KORDSA BULLETIN N.07 2017 TURKEY Determined to Create Value Reinforcing out of every 3 aircraft tires and 1 out of every 3 automobile tires produced in the world. N. 07 2017, The Reinforcer is a bi-annual publication by Kordsa [email protected] - www.kordsa.com
Published by Director Graphic Design Kordsa Corporate Communication O ce Tazefikir Group
Contents
03 / 04 Foreword 21 / 22 We Reinforce Life Manifesto Ali Çalışkan 23 / 24 Michelin View on Material 05 / 06 CSR Projects Patrick Cohen
07 / 10 News 25 / 26 Future Focus on Rolling Resistance Burak İlgün 11 / 13 Awards 27 / 32 Carbon Fiber Growth in the Automotive Market 14 / 16 The Need for Concrete Innovation Giacomo Dal Busco Mathieu Mottrie
33 / 34 The Manager Hard at Work! 17 / 18 It’s Never as Simple as It Looks Serving the Customers Patrick De Keyzer Vahe Hanamirian
19 / 20 The E ects of Capmax on Tire Rolling Resistance Bahadır Kaya
Our products not only improve the lives of individuals, families and our loved ones, but also “Reinforce Life”.
3 THE REINFORCER 9 m nutes to 3 m nutes. Prov d ng the compos te mater al w th a smoother and h gher qual ty surface f n sh, the new res n technology developed at our R&D center n Compos te Technolog es Center of Excellence s also a process technology su table for ncreas ng automot ve product on speed. We also cont nue to support collaborat ve un vers ty projects. In an e ort to encourage students to part c pate n technology, nnovat on and R&D, we prov ded compos te mater als to the YTU Rac ng Team composed of Yıldız Techn cal Un vers ty students. The compos te mater als suppl ed by Kordsa are used part cularly for the hull, w ngs and seats of the veh cle. The YTU Rac ng team part c pated n the Formula Student East compet t on, one of the world's b ggest student eng neer ng compet t on. We, Re nforcers of the World, constantly nnovate to re nforce l fe and cont nuously nvest n our human resources, wh ch s one of the p llars of our corporate culture. I can proudly say that mov ng up to 3rd place th s year, Kordsa s l sted among best employers n Bah a, Braz l by the Great Place to Work Inst tute two years n a row. Rank ng n 3rd place s the result of the h gh standard of human resources management that we mplement n our operat ons on var ous geograph es. Moreover, we reached our njury-free safety targets at our four plants, wh ch s a clear s gn of our ded cat on to workers’ health and safety. Foreword Hav ng embedded the susta nab l ty approach nto our targets and strateg es, we are presently comp l ng our th rd susta nab l ty report and t w ll be publ shed soon. Last year, we were ent tled to enter the ALİ ÇALIŞKAN BIST Susta nab l ty Index and were l sted n the BIST 50 Index. In parallel to our susta nab l ty e orts, we are susta n ng our steady CEO growth w th n the BIST 50 Index. We are rewarded for our e orts w th numerous prest g ous awards. We were l sted among the “Most Eth cal Compan es n Turkey” for Dear Esteemed Partner, the fourth consecut ve years, wh ch o c ally recogn zes our ded cat on to eth cal pr nc ples, one of our seven corporate values. 2017, l ke 2016, s turn ng out to be an exc t ng year econom cally, Add t onally, we were awarded n “Brand and Export Support" soc ally and pol t cally, w th both h ghs and lows across the globe. category at the "Contr butors to Turkey’s Brand Value and Regardless of these challenges, I am proud to say that the f rst half Turqual ty Awards” ceremony by Brand Turkey 2017, the of 2017 s yet another remarkable year for Kordsa from many ntersect on of Turkey's lead ng brands, wh lst Kordsa teams were d erent perspect ves thanks to our nnovat ve, technology-or ented granted s x awards at the Sabancı Hold ng Golden Collar Awards, m ndset and our ag l ty n adapt ng to change. In order to ga n a nclud ng the Creat ng Value category award. broader v s on that can lead to new d scover es of the k nd that Our nnovat ve technolog es are very much ntegrated n our gn te organ zat ons or ndustry, we need to get out of our cocoon, everyday l fe, mak ng t safer, more e c ent, comfortable and comb ne mult ple ex st ng deas and d sc pl nes and un te our conven ent. Kordsa, the re nforcer of one out of every three power. Today, we seek new technolog es and deas not only automob le t res and two out of every three a rcraft t res, str ves to nternally through our R&D Centers but also externally through make l fe more susta nable by reduc ng roll ng res stance to collaborat on w th un vers t es, suppl ers and customers n order to decrease fuel consumpt on through ts t re re nforcement create value-added products. technolog es as well as l ghten ng veh cles through ts compos te One good example of our open nnovat on pract ces s “Beh nd the technolog es. We develop new products and technolog es w th an Borders” project, wh ch br ngs t re manufacturers and our t re env ronmentally-fr endly m ndset. Our products not only mprove experts together. Th s project cont nues at full speed through the l ves of nd v duals, fam l es and our loved ones, but also customer v s ts wh ch g ve us opportun t es to develop new “Re nforce L fe”. technolog es together as well as creat ng pract cal solut ons that W th th s new ssue of the Re nforcer, we are nv t ng you to take a ease our da ly work rout nes. Moreover, as a result of our f rst-hand look at Kordsa’s bus ness development n the f rst half of technology-dr ven m ndset, we made a record number of patent 2017 as well as emerg ng trends n our l nes of bus ness. Wherever appl cat ons n 2016: we appl ed for 32 nvent ons and 103 patents n our ndustr es are evolv ng and the future s be ng shaped, you w ll 2016. In total, we have 411 patent appl cat ons and 128 nvent ons. encounter Kordsa. We are proud to announce that our Compos te Technolog es Center We are conf dent about the progress we have made n 2017, and we of Excellence has become operat onal as a platform of open w ll keep on re nforc ng more and more areas n l fe. nnovat on pract ces. Our R&D center located at the Compos te I w sh you a good read ng. Technolog es Center of Excellence has been recently qual f ed as an R&D Center by the M n stry of Sc ence, Industry and Technology. We are honored to say that we now have two o c ally-approved R&D centers. As an output of th s center, we have developed a res n technology for automot ve compos tes that br ngs speed and ncreased product v ty to the ndustry by reduc ng the cur ng t me of
THE REINFORCER 4 WE REINFORCE LIFE CSR Projects
Kordsa Brings Composite Technologies and Young People Together
Re nforcement technolog es profess onal Kordsa are support ng projects at Yıldız Techn cal Un vers ty and Trakya Un vers ty n an e ort to ntroduce young people to compos te technolog es. In order to engage youth n compos te technolog es and to encourage them to be nvolved n technology, nnovat on, R&D and eng neer ng, Sabancı Hold ng a l ate Kordsa ntroduced un vers ty projects powered by the company to the students of Kocael Un vers ty. Kordsa supported these un vers ty projects by sponsor ng the carbon mater al for the cars be ng bu lt. These veh cles, re nforced w th compos te technolog es, were d splayed at Kocael Un vers ty Teknopark for an ent re month. The Trakya Un vers ty Des gn Project Team’s Pehl van-02 and Pehl van ElekTrak, powered by Kordsa Plat num sponsorsh p, were two pr ze-w nn ng cars n several d erent compet t ons. The Pehl van Elektrak’s body s fully made of carbon f ber; thus, t s enabled to rema n l ght-we ght yet strong. The env ronmentally-fr endly car recharges tself n 45 m nutes and can run for 100km on only 0.75 TL (around $0.21) worth of electr c ty. The Pehl van Team, sett ng out from Ed rne, toured around the Balkans last year.
The YTU Rac ng Team, wh ch was establ shed as a part of the Mach ne Technolog es Club n order to part c pate n the Formula Student Compet t on, des gned and bu lt a s ngle-seat, open-wheel rac ng car w th Kordsa sponsorsh p. The team successfully part c pated and got a good rank ng n Formula Student England (S lverstone) and Formula Student Germany (Hockenhe m). Re nforcement technolog es leader Kordsa, w th ts open nnovat on m nd-set, works together w th young people n an e ort to encourage academ c and ndustry collaborat on. Kordsa also str ves to engage young people n entrepreneursh p by support ng them n the R&D and product on phases.
Indonesia Internship Program
On January 16, 2017, we held an event to mark the end of our Vocat onal H gh School Internsh p Program. From October 16, 2016 to January 17, 2017, 36 students part c pated n the 3-month nternsh p. Dur ng th s event, the nterns put on two performances—a drama performance and a band performance—to show the r apprec at on of Indo Kordsa, the nterns got cert f cates and mementos from Indo Kordsa, and the company’s superv sor, company head, and h gh school ndustr al cooperat on o cer had the r p ctures taken together w th the nterns,.
Kordsa Meets Future Reinforcers in Indonesia
Mechan cal eng neer ng students of the Gajah Mada Un vers ty pa d a v s t to Kordsa's Indones a plant. The students had a busy agenda w th presentat ons from Kordsa re nforcers and a tour of the plant, and they ran s mulat ons of Kordsa's manufactur ng and management processes. Kordsa a ms to ra se brand awareness n the m nds of the future re nforcers through such get-togethers w th eng neer ng students.
