 winter

39 Better grass The Dutch pavilion in Shanghai attracted over 7 million visitors. Every day thousands of Chinese took advantage of the opportunity to relax in a park equipped with TenCate Grass. The Netherlands could rejoice in considerable international interest during the World Expo Better City. Better Life in Shanghai (China). The pavilion Happy Street welcomed more than 7 million visitors a feat that placed the Netherlands among the top 5 most visited pavilions. Many took a peek at this compact dynamic city, which was organically constructed by designer and architect John Körmeling along a pedestrian strip in the form of the Chinese lucky number 8 and illustrated every facet of Dutch life. Beneath this elevated city was a kind of Vondelpark in miniature with synthetic turf (made from fibres and backing from TenCate Grass). Every day thousands of visitors, including many Chinese, sought the shade to rest for a while. The World Expo closed at the end of October and the pavilion is now being dismantled. The materials will be reused or recycled. Over the past years TenCate has built up a leading position in the Asian synthetic turf market. This market is characterized by consistent growth, which is stimulated by an increasing number of new users and a growing preference for synthetic turf. [email protected] photo: Peter Cox 39

40 Innovation TenCate presented with AWVN Innovation AWARD Recognition for social innovation Royal Ten Cate has received the quarterly innovation award and with this has also been nominated for the AWVN Annual Innovation Award AWVN (the general employers association) praised TenCate for its integrated approach to technological and social innovation. Ron Bijkersma, corporate director HRM According to the jury, TenCate sets the trend in product and process innovation in its core markets through an appealing vision, entrepreneurship, the consistent implementation of the strategy and corresponding core values: progressiveness, proficiency, inventiveness and reliability. These core values are translated within the organization and the HR policy in such a way that the AWVN Innovation Trophy for social innovative policy is thoroughly deserved. Ron Bijkersma, TenCate corporate director HRM, sees it as an award for the whole body of work. The AWVN is enormously impressed by the transformation we have undergone. We have consistently reinvented ourselves, and you can only do that by taking good care of your people and by innovating. Development Social innovation is an integral part of TenCate s whole company policy, especially the management model and the company philosophy. The company applies a clear business model and a flat management model. Authorities and responsibilities are established decentrally as far as possible, with the exception of those matters that must be centralized. In this way you get entrepreneurs rather than managers. By giving employees freedom and responsibilities, there is room for creativity and you create entrepreneurship. That s how innovative power is stimulated within the company. There s no actual blueprint but this philosophy incorporates an important basis for innovative entrepreneurship. We re therefore on the lookout for entrepreneurial people. And the fact that people like working for TenCate is also a contributive factor. Schooling and training Social innovation also takes shape within the TenCate People Programme, a schooling and training programme that stimulates employees to look at new or other product-market-technology combinations. Within the TenCate Active programme, which is part of this, potential managers from different market groups worldwide work intensively together. We try to see that exchange between managers and workers takes place as much as possible, says Ron Bijkersma. This cross-fertilization leads to new ways of working and new products and services. Because of the economic circumstances, TenCate soft-pedalled the training programme to a certain extent in 2009 and at the start of Nevertheless, the international TenCate Business Game was wound up in Activities will again be initiated within the TenCate Active and TenCate Talent programmes in AWVN impressed by the transformation that TenCate has undergone By giving employees freedom and responsibilities, TenCate provides room for creativity and entrepreneurship Activities will again be initiated within the TenCate Active and TenCate Talent programmes 40 txtures number 4 winter

41 Safety & Protection TenCate Tecasafe Plus gains ground Key products in quality and durability TenCate Protective Fabrics is continuing to work on product differentiation, innovation and end-user marketing. The TenCate Tecasafe and the TenCate Defender M platforms are being expanded. Increasingly stringent demands and the desire for more cost-efficient solutions also lie at the bottom of this. Through directly approaching the customer and end-user, these become acquainted with the characteristics, durability and cost benefit of these and other protective fabrics. Daniel Hauert (middle) (president TenCate Protective Fabrics USA) at the international trade fair for safety and protection in São Paulo (Brazil) At the beginning of October three teams from TenCate Protective Fabrics USA showcased Tecasafe Plus, TenCate Oasis and TenCate Tuffweld in North and South America, with a view to promoting these three key products. These TenCate materials are based on own fibre blends developed for specific applications. TenCate Oasis is an inherently fire-resistant fabric that is light in weight and offers protection against, for example, molten aluminium spattering and radiation heat. It is therefore applied extensively in the aluminium industry. TenCate Tuffweld is a flame-retardant, protective fabric competitively priced for the clothing of welders, mechanics and the like. Successfully launched on the market for industrial safety in the United States at the beginning of 2007, TenCate Tecasafe Plus is the most popular fabric of the three. Further development TenCate Tecasafe Plus is a further development of TenCate Tecasafe in Europe. It owes its US success to the focused end-user marketing in the US as well as the quality of the material. It is reliable, cost-efficient, and is more comfortable and has greater durability than the industrial flameretardant fabrics of other suppliers. Safety and protection of workers is high on the agenda in the US too. This explains why 2 million metres of TenCate Tecasafe Plus have left the production facilities to date (October 2010) an amazing achievement for such a new product in a mature market with numerous competitors. In view of the price and durability, it means an important cost advantage for industrial laundries and rental services. So TenCate Protective Fabrics scores also in terms of cost leadership. Electric arc protection One specific application of TenCate Tecasafe Plus concerns equipping the American navy in risk class 2 electric arc protection in compliance with NFPA (National Fire Protection Association) standards. A five-year contract was recently concluded in this respect. TenCate Protective Fabrics USA has collaborated with the navy and its customer UniFirst on a version that is Berry Compliant, which means to say in accordance with the Berry Amendment. This relates to the purchase of articles, including fabrics, manufactured preferably in the home country. The development started after an investigation into alternatives to the current fire-resistant cotton fabric, which had caused comment as far as thermal and allergenic properties were concerned. The new version of TenCate Tecasafe Plus was developed by Craig Tutterow (senior development engineer), while John Blackmon (marketing manager air force and navy), through his contacts with the Department of the Navy, and Peggy Holcomb (industrial sales manager), who coordinated the activities with UniFirst, also contributed to this positive result. Since August 2010 the cotton fabric used up till then has been replaced by TenCate Tecasafe Plus. Coupled with end-user marketing The teams consisting of sales & marketing managers and a product developer have been present at leading trade fairs, conventions and the like. Craig Tutterow and Mike Stanhope (global manager for product development) were at the National Safety Congress in San Diego, where they also attended the meeting of the NFPA Standards Committee. The NFPA is a US authority in the field of fire safety. Charles Dunn (director of product development) helped a team during the National Electrical Contractors Association convention in Boston. TenCate Tecasafe Plus has also been enthusiastically received in the end-user market for electronics. [email protected] 41

42 Safety / Protection TenCate Defender M sales continue to grow TenCate Defender M fabrics are repeatedly chosen by the American army and the American marine corps for the FR-ACU and FROG programmes for their ground troops 42 txtures number 4 winter

43 Protection US army and navy A significant rise in the demand for TenCate Defender M is indicated in the fourth quarter of 2010, and sales amounting to approximately 60 million US dollars are anticipated for this quarter (fourth quarter 2009: 29 million US dollars). The increase in demand is expected to continue well into the first quarter of The success of TenCate Defender M fabrics is based on the unique blend and application of the Lenzing FR fibre. The rise in growth began in the third quarter, after a temporary relapse in sales as a result of changes in the camouflage print. The TenCate Defender M fabrics now supplied are processed in the Flame Resistant Army Combat Uniform (FR-ACU) of the American army and in the Flame Resistant Organizational Gear (FROG) issued by the navy. TenCate Defender M fabrics are repeatedly chosen by the American army and the American marine corps for the FR-ACU and FROG programmes for their ground troops. Blend TenCate Defender M is durable and has good wear resistance and excellent colourfastness. It offers not only protection against heat and fire, but also antistatic properties and room to move. This is attributable to the self-developed blend of fibres that are used to make TenCate Defender M. Together with fibre manufacturer Lenzing (Austria), knowledge is shared regarding the development and production of fire-resistant fabrics using fibres that are inherently fire-resistant and comfortable. The Lenzing FR fibre is an important ingredient in TenCate Defender M fabrics. In contrast to other fire-resistant fibres, the Lenzing FR offers inherent fire-resistant characteristics, while at the same time the fibre absorbs moisture. This combination allows the fabric to breathe and ensures comfort. [email protected] 43

44 Sustainability / Environment TenCate Cetex round engine block of concept car Historic car make revived Avions Voisin, an historic French car make, is soon to take on a second lease of life. In a hangar on the Twente air base, work is in progress on a new, luxury concept car with this name. Design, sustainability and eco-efficiency are of paramount importance in this mobility concept that s also why TenCate Cetex is one of the materials applied. 44 txtures number 4 winter

45 Visitors to the AutoRAI in April 2011 will probably see its first outing and be eyewitnesses to the revival of Avions Voisin. The hand-made Voisin A-JT is the brainchild of Mattthijs Meulenbelt and Frans Lievaart. These two Delft engineers are working on this jointly with the University of Twente, where they are responsible for the master class on automotive design. As an innovative Dutch car company, they are going to design and build hand-made cars for the executive sector. Heat resistant The bodywork of the prototype consists mainly of aluminium, which makes the car lighter and ensures fuel savings., The temperature in the engine compartment can rise considerably, so that s why TenCate Cetex is used here. This material is durable and heat-resistant, and consists of a Nomex honeycomb core between two carbon layers. Every component is scrutinized for possibilities to save costs and fuel, and the ideas being developed in this respect are also interesting for the car industry as a whole. Applications have now been made for patents in a number of cases. The sale price will be around 75,000. The prototype in aluminium will be unveiled at the AutoRAI. Revolutionary Gabriel Voisin was an aviation pioneer, who from 1919 applied his experiences and revolutionary ideas to cars. Until 1939 the company produced luxury cars. The design of the second-generation Voisin is taking careful account of the buyer s wishes. Mass production is out of the question, so the A-JT is not a car for the multitude; it is distinctive just like the TenCate materials it incorporates. Concept car seeks to be distinctive and eco-efficient TenCate Cetex is being applied in the first instance in engine compartment 45