5 THE REINFORCER Kordsa Reinforces the Future with Youth People
Sponsored by re nforcement leader Kordsa n an e ort to encourage young people to part c pate n technology, nnovat on, R&D and eng neer ng, Yıldız Techn cal Un vers ty student team YTU Rac ng has produced ts fourth veh cle and took part n Formula Student East, one of the b ggest student eng neer ng compet t on. Kordsa has prov ded compos te mater al support to the YTU Rac ng project team n recent years. The team has already taken part n the Formula Student race, held every year at one of the most famous F1 c rcu ts, S lverstone n the UK, and s the f rst and only Turk sh team to take part n th s race. The YTU Rac ng team, one of the many projects powered by the technology exporter Kordsa n l ne w th ts m ss on to re nforce the future, was establ shed as part of the Mach ne Technology Club of Yıldız Techn cal Un vers ty n 2011 w th the part c pat on of 30 students from d erent facult es. The YTU Rac ng team, hav ng produced ts fourth veh cle th s year, s ready to part c pated n the Formula Student race that takes place annually on the S lverstone c rcu t n Hungary. The launch of the veh cle took place at Yıldız Techn cal Un vers ty. The sponsors, academ cs and students’ fam l es were present at the event. In the foyer area, part c pants had the chance to see the f rst three cars that had taken part n prev ous years’ Formula Student races. The YTU Rac ng team s the f rst and only Turk sh team to take part n the Formula Student East race. Kordsa, thanks to ts p oneer ng approach, has always encouraged un vers ty– ndustry collaborat on. As one of the sponsors of the YTU Rac ng team th s year, just as n prev ous years, Kordsa prov ded compos te mater als to the YTU Rac ng team. The compos te mater als suppl ed by Kordsa can be used n part cular for the hull, w ngs and seats of the veh cle. Thanks to Kordsa’s contr but ons, the veh cles have become stronger, more robust and faster due to the r l ghter we ght. At the launch event, the Cha rman of the Turk sh Exporters Assembly, Mehmet Büyükekş , made a speech emphas z ng the mportance of young people’s success for the future of the country. In h s speech, he also thanked sponsors for support ng young people and hence re nforc ng Turkey’s future.
Kordsa Raises Awareness
Kordsa Indones a plant organ zed a blood donat on campa gn at Indokordsa. W th ts "G ve Blood, Save L ves" slogan, Kordsa re nforcers nv ted other compan es n the area to jo n them. The campa gn served to create awareness among Kordsa re nforcers as well as throughout the whole organ zat on and the compan es nvolved.
THE REINFORCER 6 WE REINFORCE LIFE News
Kordsa Makes Record Number of Patent Applications in 2016
Kordsa, wh ch was recently analyzed as a success story by INSEAD Professor Ben Bensaou for h s book “Innovat on Mach ne” due to ts R&D and nnovat on pract ces, closed 2016 w th a record number of patent appl cat ons. Supply ng re nforcement technolog es around the world from the U.S. to Tha land, Kordsa created 32 nvent ons and f led 103 patent appl cat ons n 2016 alone. W th ts bus ness processes based on R&D and nnovat on, Kordsa ma nta ns ts leadersh p n nnovat on n the global re nforcement market w th 411 patent appl cat ons and 128 nvent ons n total.
Kordsa’s Second R&D Center Gains Ministry Approval
Kordsa, a subs d ary of Sabancı Hold ng and a global player n the t re, compos te and construct on re nforcement technolog es market, had had a second R&D center approved by the M n stry of Sc ence, Industry and Technology. The Compos te Technology Excellence Center, where R&D and product on processes for compos te technolog es are brought together under a s ngle roof, has o c ally qual f ed as an R&D Center. Kordsa's Compos te Technolog es Center for Excellence, wh ch has been created n collaborat on w th Sabancı Un vers ty n an e ort to br ng together R&D and nnovat on pract ces n compos te technolog es under a s ngle roof, s now o c ally reg stered as an R&D Center, mean ng that Kordsa now has two o c ally-approved R&D centers. Kordsa's other approved R&D center, located n İzm t, s seen as an R&D and nnovat on hub for the global and Turk sh market n t re re nforcement and construct on re nforcement technolog es. As one of the lead ng development centers n the world, the Compos te Technolog es Center for Excellence prov des an env ronment n wh ch bas c research, pract cal appl ed research, technology development, product development, entrepreneursh p, and product on processes can all be carr ed out under the same roof. All the relevant players n these processes—researchers, des gners, eng neers, managers and sta nvolved n the product - on process, PhD students, postdoctoral fellows, faculty members and entrepreneurs from ncubators—w ll co-ex st n th s ecosystem. W th the Compos te Technolog es Center for Excellence, Kordsa s serv ng ts stakeholders n all the phases of the R&D cycle, start ng from bas c research, cont nu ng w th prototype product on and end ng n mass product on, accord ng to customer requ rements.
Kordsa at Tire Technology Expo
Kordsa part c pated n the T re Technology Expos t on n Hannover, where the latest t re ndustry technolog es and trends are shared. Wh le d splay ng ts t re re nforcement technolog es, Kordsa also shared nformat on on ts product Monolyx for heavy construct on equ pment w th part c pants at the conference as part of the expos t on. Kordsa, a Sabancı Hold ng a l ate, attended the 17th T re Technology Expo, one of the lead ng expos t ons at wh ch the latest developments n the t re ndustry are shared, n Hannover, Germany. Wh le d splay ng ts latest t re re nforcement technolog es at ts stand, Kordsa also made a presentat on at the T re Technology Conference on the features and usage areas of Monolyx. Monolyx, wh ch has a protect ve rubber layer w th a cord structure formed by monof lament f bres tw sted together, protects the structural ntegr ty of t res n harsh road cond t ons. In add t on, the cut-res stant Monolyx o ers 2.5 t mes h gher cut res stance performance compared to standard text le mater als. The presentat on attracted great attent on from part c pants, convey ng the message that Monolyx can be used n many other areas due to ts ex st ng qual t es. The presentat on also ncluded an ntroduct on to Kordsa's exper ence n the re nforcement market and ts work n nnovat on.
7 THE REINFORCER Kordsa Gets Environmental Management Certificate
Kordsa earned the ISO14001:2015 Env ronmental Management System cert f cate n Indones a, follow ng Turkey. Hav ng fulf lled such cond t ons as e ect ve waste management for a susta nable future, energy conservat on, and emergency and d saster preparedness, Indokordsa earned ts ISO14001:2015 cert f cate. Recogn zed around the world, the ISO14001 cert f cate also adds to the prest ge of the organ zat ons as an nd cator of the econom c d mens on of susta nab l ty, such as e ect ve cost control, ncreased e c ency and market share.
Kordsa at JEC World 2017
Kordsa, a global player n the t re, compos te and construct on re nforcement market, part c pated n JEC World, the largest compos tes show n the world. The exh b t on has been held n Par s s nce 1956 and took place between March 14-16 th s year. 1,250 compan es from more than 100 countr es exh b ted at JEC Compos tes World th s year. The show attracted more than 35,000 v s tors from all around the world. Kordsa, attend ng the most s gn f cant gather ng of the ndustry for the fourth t me, also hosted a group of journal sts from Turkey. Kordsa shared w th part c pants ts nnovat ve compos te technolog es that prov de e c ency n the automot ve ndustry. Br ng ng speed and product v ty ncreases w th ts new res n technology, Kordsa prov des a revolut onary shorten ng n the cur ng process and reduces cur ng t me from 9 m nutes to 3 m nutes. Kordsa’s new res n technology, wh ch prov des compos te mater als w th a smoother and h gher qual ty surface f n sh, s also a process technology su table for automot ve product on speed. Kordsa s expect ng to expand ts share n the European compos te technolog es market and a ms to reach $70 m ll on of revenue n compos te technolog es.
Kordsa's New Resin Technology for Fast Curing Prepreg Systems Brings Speed and Eciency to Automobile Industry
Kordsa’s technolog es are br ng ng speed and e c ency to the automot ve ndustry, reflect ng the power of ts compos tes. Through the speed and product v ty ncreases prov ded by ts new res n technology, Kordsa can announce a revolut onary shorten ng n the cur ng process thanks to ts ab l t es n nnovat on. W th the new res n technology developed by Kordsa, the cur ng t me of 9 m nutes has been reduced to 3 m nutes, wh le the surface qual ty of the compos te mater al has also ncreased. Alongs de th s new res n technology, Kordsa has also developed and launched a process ng technology su table for automot ve product on speed. Kordsa’s new technology has been developed by the groundbreak ng R&D Center at the Compos te Technolog es Compos te Center of Excellence, wh ch br ngs together ndustry representat ves and academ cs under the same roof for bas c research, appl ed research, technology development, product development, entrepreneursh p and manufactur ng processes. Th s new technology w ll br ng a fresh new d mens on to the ndustry and Kordsa’s range of thermoset prepregs, wh ch nclude a w de range of res n formulat ons spec ally formulated by Kordsa for d erent appl cat ons and product on processes. Its short cur ng cycle and hot de-moldable nature are espec ally opt m zed for mass product on n the automot ve ndustry. Compress on mold ng s the recommended process for th s new res n system. It not only cures under 3 m nutes at 150°C at the press under sothermal cur ng cond t ons but s also hot de-moldable and has a long out-l fe of 2 weeks at amb ent temperature. These extreme cond t ons do not a ect the v sual performance of th s nnovat ve prepreg system, wh ch s capable of g v ng class-A surface qual ty. The new v sual prepreg shows good drapab l ty and s su table for both fast press mold ng and low-to-med um tack opt m zed for press cur ng. Thanks to ts m d-to-h gh Tg formulat on, t s su table for cataphores s, hot pa nt ng, and hot adhes ve bond ng. The new all- n-one fast cure hot de-moldable press curable v sual prepreg s ava lable as UD and through var ous weav ng styles n carbon and glass. Des gned also for structural appl cat ons requ r ng excellent chem cal res stance, t g ves flex b l ty w th ts good chem cal res stance. Kordsa’s new prepreg s l kely to have an exc t ng future, as t s well-su ted to the autoclave short cur ng cycle that serves as the everyday standard for the world’s automot ve ndustry.
THE REINFORCER 8 Reinforcers Meet at All Stars Award Ceremony
Kordsa re nforcers got together at the 11th All Stars Award Ceremony wh ch recogn zes the most successful projects mplemented at Kordsa throughout the year. 104 Projects and 830 part c pants competed n 12 categor es rang ng from nnovat on to technology projects and f nanc al performance. W th the part c pat on of employees from Indones a, Tha land, Braz l and the U.S. through l ve v deo connect on, the All Stars Awards demonstrated that Kordsa re nforcers accompl sh more and more projects w th a greater success each year.