46 Sustainability / Environment TenCate Geosynthetics USA educates students in geotextiles Geosynthetics in the college desks Once every year or two TenCate Geosynthetics USA welcomes students in their final year who wish to get their bearings in the production and possibilities concerning the design and application of geosynthetics. Within this context a group of students in Civil and Environmental Engineering at the University of North Carolina (US) recently paid a visit to the production facilities in Pendergrass and Cornelia (Georgia, US). The students, with on the right Prof. Kimberly Warren, professor of Geotechnical Engineering, Geosynthetics and Soil Improvement Techniques Prior to the visit Fred Chuck (director reinforcement markets) gave a presentation on the campus on the diversity of geosynthetics, their applications and how to distinguish between the different types of wovens, non-wovens and geogrids. The visits to the plants in Jefferson and Cornelia were coordinated and managed by Bruce Lacina (senior engineer). Authority For TenCate the most important feature of such visits is helping to confirm TenCate Geosynthetics as the authority on the manufacture of geosynthetics. Attention is also paid to the practical side, with the universities being briefed as far as possible about current projects where geosynthetics are being applied. The response of the students to their visit has been very good, and an additional advantage is that students will be predisposed to value TenCate positively during their future career. [email protected] 46 txtures number 4 winter

47 txtures in 2011 LOOKING AHEAD TO THE SPRING EDITION Theme: Connected with end-user marketing TenCate seeks to know what motivates its end-users and what their requirements are. This is why it is stepping outside its traditional role of supplier. TenCate is allowing itself to be inspired by the challenges that it sees in its direct contacts with the end market. This does not mean, however, that TenCate will deal directly with the end-user. The company is familiarizing the market with the possibilities and as a result is endeavouring to exert influence on the specifications, quality criteria and/or functional requirements that end-users lay down. Connected with the end-user is the theme of the 2010 annual report. IAA Award of Excellence for 2010 In 2010 TenCate Geosynthetics North America has for the fifth time won the IAA Award of Excellence in the Geosynthetic Products category. This is the sixth year in a row that the company has won an IAA award. The winning project was our contribution to the Incheon Bridge Project in South Korea. NA, said. We are also proud to have won an IAA Award for the sixth straight year. This year s winning entry, submitted by Yee Tack Weng, highlights TenCate s unique position to provide solutions for critical projects around the globe Annual figures TenCate will publish its 2010 annual figures on 2 March and in this edition we will provide the background to the results achieved. We are honoured to have been awarded the 2010 IAA Award of Excellence for TenCate Geosynthetics, John Henderson, Senior Vice-President at TenCate Geosynthetics Innovatie Route Twente TenCate is a partner in the Innovatie Route Twente. The presentation of the report Op Koers (On Course) was given on 20 October last. This related to a study of the innovation route, which was carried out by the Eastern Netherlands Audit Office. TenCate s activities in the context of regional innovation programmes will be explained in txtures and an outline will be given of their connection with the company s strategic themes. Digitex conference The 2010 Digitex conference will be held in Bergamo and Grassobio (Italy) on 2 & 3 December. At this conference the results of the Digitex project will be shown and new process technologies presented. There will also be an impression given of the new functionalities that can be achieved with it. Volume 44 number 4 winter 2010 txtures is a corporate review of Royal Ten Cate for its employees and external stakeholders. The magazine is published four times a year in a Dutch and English version. Reproduction of articles or parts of articles is authorized, providing the source is acknowledged and that passages and quotations are not placed in a different context. Editor s address Translations Design printing Royal Ten Cate Gay Howells DeNK creatieve vrijdenkers LulofDruktechniek Coen Heldeweg (chief editor) Janice Collins Almelo Almelo phone [email protected] 47

48 Our sandwiches are stiff panels In the world of aerospace, it is vital that all systems work perfectly, to guarantee lifelong service. As a leader in high performance composites for primary and secondary aerostructures, TenCate supplies materials that can provide the lightest weight and highest strength, whilst making no compromise to safety. TenCate supplies the aerospace industry with TenCate Cetex and its derivative sandwich panels, which are also used in aircraft trolleys. So, the next time you bite into your sandwich at 20,000 feet, just remember that it was kept fresh between a set of rigid, yet lightweight trolley panels.