Kordsa at Techtextil, the World’s Leading International Trade Fair for Technical Textiles
Kordsa, a Sabancı Hold ng a l ate, attended Techtext l 2017, the lead ng trade fa r and platform for the techn cal text les ndustry. The fa r connects today’s techn cal text le technology to the future, and Kordsa presented ts most nnovat ve products n the compos te and construct on re nforcement technolog es sector to v s tors. Over 30,000 v s tors made the r way to Techtext l n Frankurt between May 9–12 to d scover the most nnovat ve products nclud ng nearly 1,500 yarns, ready-to-wear fabr c, mach ne manufacturers from more than 50 countr es n the f eld of techn cal text les and the latest process ng technolog es. Kordsa, the re nforcement leader, presented ts compos te technology and construct on re nforcement brand KraTos to the part c pants at Techtext l 2017. Used as re nforcement technology n var ous nfrastructure and superstructure construct on projects, such as ndustr al floors, concrete roads, under-ra l concrete and a rports, KraTos s an nnovat ve product that re nforces concrete, sav ng labor, t me and cost. Moreover, Kordsa develops nnovat ve and un que ntermed ate products and appl cat ons n the f eld of compos te re nforcement for a var ety of ndustr es, notably the av at on and automot ve ndustr es as well as mar ne and ra l systems. Produc ng thermoset prepregs for var ous ndustr al appl cat ons, Kordsa boasts a w de product range and flex ble product on capab l t es thanks to the strength t ga ns from weav ng ts own fabr c.
Excellence Visit to Brazil
Kordsa organ zed an excellence v s t to ts plant n Braz l. Operat ng n a w de geography from Amer cas to the As a Pac f c, Kordsa a ms to extend good pract ces to all ts plants through Excellence V s ts. Dur ng the v s t, good pract ces n manufactur ng and technology were shared w th the part c pants, and Kordsa's latest awards were celebrated. Korda Braz l team won the 1st place n the E c ency Category at the Golden Collar Award Ceremony, and was dent f ed as the 3rd best workplace n the Bah a reg on accord ng to the Great Place to Work l st.
U.S. Leg of Leadership Training
Kordsa North Amer ca profess onals came together for a fresh round of "Leadersh p Tra n ng." Leaders jo ned var ous workshops dur ng the three-day program that was bu lt to develop operat onal excellence, and lean and e ect ve management. They worked on team bu ld ng sk lls, and methods for personal leadersh p development and e ect ve ways of work ng.
9 THE REINFORCER Kordsa Presents Concrete Reinforcement Technology KraTos at 40th Turkeybuild Exhibition
Sabancı Hold ng a l ate Kordsa, known as "the Re nforcer" n the t re, construct on and compos te ndustr es, has part c pated n the 40th Turkeybu ld Exh b t on held at TÜYAP Beyl kdüzü exh b t on center between May 23–27 and shared ts nnovat ve concrete re nforcement synthet c f ber product KraTos w th construct on ndustry profess onals. Re nforcement leader Kordsa took part n the nternat onal bu ld ng and construct on mater als fa r Turkeybu ld n Istanbul, present ng KraTos, wh ch prov des long-term and h gh durab l ty as well as sav ngs on cost, t me and labor. KraTos s a more susta nable and env ronmentally fr endly concrete re nforcement mater al compared to steel, and s d erent ated by ts long term durab l ty due to ts user fr endly, non-electr c conduct ve and ant -corros ve structure prov d ng l fet me control over crack generat on n concrete thanks to ts easy and homogeneous m x ng feature. KraTos s w dely used n all k nds of nfrastructure and superstructure appl cat ons nclud ng f eld concretes, coat ng and screed appl cat ons, ndustr al floors, concrete roads, water and ports structures, under-ra l concrete, a rports, and precast concrete components.
Kordsa Reinforces its Position in the US Market
Kordsa, a global player n t re, compos te and construct on re nforcement technolog es, has supported ts ex st ng nvestment n the U.S. market w th a new purchase. Kordsa's subs d ary n the U.S., Kordsa Incorporated, acqu red the Chattanooga fac l ty of the Luxembourg-based INVISTA S.à r.l. n the U.S. state of Tennessee. Kordsa a ms to ma nta n ts leadersh p pos t on n the U.S. market w th th s new fac l ty. Kordsa Incorporated, the U.S. subs d ary company of Kordsa, has purchased the plant of Inv sta Corporat on n the Chattanooga reg on of Tennes- see. W th th s acqu s t on, wh ch w ll ensure the susta nab l ty of Kordsa's fac l t es n the U.S., Kordsa Inc. w ll have the legal r ght over the land n wh ch Inv sta and Kordsa were formerly located, nclud ng the ex st ng nfrastructure, power generat on stat on, and salt and polymer product on l nes.
Kordsa Meets with Little "Reinforcers"
A m ng to re nforce commun t es n the countr es t operates, Kordsa v s ted a school n the Bah a reg on of Braz l, w th n the scope of an Excellence V s t to ts Braz l an plant. Enterta n ng the l ttle ones w th var ous games and act v t es at the school t supports through ts soc al respons b l ty project, Kordsa w ll cont nue to re nforce the future w th the help of ts soc al respons b l ty projects.
Kordsa Participates in Indonesian President’s Ocial Visit
Kordsa, a global brand from Turkey, has attended a meet ng held as part of Indones an Pres dent Joko W dodo’s o c al v s t to Turkey as a spec al nv tee of Joko W dodo. At the meet ng held n Ankara w th the part c pat on of execut ves from lead ng Turk sh compan es, Zek Kanadıkırık, Ch ef Operat ng O cer for the As a-Pac f c reg on, represented Kordsa. Kordsa won an Indones an Export Champ on award n 2016, and was l sted among the top 100 fastest grow ng compan es n Indones a by Infobank, one of Indones a's b ggest econom c magaz nes, earl er th s year. In 2015, n an e ort to meet demand n the reg on, Kordsa undertook an nvestment of $100 m ll on and opened a second t re cord and polyester yarn factory n Indones a. Later, Kordsa strengthened ts pos t on n Indones a w th another nvestment to add an add t onal 7 k loton capac ty. The Free Trade Agreement negot at ons expected as part of Indones an Pres dent Joko W dodo’s v s t w ll def n tely strengthen Kordsa’s pos t on, as well as those of other Turk sh compan es n the As a-Pac f c reg on by develop ng b lateral bus ness cooperat on and trade opportun t es.
THE REINFORCER 10 WE REINFORCE LIFE Awards
Kordsa among the Best Employers in Brazil, Two Years in a Row!
human resources management that we mplement n our operat ons n all d erent reg ons. I am del ghtful that we have been recogn zed among the compan es w th a strong human resources culture by strengthen ng our pos t on versus last year as a brand that s spread ng from Turkey to the world. My s ncere congratulat ons to all my colleagues for the r contr but ons to our success. Th s result proved once aga n the strong relat onsh p between our operat onal and f nanc al success and our employees’ happ ness. We w ll cont nue to nvest n our human resources, wh ch s one of the p llars of our corporate culture.” About Great Place to Work Great Place to Work® s the global author ty on bu ld ng, susta n ng, and recogn z ng h gh-trust, h gh-perform ng employee-centered workplace cultures. W th more than 25 years of exper ence, GPTW’s survey exam nes the relat onsh p between employees and employers or managers, the comm tment of employees to the r work, and the relat onsh ps between employees and the r teammates. One of the most mportant tools n these analyses s the Trust Index © Employee The Kordsa plant n Braz l has once aga n been l sted among Braz l’s Survey wh ch further expla ns the corporate culture through best employers for the second consecut ve year. Accord ng to a cred b l ty, respect, fa rness, pr de and camarader e. The other s the survey conducted by the Great Place to Work Inst tute (GPTW) that Culture Aud t©, wh ch measures HR and management pract ces. ncluded 33 compan es, Sabancı Hold ng a l ate Kordsa, renowned globally as “The Re nforcer”, ranked 3rd n the l st of the best How s the evaluat on made? employers n Bah a, Braz l w th an 86 percent Trust Index. Survey results from the Great Place to Work Inst tute der ved 2/3 of Kordsa CEO Al Çalışkan, comment ng on two stra ght years of the r scores from company employees, and the rema n ng 1/3 was success, stated: “In last year’s survey by the Great Place to Work based on comparat ve analyses of the human resources programs Inst tute, Kordsa was l sted n 7th place among the best employers. and pract ces establ shed by each company. Our rank ng 3rd place th s year s the result of our h gh standard of
Kordsa is Among Top 100 Fastest-Growing Companies in Indonesia
Kordsa, str ves to atta n susta nable growth n every country t operates and to prov de products and serv ces that w ll br ng value to ts customers, and has been rewarded for ts e orts w th numerous prest g ous awards. In be ng counted among the top 100 fastest-grow ng compan es n Indones a, world's re nforcement leader Kordsa has added a new award to ts global successes. Kordsa, l sted among the top 100 compan es by one of Indones a's b ggest econom cs magaz nes, Infobank, rece ved the award from Indones an Economy M n ster Darm n Nasut on. Kordsa, selected as “Export Star of the Year” n Indones a n 2016, had re nforced ts growth momentum n Indones a w th th s award. In 2016 a Kordsa project manager also rece ved the "Best Employee" award n Indones a for carry ng out the project "Safety Exper ence Center”. Kordsa CEO Cenk Alper, express ng h s apprec at on for th s success, sa d: “2016 has been a year n wh ch we have re nforced our global leadersh p w th the awards we have rece ved. We had been honored w th numerous awards for our R&D and nnovat on e orts. We were selected as an export champ on both n Turkey and n Indones a. We were l sted among the “Great Places to Work” n Braz l. Now we are among the 100 fastest-grow ng compan es n Indones a. Kordsa w ll cont nue to pos t vely mpact every reg on t operates n and to atta n susta nable growth. Apart from our operat onal and f nanc al growth we w ll endlessly cont nue to make nnovat ve changes that w ll create value.”
11 THE REINFORCER Energy Eciency Practices Bring Kordsa an Award
Kordsa won the Jury’s Spec al Award n the “Project Contest on Energy E c ency n Industry” organ zed by the Renewable Energy D rectorate-General at the M n stry of Energy and Natural Resources thanks to the energy e c ency pract ces t has put nto e ect. A global player n the t re, construct on and compos te re nforcement technolog es market, Kordsa has added one more award to ts already-ex st ng successes. Thanks to the energy e c ency pract ces the f rm adopted n the scope of ts broader susta nab l ty approach, Kordsa was granted the Jury’s Spec al Award n the “Project Contest on Energy E c ency n Industry” wh ch the Renewable Energy D rectorate-General at the M n stry of Energy and Natural Resources organ zes every year. The award was accepted by Al Çalışkan, Kordsa’s Deputy D rector-General respons ble for the Europe, M ddle East and Afr ca reg ons. In the contest, organ zed by the Renewable Energy D rectorate-General organ zes n order to ncrease the amount of nformat on exchange between ndustr al bus nesses and to encourage new and s m lar appl cat ons, Kordsa was granted the award n the “Projects to Increase Energy E c ency n Industry” category. Kordsa’s award plaque was bestowed by M n stry of Energy and Natural Resources Undersecretary Fat h Dönmez at the award ceremony that took place as part of the 8th Energy E c ency Forum and Fa r held n Istanbul.
Kordsa Ranked First in Textiles Category of Platin Magazine Awards
Kordsa has been l sted among the "Global 100 Compan es" by the prest g ous econom cs and bus ness l fe magaz ne Plat n, work ng together w th Ipsos Research and Consultancy, and ranked n f rst place n the text le ndustry category. At the awards ceremony, 21 lead ng compan es n var ous ndustr es were g ven awards n 21 d erent categor es from energy to m n ng, and from pharmaceut cals to log st cs. The l st was formed by analyz ng numerous corporat ons reg stered n Turkey and the r act v t es on a global scale based on 13 key cr ter a, nclud ng balance sheet data, value added product on, reputat on and partnersh p structure. Plat n Magaz ne’s Global 100 l st began th s year w th the a m of reward ng the Turk sh corporat ons that contr bute the most to nternat onal trade. The l st a ms to recogn ze the e orts of trad ng compan es as well as celebrat ng the strength and d vers ty of Turk sh exporters. Th s l st, h ghl ght ng exemplary exporters n var ous ndustr es, w ll surely also encourage other compan es n the Turk sh bus ness world.
KordsaKordsa ParticipatesAmong Turkey's In “Export Top Ethical Under CompaniesThe Stars” Summit for the 4th Time in a Row
Kordsa got l sted among the most eth cal compan es n Turkey for the fourth t me. Work ng n l ne w th ts pr nc ple of respect ng laws and eth cal values n the countr es t operates, Kordsa won the ETIKA Turkey's Most Eth cal Compan es Award for the fourth t me, g ven to create awareness about eth cs and bus ness morals by the Center for Eth cal Values Assoc at on. Operat ng n a w de geography from Amer cas to As a Pac f c, Kordsa's comm tment to "eth cs" as one of ts 7 values s rewarded once aga n.
THE REINFORCER 12 Kordsa Among The Companies Who Add Value to the Turkey Brand
Kordsa has been g ven an award n the "Brand and Export Support" category at Brand Turkey 2017, wh ch was organ zed by the Turk sh Exporters Assembly and brought together the country’s lead ng brands. Kordsa, an a l ate of Sabancı Hold ng, has been g ven an award n the “Brand and Export Support" category at the "Contr butors to Turkey’s Brand Value and Turqual ty” awards ceremony at Brand Turkey 2017, wh ch s organ zed by the Turk sh Exporters Assembly. The event represents the ntersect on of Turkey's lead ng brands. Brands were g ven awards based on an evaluat on of the r work wh ch has nsp red Turkey’s brand ng journey and enr ched ts brand value as a country. Regard ng the award, Kordsa CEO Al Çalışkan stated: "We are proud to be among the global brands belong ng to Turkey. Today, Kordsa exports technology from Turkey to the ent re world. By transferr ng our 44-year t re re nforcement exper ence nto compos te and construct on re nforcement technolog es, we ma nta n our pos t on n the global market w th our t tle 'The Re nforcer'. Thanks to the Compos te Technolog es Center of Excellence wh ch became operat onal last August, we have become the exporter of not only t re re nforcement technolog es, but also compos te technolog es, from Turkey to the world. In th s regard, we w ll keep add ng value to the Turkey brand wh le cont nu ng to re nforce w der areas around the world. "
Kordsa Wins Leaders of Export Award
Kordsa won the plat num award n a ceremony by Istanbul Text le and Raw Mater als Exporters' Assoc at on (ITHIB) that rewards the performance of compan es' export ng the r manufacture. Export ng ts re nforcement technolog es to 42 countr es, Kordsa earned ts place among the leaders of export.
Kordsa is the Winner of Creating Value Category at the Golden Collars
Kordsa left the Golden Collar Awards, organ zed for the 8th t me th s year, as the w nner of four categor es – nclud ng the "Creat ng Value" category –, an honorable ment on, and a spec al award. Export ng technology to global markets w th ts m ss on to re nforce l fe, Kordsa celebrated once aga n ts susta nable success and p oneer ng good pract ces w th ts employees. Kordsa w ll cont nue to re nforce the Sabancı Group w th ts novel technolog es.
13 THE REINFORCER “The innovation process consists of anticipation, creation and implementation.” “E cient innovation is avoiding reinventing the wheel.”
THE REINFORCER 14 An e c ent nnovat on process cons sts of three phases: ant c pat on, creat on and mplementat on.
Ant c pat on: The Need for an Innovat on Strategy In order to nnovate e c ently, t s necessary to have a sound nnovat on pol cy. Th s must max m ze the return on nnovat on and help the company to renew and mprove. In the f rst place, an nnovat on strategy s the translat on of corporate strategy nto a concrete plan. Th s plan sets out clear act ons wh ch w ll make the most e c ent use of scarce resources, t me and budget. These act ons, n turn, must make t poss ble to e ect vely carry out the organ zat on's general bus ness strategy throughout the short, med um and long term. In add t on to corporate strategy, a second mportant source of nput for an nnovat on strategy s your knowledge of your own play ng f eld, the sphere n wh ch you operate. Who are the d erent players n your market? What are the most recent developments and trends? Who are the experts? And what new technolog es are about to break through? Before an organ zat on can renew tself ( .e. nnovate), t f rst needs to know where t currently stands and what potent al solut ons already ex st. Th s s a log cal and cruc al step, but one that s frequently overlooked. Why s t so mportant? F rstly, because we need to understand that nnovat on does not mean that we need to The Need for Concrete Innovation re nvent the wheel—although, sadly, th s s what all too often happens. A second mportant reason s that compan es need to try and d erent ate themselves from the r 'compet ng colleagues', and MATHIEU MOTTRIE th s s only poss ble f you know what other people n your sector are do ng and nvest gate where potent al po nts of d erent at on m ght CEO CREAX be found. Th s br ngs us to the th rd mportant nput element for your nnovat on strategy: your company’s spec f c 'core competenc es'. A Innovat on has become an nd spens ble part of modern-day bus ness f rm's core competenc es are d cult for ts compet tors to m m c, pract ce. Every company and organ zat on has the word ' nnovat on' allow ng the company to d erent ate tself. somewhere n ts m ss on, v s on or values statement. Even so, many of these compan es and organ zat ons st ll struggle to g ve concrete express on to nnovat on. They struggle even more to mplement t Creat on: Concrete Innovat on Projects successfully. Th s s a ser ous problem, because nnovat on s Once you have an nnovat on strategy, t must be translated nto mportant—nay, cruc al—for every enterpr se, whether large or small, concrete nnovat on projects. In th s respect, there are three poss ble young or old. Part of the problem s that nnovat on has become a d rect ons you can take: product nnovat on, process nnovat on catch-all concept that means (too) many d erent th ngs to (too) many and/or market nnovat on. Product nnovat on places the focus on the d erent people. So how should we properly def ne nnovat on? And development of new products and technolog es for ex st ng markets. why s t so mportant? In process nnovat on, ex st ng processes are ref ned and mproved, so that the prov s on of products or serv ces become more e c ent and cost less. Market nnovat on nvolves seek ng new markets and Innovat on: What and Why? appl cat ons for ex st ng knowledge, products and processes. It s Innovat on s the process of cont nually seek ng to f nd more e ect ve poss ble to comb ne all three of these poss b l t es, or to have them ways to carry out the funct ons we want to employ. As a consequence, t runn ng alongs de each other. s mportant to th nk n terms of funct ons, not solut ons. Cons der, for example, the funct on of 'commun cat ng'. People have always wanted to commun cate w th each other and w ll cont nue to do so n the Implementat on: Gett ng Th ngs Done future. But the solut ons that make th s poss ble have evolved over F nally, t s necessary to draw up concrete plans for the t me: smoke s gnals, drums, telegrams, f xed-l ne telephones, etc. mplementat on of your nnovat on projects. Th s s where the ma n Nowadays, we fulf l many of our commun cat on needs through mob le d erence s to be found between creat v ty and nnovat on. telephony. But even th s solut on w ll eventually change—and perhaps Successful renewal, whether of products, processes or markets, must much sooner than we th nk. But whatever solut on technology be carr ed through n pract cal terms so that the necessary return can develops, the bas c funct on—commun cat on—w ll rema n constant. be generated as qu ckly as poss ble. The translat on of concepts and You can eas ly th nk of many other examples. What about transport? deas nto workable products and serv ces for the 'real world' can be a Yesterday, the horse and cart; today, cars; tomorrow, drones? ser ous challenge. Techn cal, econom c and consumer perspect ves must all be cons dered and conf rmed. It s only when the The compan es who th nk n terms of funct ons rather than the mplementat on has taken place and the new bus ness conf gurat on solut ons are the compan es that surv ve. And that s prec sely why beg ns to y eld a good return that we can speak of successful nnovat on s so v tally necessary: t ensures the future of the nnovat on. organ zat on n the long term. Look at the detergent sector: are compan es l ke Procter & Gamble and Un lever n the bus ness of 'sell ng detergents' (solut ons) or n the bus ness of 'clean ng clothes' Ex st ng Knowledge as a Source of Innovat on (funct ons)? We are already see ng electron cs g ants l ke LG, Sanyo A recent study nto the future of nnovat on management concluded and others br ng wash ng mach nes to market that no longer requ re that knowledge management and 'h gh speed/low r sk nnovat on' detergent. Technolog es l ke electrolys s and acoust c cav tat on are play an extremely mportant role n ach ev ng e c ent nnovat on. tak ng over the clean ng funct on, so the need for detergent w ll soon become obsolete. Nowadays, everyth ng s evolv ng at l ghtn ng speed. Th s makes t a
15 THE REINFORCER €
real challenge for compan es to ga n the key ns ghts that they need, f bers and paper f bers all have s m lar character st cs. Another even n the r own sector and ndustry. What's more, these ns ghts need example: one of the rr tat ng th ngs about cutt ng cheese s that t to be constantly mon tored and updated. Today, we l ve n a so-called always st cks to the kn fe. Food compan es face th s challenge on an knowledge economy. Knowledge s present n abundance and s freely ndustr al scale. In real ty, however, cheese s an elastomer c mater al and eas ly ava lable to all. As a result, the wheel cont nues to be that s very much l ke rubber. As a result, research has shown that re nvented—and that s an unnecessary waste of prec ous and l m ted ex st ng technology from the tyre sector for the cutt ng of rubber also resources. o ers an deal solut on for the more e c ent cutt ng of cheese. If we want to nnovate qu ckly and e c ently, we need to explo t th s s tuat on by match ng external knowledge w th nternal expert se. It s Everyone can and must Innovate mportant to stay aware that relevant and nterest ng knowledge s not Many publ cat ons on nnovat on po nt to the examples of the Apples only to be found n your own sector and ndustry, but n other sectors and Googles of th s world. Th s does not always encourage the dea and ndustr es as well. Most problems have already been solved that everyone should modern ze and mprove. Qu te the reverse; t somewhere. We therefore need to avo d the m stake of develop ng actually fr ghtens people o . Th s s not good. Every company and solut ons and deas that already ex st. Instead, we should be explo t ng every organ zat on can and must nnovate. ex st ng deas and solut ons. Cons der the follow ng s mple example. Imag ne that we want to remove some water from a glass w thout Not new, but new for you. That s what t amounts to. By recycl ng touch ng t. Th s s a spec f c problem. However, we can translate th s ex st ng knowledge and transferr ng t between doma ns and problem nto the quest on 'how can we set a flu d n mot on?' In other ndustr es we can nnovate n a much more e c ent manner. More words, we can transform a spec f c problem nto an abstract problem. If e c ent means better targeted, faster and w th more l m ted r sk. we then exam ne ex st ng knowledge n th s area—for example, patents, What's more, we have l ttle cho ce n the matter, certa nly not n the the profess onal l terature, the nternet, etc.—you w ll l kely soon current econom c cl mate. Budgets are under pressure and are be ng d scover that there are already more than 50 solut ons to th s part cular cut everywhere. At the same t me, the need for renewal and conundrum. mprovement has never been greater. If we do not nnovate, there s a danger that we w ll m ss the boat of econom c progress. The solut on In the f eld of ha r color ng shampoos, color fastness s the ma n to th s contrad ct on l es n the reuse of ex st ng knowledge. Th s challenge. But once aga n, th s problem s not conf ned to a s ngle stops us from try ng to re nvent the wheel, reduces the level of r sk sector. It s also mportant that clothes keep the r color and that and allows better use of the scarce resources that are st ll ava lable. photograph c paper does not fade. D erent doma ns face the same challenges and have probably developed solut ons. And there s a good chance that these solut ons are transferable from one sector to another: th s s what we mean by technology transfer. After all, ha r f bers, text le
THE REINFORCER 16 1.1. External customers The f rst and only reason for a customer to nnovate w th you s to make h m more prof table and/or compet t ve n the marketplace. Th s means that as a suppl er you need to have a profound knowled- ge of h s market(s) and the assoc ated value propos t on. It requ res also a very good appl cat on knowledge: What s the funct on of your product, how s t appl ed, etc… When try ng to enter new markets and create new appl cat ons for your products, the e ort to acqu re th s appl cat on knowledge s almost always underest mated, s nce often t takes years of study and talk ng w th customers! Wh le nowadays ‘open nnovat on’ s be ng broadly adopted by many compan es, a customer w ll not haphazardly choose a suppl er as a partner for the r nnovat on e orts. In my exper ence t requ res the follow ng: • Your current product supplies need to be QCD: top Quality at a compet t ve Cost w th rel able Del very. If you cannot meet th s bas c requ rement, t s very unl kely that your customer w ll choose you as h s or her partner. • Proven technology market leadership. To reinforce your product leadersh p tak ng patents, part c pat ng n fa rs and convent ons, and publ sh ng art cles s very useful. • Long term relationship. It is clear that the customer will only work It’s Never as Simple as It Looks w th you f he can trust you to treat conf dent al nformat on respect- fully. Wh le you m ght th nk that NDA o ers the necessary protect - on there s always a strong one on one relat onsh p needed of people PATRICK DE KEYZER that bel eve n nnovat on and cooperat on. The NDA s then merely the formal express on of that relat onsh p and trust. Partner, DeKep Another challenge or ssue s the t me t can take to develop and commerc al ze the nnovat on. Th s s governed by the appl cat on tself and the customer’s test ng and approval procedures. Unfortuna- W k ped a def nes nnovat on s mply as a “new dea, dev ce or tely, the t re (re nforcement) ndustry has proven to be very slow n method”, but where the s mpl c ty stops s when you try to manage th s regard. W th customers that have a very strong brand reputat on, nnovat on n your company or bus ness. t can be ncred bly slow, and here we are eas ly talk ng about years! Desp te read ng many books, attend ng courses at prest g ous bus ness In th s context and n order not to lose even more t me, t s cruc al schools and over 30 years of exper ence at a global company that that a r gorous stage-gate process s followed dur ng the project. touted global market and technolog cal leadersh p I st ll cannot come Tak ng shortcuts n th s process w ll usually lead to fa lure and set up w th a clear answer to the quest on: “How do you manage nnovat - you back for months f not years. The conclus on s that endurance, on successfully? “ However I can share w th you what has worked the pat ence and systemat c project management are your best chances. best for me: Innovat on should be F nally, very few customers w ll want to comm t to a s ngle suppl er 1. Customer centered s tuat on. Th s needs to be cons dered and d scussed early on and can be solved through l censes or partnersh ps w th other suppl ers. 2. Technology centered 1.2. Internal customers 3. People centered Internal nnovat on should be dr ven by the company’s own strategy to reduce the cost of qual ty (rejects, scrap, …), the cost of manufactu- 1. The customer r ng (cash cost, product v ty,…) and cap tal employed ( nvestment and Here I want to d erent ate between nternal (own company) and work ng cap tal). external customers (the market) that both need to be served through As w th work ng w th external customers the f rst step s to do a nnovat on e orts. thorough VOIC (Vo ce Of the Internal Customer) and not to rely on pure technology! Internal nnovat on projects are many t mes very reward ng s nce they tend to be faster and y eld v s ble and tang ble results. A good balanced project portfol o conta ns a m n mum of 50 percent nternal nnovat on projects
2. Technology In an ndustry that thr ves on technolog cally advanced solut ons (such as t re re nforcement) t s obv ous that technology s key n br ng ng nnovat ve solut ons to the market. Technology s the complex nteract on between Product x Process x Equ pment. If you have the scale to have the three n-house, th s s def n tely a strong (compet t ve) advantage. However, you have to be clear n what you cons der as your core technology. Th s comes from answer ng the quest on “wh ch (process) technology g ves my
17 THE REINFORCER company a compet t ve advantage n the marketplace?” Wh le the easy knowledge. Interact on sk lls are needed to cont nuously check your and very often heard answer s “all of t”, th s w ll result n a lack of value propos t on w th the vo ce of the customer. In my exper ence, focus and resources (people). So t s cruc al to do an honest and the most successful people were ‘groomed’ n technology and n-depth exerc se to determ ne your two or three core technolog es and acqu red the r commerc al and nteract on sk lls through tra n ng, allocate the resources for t n the long term. Developments n non-core exposure and mentor ng by more sen or people. technolog es need to be found w th other part es. How do you recogn se and reward people work ng n nnovat on Once a new technology (product, process, equ pment) s developed, the projects? When the project s successful, there s not much d scuss - next challenge s to get t ntroduced nto the plant(s). A good pract ce on, but what f the project fa ls for (unforeseen) sc ent f c or commer- s to do the f rst mplementat on n a ‘mother’ or ‘key learn ng plant’. c al reasons? The only way out s to cons der not only the result but Th s s a plant that has the necessary exper ence and (extra) resources also the approach and way of work ng. A project that has been to support th s mplementat on together w th the people from ‘central’ executed systemat cally w th a good nteract on w th other people technology. It s very mportant that th s plant has a KPI related to th s (external and nternal) should be recogn sed as well! Th s approach development work so t gets recogn sed for th s ‘extra’ work. w ll keep people challenged and above all not scared away from work ng on h gher-r sk projects. 3. People “It’s all about people” s one of my key bel efs and noth ng can be truer 4. Conclus on when deal ng w th nnovat on, espec ally external nnovat on w th It s extremely d cult to manage nnovat on from dea generat on to customers. In work ng w th customers you need the r ght blend of successful market mplementat on. It s necessary to play very techn cal, commerc al and nteract on sk lls. sk lfully the d mens ons of the customer, technology and people. The S nce we are mostly talk ng about techn cal solut ons, t s obv ous that above suggest ons and exper ences n no way g ve the full answer to we requ re techn cal and appl cat on knowledge. But to get the most th s complex quest on, but what rema ns unm staken true s: “ t s value for your nnovat on you need commerc al sk lls and market never as s mple as t looks” and “ t’s all about people.”
THE REINFORCER 18 Global warming is a tremendous concern in modern times and the transportation sector was responsible for 14 percent of 2010 global greenhouse gas emissions.
19 THE REINFORCER Three ma n deformat on types are dom nant on the contact patch of the t re: transversal bend ng of the crown, s dewalls and bead area, compress on of the tread, and shear ng of the tread and s dewalls. In generally, wh le 70 percent of energy d ss pat on occurs n the crown area, energy d ss pat on s equally d str buted n the s dewalls and bead reg ons of t re structures. Several external factors a ect roll ng res stance as well: load, nflat on pressure, long tud nal veloc ty, appl ed torque, t re rad us, w dth, and t re’s operat ng temperature. It should be noted that load ncrease s almost perfectly correlated to ncreases n t re roll ng res stance[2-3]. So, many t re manufacturers ntend to use low roll ng res stance structures and tread compounds n order to reduce the we ght and roll ng res stance of the r t res. Looked at th s way, Kordsa o ers an nnovat ve product for t re manufacturers. Kordsa has developed a ready to use cap ply solut on—Capmax®—wh ch s eng neered as an eco-fr endly replacement for calendered t re cord fabr c as a cap-ply mater al. Capmax® str ps can be d rectly appl ed to the t re dur ng the manufactur ng stage, reduc ng the use of rubber n cap-ply as well as el m nat ng many stages n t re product on, such as rubber preparat on & m x ng, calender ng and the sl tt ng of rubber coated fabr cs. T res manufactured w th Capmax® consume less resources, energy and raw mater als and contr bute to reduc ng the carbon footpr nt and roll ng res stance of the t re. The E ects of Capmax on Tire Rolling Resistance Rubber Compound Tire Cords Capmax® Cords
BAHADIR KAYA Project Leader, Global Technology Center Calendered Rubberized Cap Ply Ready-to-use Capmax® Strip
Global warm ng s a tremendous concern n modern t mes and the For nstance, when a 205/55 R16 91H t re s replaced w th a Capmax® transportat on sector was respons ble for 14 percent of 2010 global NY 940x2 construct on, almost 280g of rubber compound s saved greenhouse gas em ss ons. Foss l fuel use rema ns the ma n source of and roll ng res stance of the t re s reduced by 3.5 percent when CO2, and therefore reduc ng foss l fuel consumpt on w ll decrease CO2 compared to calendered rubber zed cap ply. The e ects of Capmax® em ss ons. In order to m n m ze greenhouse em ss ons, str cter NY 1400x2 on roll ng res stance can be g ven as another example: the em ss on goals are be ng set by car manufacturers. By 2020, the EU amount of rubber compound s reduced by between 100–200 g when CO2 automob le em ss ons target s 95 grams of CO2 per k lometer and Capmax® s appl ed to one layer as a cap-ply. Also, the roll ng the target for 2025 s n the range of 68–78 grams of CO2 per k lometer. res stance of the t re can be reduced by 2 percent when compared to In order to ach eve th s goal, car manufacturers have str ct rules and calendered rubber zed cap ply. select Or g nal Equ pment t res (OE t res) n order to l m t CO2 em ss ons. So, t re manufacturers are now enthus ast c to reduce t re References: we ght and roll ng res stance w thout los ng other t re performance [1]- Akutagawa, K. Ko de, M and Hegur , H. (2003). Appl cat on of non-l near FEA to tyre roll ng res stance parameters. s mulat on. Const tut ve Models for Rubber III: Proceed ngs of the Th rd European, p.175. [2]- The Tyre - Roll ng Res stance and Fuel Sav ngs. (2015). 1st ed. [ebook] M chel n. Ava lable at: Wh le a t re rolls on the road, mechan cal energy s transformed nto https://commun ty.m chel nchallengeb bendum.com/docs/DOC-3212 [Accessed 8 Jun. 2017]. heat due to the phenomenon known as roll ng res stance. Hence, [3]- LaCla r, T.J. (2006). Chapter 12: Roll ng Res stance. In: 1st ed. Nat onal H ghway Tra c Safety Adm n strat on, U.S. Department of Transportat on, pp.476-500. roll ng res stance dramat cally a ects the total fuel consumpt on of any veh cle. In The Pneumat c T re, a book publ shed by the US Nat onal H ghway Tra c Safety Adm n strat on (NHTSA), roll ng res stance s def ned as follows: “Roll ng res stance ncludes mechan cal energy losses due to aerodynam c drag assoc ated w th roll ng, fr ct on between the t re and road and between the t re and r m, and energy losses tak ng place w th n the structure of the t re.” Var ous factors cause ncreased roll ng res stance, nclud ng w nd drag on the car, fr ct on between the road and tread of t re and t re d stort on due to hysteres s of t re mater als dur ng deformat on. Hysteres s losses are the lead ng cause, and almost 90 percent of t re d stort on can be connected to v scoelast c behav or, wh ch means that t res d ss pate add t onal energy n the form of heat when the cord and rubber components of t re mater als are deformed [1]. It s well known that rubber compounds have a b gger e ect on t re roll ng res stance than t re cords. Adaptat on of t re cords to reduce roll ng res stance s ma nly a med at lower ng t re roll ng res stance by reduc ng the rubber volume n the crown area.
THE REINFORCER 20 We are the Reinforcers of Life! OUR INNOVATIVE TECHNOLOGIES ARE VERY MUCH INTEGRATED IN OUR EVERYDAY LIFE TO MAKE IT SAFER, MORE EFFICIENT, COMFORTABLE AND CONVENIENT. AS KORDSA, THE REINFORCER OF 1 OUT OF EVERY 3 AUTOMOBILE TIRES AND 2 OUT OF EVERY 3 AIRCRAFT TIRES, STRIVES FOR MAKING LIFE MORE SUSTAINABLE BY REDUCING THE ROLLING RESISTANCE TO DECREASE THE FUEL CONSUMPTION WITH ITS TIRE REINFORCEMENT TECHNOLOGIES AS WELL AS LIGHTENING THE VEHICLES WITH ITS COMPOSITE TECHNOLOGIES AND OFFERING LOW CARBON EMISSION AND LONG LASTING DURABILITY FOR SUCCESSFUL AND SUSTAINABLE CONSTRUCTION PROJECTS. OUR PRODUCTS NOT ONLY IMPROVE THE LIVES OF INDIVIDUALS, FAMILIES AND OUR LOVED ONES, BUT ALSO “REINFORCE THE LIFE”. AS KORDSA REINFORCERS, WE DECIDED TO TELL HOW WE TOUCH EVERY ASPECT OF LIFE AND KEEP WORKING TO IMPROVE PEOPLE’S LIVING CONDITIONS WITH OUR INNOVATIVE VALUE ADDED TECHNOLOGIES. FOR THIS REASON, WE PUT A CAMERA IN VARIETY OF DEPARTMENTS IN DIFFERENT PLANTS AND EACH REINFORCER TOLD HIS OR HER REINFORCEMENT STORY. WE ARE PROUD TO SEE OUR DEDICATED POWER TO CREATE VALUE, AND WE WILL BE SHARING THOSE CONTENTS WITH YOU BY OUR ONLINE AND OFFLINE CHANNELS. WE REINFORCE LIFE WE REINFORCE LIFE
I REINFORCE LIFE A reinforcer should show higher performance in all WE REINFORCE LIFE processes to reach sustainable service and safety. So being a reinforcer I REINFORCE LIFE is to touch people’s life by With the products that we’ve giving them high reliability developed in our R&D Center, and safety. we help to shorten the breaking distance and strengthen the tire grip. Thus, people can use much more sustainable tires and safely reach their homes and families.
WE REINFORCE LIFE
I REINFORCE LIFE As a part of his job, my husband has to use rigging and fall protection every day. It gives me reliance that he uses protection, which are reinforced by Kordsa products. That reminds me what we do as reinforcers touches our daily lives!
WE REINFORCE LIFE
I REINFORCE LIFE Kordsa products should answer the necessities of our customers. My job is to ensure the quality of our products to reach the customer satisfaction. In order to do this, I have to know my product and my customer very well. And make agile and attentive decisions.
WE REINFORCE LIFE
I REINFORCE LIFE The use of composite materials in transporting vehicles improves the environment in many ways. Composite materials enables our customers to produce much more lighter vehicles, which helps reducing the fuel consumption.
WE REINFORCE LIFE
I REINFORCE LIFE While making decisions by considering meticulous approval processes and operational excellence goals, it makes me happy to know that decision is not only touch my life but also changes other individuals’ life in better way. 2. Text le n T res. Cont nuous Techn cal Progress The cas ng of the t re was for many years of natural or g n (cotton) and then b osourced (rayon extracted from cellulose). The r se of synthet c thermoplast cs such as nylon 66 and PET has made t poss ble to ach eve a comprom se of we ght and performance, wh ch s very nterest ng n terms of cost. Although th s r se has ncreased the dependence on petroleum-based mater als, th s evolut on has reduced the development of the complex chem stry requ red for the rayon process. However, the spec f c character st cs of rayon n terms of r g d ty of extens on and res stance to temperature cont nue to make t a preferred f ber for h gh performance passenger car t res, as well as for h gh-temperature uses n run-flat appl cat ons. W th th s sa d, the mastery of polyesters has also reduced, l ttle by l ttle, the use of rayon. The we ght and roll ng res stance of the t re carcasses are also reduced when t re models are upgraded from mult -ply cas ngs to s ngle-ply cas ngs. The ab l ty to ma nta n res stance to road hazards s then obta ned (but not exclus vely) by an ncrease n the cord s ze of the re nforcements used. However, th s evolut on has ts l m ts, n part cular n manufactur ng.
Michelin View on Material
PATRICK COHEN
Michelin Material Product Line Reinforcement and Tissue Technical Director
1. Introduct on “Susta nable mob l ty should be safer, more e c ent, more access ble, clean, connected and more enjoyable.”
In the f eld of t re summ t mater als the major evolut on n the last th rty years has been the add t on of nylon zero-degree cap pl es on top of the steel belt. For the h gh speed ndexes, th s add t on has made t poss ble to reach the speed l m t requ rements. For the low speed ndexes t was an mportant mprovement to the endurance of the summ t of the passenger t res. Th s technology cap tal zes on the thermosens t ve nature of the nylon, wh ch makes t poss ble to reconc le t re performance and manufactur ng of t res. Start ng n 2000, a new text le re nforcement developed by M chel n has s gn f cantly mproved h gh-performance t res. Th s product s a hybr d aram d/nylon re nforcement. At the beg nn ng, they were reserved for a spec f c t re process of manufactur ng w thout the nflat on stage. Then afterwards they were appl ed to the convent onal processes. Th s nvent on allows an ncrease n speed l m t wh le reduc ng the mass of the summ t of the t re. It s also benef c al to many other performance nd cators. Its development s l m ted by the cost of aram d f ber. In the f eld of rad al a rcraft t res, M chel n Near Zero Growth technology, based on the replacement of nylon re nforcements by nylon aram d hybr ds, has made s gn f cant progress n terms of we ght, t re robustness and safety. The use of text le re nforcements n the f eld of truck and bus t res Re nforc ng technolog es are at the heart of t re advances, part cularly rema ns marg nal. the r we ght, roll ng res stance, cost, endurance and road hazard res stance.
23 THE REINFORCER 3. Susta nable Performance, a Major Issue areas of progress wh ch also deserve attent on. On the one hand, ncremental progress paths w ll make t poss ble to opt m ze the The susta nable performance of the t re s reflected n the 4 axes of the e c ency of the mater al: n part cular nylon 66, PET, or the large c rcular economy (Reuse, Reduct on, Recycl ng, and Renewal), n formulat on f eld opened up by the hybr d cable construct ons. part cular through performance enhancement, more robustness, we ght reduct on and a longer l fe. On the other hand, breakthrough nnovat ons w ll allow for progress on e ther t re performance or on more susta nable supply bases than the o l ndustry. Thus, t may be relevant to carry out research on new f bers, allow ng us to ach eve the same performance as w th the aram d or hybr d cables at a compet t ve cost. B osourced or recycled f bers are also nterest ng f elds of nvest gat on. The r se of green chem stry, the development of the use of b o-resources and the search for susta nab l ty of access to h gh-performance f bers leads to a demand for f ber that respects the env ronment and s ndependent of petroleum resources. As part of M chel n's 4R approach, future re nforcements w ll have a reduced env ronmental mpact. Many publ cat ons present paths to obta n ng b omass monomers. It rema ns to be seen wh ch w ll become econom cally v able and able to compete w th the current supply cha n n terms of feedstock, process ng, costs and pur f cat on. REDUCE REUSE RECYCLE RENEWABLE F nally, the adhes ve systems rema n mportant for the r n t al performance and the r durab l ty over t me and at h gh temperatures. The r ndustr al performance, n terms of hyg ene, the env ronment, Text le nnovat on has been a major element n techn cal advances n energy reduct on and mplementat on costs, are also elements of the passenger car t res n past years. Yet there are many other potent al M chel n 4R approach.
THE REINFORCER 24 Ultimate Goal Options Solution Road Blockers
Electric Mileage Eliminate Vehicles Cost/km CO2 Emissions Tire weight Novel Materials Reduce Tire Geometry Vehicle & Rigidity Dynamics
Table 1: There are d erent opt ons and solut ons to reach the EU target of
reduc ng CO2 em ss ons.
The el m nat on of CO2 em ss ons through electr f cat on: an obv ous cho ce for the long term As regulat ons are becom ng str cter than ever, the opt ons that can solve the em ss ons puzzle are becom ng more l m ted. Although the
total el m nat on of CO2 em ss ons s a h ghly des red outcome, t seems that the only solut on that would lead to total el m nat on s the use of electr cal veh cles (EVs). EVs are not a new subject n the automot ve ndustry, and moreover many mprovements have Future Focus on Rolling Resistance already been made by the ndustry. For example, the current total m leage level s better than 5 years ago and battery packs are 65 percent cheaper. Nevertheless, EVs st ll have low penetrat on w th n BURAK İLGÜN the automot ve ndustry: less than 1 percent n some markets. It s obv ous that any new technology ntroduced nto the automot ve Market Development, Manager /PCR ndustry w ll take many decades to become accepted. Look ng to h story, we see that automat c transm ss on, the a rbag, nav gat on systems and hybr d veh cles have had a deployment cycle between 15 There have been many stud es carr ed out w th the a m of f nd ng a and 50 years. Therefore, a long deployment cycle s also expected for solut on to reduc ng roll ng res stance, but only a few have related to EVs. However, there s one very major dr v ng force that w ll the ma n reason why roll ng res stance s mportant. It s t me to accelerate the deployment of EVs: mandatory regulat ons. As soon as rem nd ourselves how the Roll ng Res stance story began and how far CO2 em ss ons author t es d ctate newer and h gher standards, car t has gone from a CO2 em ss ons perspect ve through med um- and manufacturers w ll need to put more e ort nto bu ld ng EV cars. long-term scenar os. Some analys s suggests that f regulat ons mandate em ss ons levels A global perspect ve on t re re nforcement w ll help us to understand of 70gr/km CO by 2025, sw tch ng to electr cal eng nes nstead of future challenges. It s obv ous that both the heart of the problem and 2 nvest ng n convent onal eng nes w ll become a s gn f cantly more poss ble solut ons to t are compound related. At f rst, t looks l ke econom c opt on. Recently, many major OEMs have e ther re nforcement mater als do not have as much of an mpact on reduc ng announced that they are nvest ng n EVs, or have declared that they roll ng res stance as compounds do. However, when compounds and w ll not nvest any more nto nternal combust on eng nes. A recent re nforcement mater als are cons dered together, then re nforcement analys s by KMPG look ng at surveys w th auto ndustry execut ves mater als are an mportant factor. Th s s because th nner t re the past 5 years r ghtly conf rms that there s an nev table trend re nforcement cords mean less compound s used. towards EVs. Another novel solut on s the el m nat on of compounds and the In future, wh le the automob le ndustry w ll be devot ng more e ort appl cat on of t re re nforcements w thout compounds. Kordsa to the development of EVs, ma nly tr ggered by CO regulat ons, cont nuously str ves towards e ther the reduct on or the el m nat on of 2 eventually the all-t me star of t re ndustry research w ll rega n the compounds n t re product on to reduce roll ng res stance. spotl ght: “roll ng res stance”. Although shared mob l ty s bel eved to reduce the total cost of m leage n Evs, t s obv ous that n order to Background ncrease m leage, energy losses should be avo ded. Therefore, mproved roll ng res stance w ll mprove m leage for EVs, wh ch s The ma n dr ver of the automot ve ndustry s obv ously CO2 v tally mportant. Today’s e orts n reduc ng roll ng res stance w ll em ss ons. The EU target of reduc ng CO2 em ss ons to 95gr/km by 2020 challenges both the OEM and t re makers. Even though today’s carry the t re ndustry to the next level.
average fleet em ss ons levels are not prom s ng n the d rect on of The reduct on of CO2 em ss ons through t re solut ons: an eternal 2020, EU author t es have d scussed reduc ng em ss ons down to challenge 70gr/km by 2025. T res are sa d to be the low-hang ng fru ts of the ndustry n terms of Today, t seems that there are two opt ons to reach the EU targets: one mprov ng fuel e c ency and reduc ng em ss ons compared to the
s to try to totally el m nate CO2 em ss ons and another s mak ng development requ rements for mprovements n other components. e orts to reduce them; both of these opt ons requ re d erent problems T re ndustry has been deal ng w th roll ng res stance for a few to be solved. Table 1 shows the two opt ons and a road map towards decades w th all the part es n the supply cha n p tch ng n. Roll ng reach ng the target. We need to analyze these two opt ons together res stance was the “comprom se” factor compared to other essent al w th the r solut ons and the hand caps that we st ll have to work on. factors such as wet gr p, m leage, etc. n t re product on. Throughout
25 THE REINFORCER the years, these e orts have resulted n mproved products, from raw cord des gn results n 20 percent less cord gauge and a 35 percent mater als to t re des gn. h gher modulus level that enables compound sav ng compared to There are OEM test results that declare an enormous leap—15 percent regular NY66 1400/2 cord construct ons. mprovement— n roll ng res stance w th acceptable t re performance The el m nat on of compound from re nforcement s poss ble w th when they test tall and narrow t res. Although th s s a very mportant ready to use cap ply mater als ava lable n the ndustry such as reduct on n roll ng res stance level, the veh cle dynam cs w ll be much Capmax by Kordsa. Due to the cap ply appl cat on type, an up to a ected. Veh cle des gn w ll be essent al n avo d ng the s de e ects of c rca 300gr/t re we ght reduct on s poss ble. S nce there s no tall and narrow t res, slow ng penetrat on of the development. compound to create hysteres s, a pos t ve e ect s observed n terms Although the e orts be ng put n are cons derable, t s not that easy to of a c rca 4 percent reduct on n roll ng res stance. In outdoor test results, t res w th Capmax perform ng equally as well as t res w th reduce the average CO2 em ss ons of an OEM’s fleet. It s expected that most of the OEMs w ll not match the legal em ss on levels for 2020. convent onal rubber zed cap ply. Th s nd cates that OEMs w ll be look ng for emerg ng solut ons to New re nforcement mater als w ll play a lead ng role n shap ng the decrease the r fleets’ average CO2 em ss ons. As d scussed above, future of the t re ndustry, both n the med um term and long term. OEMs w ll stop choos ng to nvest n convent onal eng nes. So, to mprove the roll ng res stance of nternal combust on eng ne cars, t re technology w ll aga n take the lead to ach eve these targets ~300 gr econom cally. Weight A reduct on n t re we ght w ll d rectly or nd rectly prevent losses due Reduction to hysteres s. The hysteres s of the rubber compound s the controll ng factor for roll ng res stance, and therefore the reduct on of the amount of rubber compound s essent al. The most e ect ve area to reduce t s the tread of the t re and most of the focus has been g ven to th s factor over the years. Apart from the tread, rubber compound s also appl ed to cover re nforcement mater als n the t re. The carcass, cap ply, steel %4 Rolling Resistance belts, and bead are the components that are rubber zed. Improvemet It s poss ble to decrease the amount of compound used by h gher modulus NY66 cords n cap ply or h gher tenac ty PET cords n the carcass. Advanced NY66 cord des gns that enable UHP performance Table 2: The relat onsh p between we ght reduct on and roll ng res stance are produced by the tw st ng of heavy dtex s ngle yarns. Th s advanced mprovement when us ng Capmax by Kordsa.
THE REINFORCER 26 growth w ll come from the fast-expand ng Ch nese market. One report says the average car w ll ncorporate nearly 350 k lograms (771.63 lbs) of plast cs, up from 200 k lograms (440.92 lbs) n 2014. “Wh le metal and metal alloys are st ll cr t cal to automot ve des gn, automakers are f nd ng nnovat ve ways to leverage plast cs and compos tes nto the r des gns to help reduce veh cle we ght and mprove e c ency. We expect the use of plast cs w ll only ncrease as the mater als mprove and product on costs are reduced.”1 Th s s dr ven by ncreas ngly amb t ous government goals of meet ng Corporate Average Fuel E c ency (CAFE) standards of 54.5 mpg by 2025. In order for those goals to be feas ble, fuel economy must be mproved by approx mately 50 percent across the passenger veh cle fleet. The use of carbon f bers and polymer matr x compos tes enables car body-we ght reduct ons of an est mated 25-70 percent compared to compet ng mater als. “Closures, wh ch nclude doors, l ft-gates and hoods, are the eas est opt ons to s gn f cantly reduce veh cle we ght, and we see s gn f cant opportun t es for compos tes n those as well as non-cr t cal structures such as seats, nstruments, the under-tray etc.”1
1: JEC Group Strateg c Study “Carbon f bers: h story, players and forecast to 2020
Carbon Fiber Growth in the FUTURE IN AUTOMOTIVE-LIGHTWEIGHT APPLICATION Automotive Market FOR EMISSION REDUCTION OPEN SIGNIFICANT FAST GROWTH ON COMPOSITE MATERIAL SALES GIACOMO DAL BUSCO Carbon Fiber Market Trends 2014 In 000s tons 2020 Sales Manager, Composite Reinforcement
Th s art cle s an ntroduct on to carbon f ber sales growth n automot ve programs, market trends, compet t on n the mater als sector, cl ent road maps, the boom n electr cal cars and the Kordsa CM11 fast cur ng carbon prepreg solut on.
1. W ll Carbon F ber Compos tes F nd Extens ve Uses n the Automot ve Industry? 52,900 tons Carbon f ber-re nforced plast cs (CFRPs) are f nd ng the r way nto new Industry Includes Wind Energy, Automotive, Pressure vessels etc appl cat ons as ndustr es demand mater als w th ever-h gher 110,500 tons strength-to-we ght rat os, corros on res stance, and workab l ty. Over the past years, CFRPs have been ncreas ngly used to replace metal n Volumes x 2 in 5 years appl cat ons where l ght we ght has outs zed value pr mar ly for
reduc ng fuel consumpt on and reduc ng CO2 em ss ons, and n Aerospace Sports &Defense Industrial part cular where t s capable of support ng pr ces that can reach an average of 60-70 Euro/kg. Source: JEC Group Strategic Study “Carbon fibers: history players and forecast to 2020” CFRPs appl cat ons are present n h gh-value sectors such as sport ng goods, the aerospace ndustry and supercars, but pr ced out of most By 2020, CFRPs are expected to compr se a $35 b ll on market, large-volume markets, part cularly the ma nstream automot ve nclud ng a $6 b ll on sl ce of the automot ve market. However, these ndustr es. Th s w ll cont nue unt l emerg ng methods and mater als automot ve uses w ll be l m ted to luxury and rac ng veh cles. speed up CRFP product on and br ng down h gh pr ces. Analyses nd cate that large-scale, ma nstream CFRP automot ve adopt on before 2020 s unl kely. But somet me after 2020, the Kordsa has concentrated part cular attent on on reduc ng labour costs potent al volume of CRFP used n cars and trucks could dwarf all for both mold ng processes and the preparat on (sand ng and pa nt ng) other appl cat ons, potent ally reach ng hundreds of b ll ons of of nter or/exter or CFRP parts w th the launch of the CM11 fast cur ng dollars. res n system, wh ch, n parallel to the 3-to-5 m nute press cycle, o ers a great class-A surface f n sh w thout p nholes and carbon f ber As a result, most major automot ve compan es and carbon f ber pr nt-through mark ng. producers are form ng partnersh ps, jo n ng consort a, and conduct ng research to br ng automot ve CFRPs closer to Accord ng to recent publ shed reports, the usage of carbon f ber n commerc al real ty. The Carbon F ber Compos tes Consort um automot ve manufactur ng s expected to nearly double from 2015 to rema ns the most connected ent ty on the automot ve partnersh p 2020. Accord ng to these reports, global car product on s expected to map, w th 23 OEM, T er 1, and major mater al suppl er partners. r se over the next couple of years to more than 110 m ll on un ts n 2025, up from an est mated 88.7 m ll on un ts n 2015. Much of th s
27 THE REINFORCER 2. The Future of the CFRP Automot ve Market: the JDA All ance Between OEM and Compos te Mater al Suppl ers
Affiliated fabric producer Precursor producer Daimler xx% CFRP part producer owned by a Carbon fibre producer CF producer or OEM (% of shares) Mercedes-Benz, CFRP parts supply Smart, stake in Automobile group Aston Martin Design & Engineering company Automotive Agreement on CF supply owned by a carbon fibre producer xx% Composites or long term relationship (% of shares) Tesla Motors partners Consortium Other partnerships Services supply Fiat Chrysler Automobiles Abarth, Alfa Romeo, Chrysler, Dodge, Toyota Euro Advanced Carbon Ferrari, Fiat, Jeep, Daihatsu, Hino, Isuzu Fiber Composites Lancia, Maserati, Ram ACE: Advanced (stake), Lexus, Ranz, Carbon Magic >>50% Toray Composites Engineering Scion, Subaru <5% Daimler (via stake in parent 75% ?%ACE company), Toyota 21% Toray Carbon Magic Plasan Carbon Composites 100% Tesla 20% Ford See Nikkel Asian Motors Review, Dec. 2014 partners Continental Ford, Lincoln, Structural Troller, Plastics (CSP) Toray stake in Mazda DowAksa 100% (Teijin)
General Motors GH Craft Toho Hexcel Hyundai Buick, Cadillac, Chevrolet, >50% Tenax GMC & controlling interest (Teijin) Hyundai, stake in Holden, JieFang, Opel, in kia (+33%) UzDaewoo, Vauxhall & Hyosung Wuling Solvay C-Con Capricorn Composites Holdings Automotive Penso Mitsubishi 25.1% Composites % min. SGL Rayon Porsche Consortium ?% Volkswagen MRC-SGL Precursor Audi, BentleyLX, Bugatti SGL Automotive 67% MRC Lamborghini, MAN, Carbon Fibers 33% SGL 100% Porsche, SEAT, Akoda, 49% BMW, 51% SGL Volkswagen, VTB Wethje Holding Benteler SGL Brembo SGL 51% Jaguar 50% Carbon Ceramic Action Composites Land Rover Brakes International (Tata Group) 50% 35% Geely Emerald AutomotiveLX, BMW Geely, Volvo BMW, Mini Rolls-Royce LX: Lightweighting Renault-Nissan Excellence Dacia, Datsun, Infiniti, Programme Mitsubishi (34% Tesla Motors partners Nissan), NissanLX, Renault, Samsung
Source: JEC Magazine, no. 112, April–May 2017, p. 21
Table 2: In reality, most major automotive companies and carbon fiber producers are forming partnerships, joining consortia and conducting research to bring automotive CFRPs closer to commercial volume program applications. As you can see here, Kordsa have now begun making contacts and obtaining material test approval to begin similar JDA/technology partnerships with top automotive OEMs and Tier 1 CFRP components manufacturers.
In add t on to advances n f ber product on, suppl ers throughout the automot ve OEMs to make ma nstream veh cles that use s gn f cant value cha n are develop ng faster, more e c ent equ pment and amounts of CFRPs. res ns des gned for automot ve CFRP use, as well as scalable CFRP Fundamentally, the CFRP technology push toward automot ve recycl ng methods. More recently, BMW has partnered w th Boe ng, a compos tes s pred cated on the dea that reduc ng we ght s a world leader n us ng CFRPs for aerospace manufactur ng. The two cost-e c ent method for reduc ng fuel consumpt on. (A 10 percent hope to mprove CFRP product on and recycl ng. By leverag ng both reduct on n we ght typ cally leads to a 6 to 8 percent reduct on n upstream f ber capac ty nvestment and the knowledge of fuel consumpt on.) As a result, veh cles w ll gradually become l ghter exper enced players l ke Boe ng, BMW s pos t on ng tself to lead the as fuel economy standards become str cter. Meanwh le, CFRPs—the way n both large-scale automot ve CFRP manufactur ng and mater als w th the h ghest we ght-spec f c strength—w ll be wa t ng to automot ve group technology partnersh ps w th aerospace be used when they get cheaper. Low-cost f bers may become a real ty compan es. n the next 10 to 12 years, once the ndustry s able to adopt methods The future st ll rema ns uncerta n. Development trends underway n that fac l tate low-cost, large-scale product on processes. Add t onally, f ber, res n, and compos te part product on strongly suggest that by recycl ng carbon f bers w ll boost adopt on across ndustr es n the the m d-2020s, t w ll be techn cally and econom cally feas ble for med um to long term."
THE REINFORCER 28 3. Market Trends
The a m of Kordsa s to supply the best poss ble mater als solut ons for 700,000 manufactur ng large volume, low-cost, good qual ty compos te parts Industrial Sport Aerospace through: 600,000 1. Vert cal ntegrat on n sem -f n shed products (text les, prepregs, pre-cutted preform): to be cost compet t ve and be able to supply 500,000 mater al for both RTM and press mold ng processes, 400,000 2. To reduce drast cally the t me taken n the lam nat on step (the most t me-consum ng and costly step n compos te manufactur ng) 300,000 of Carbon Fibers Tons by develop ng fast-cur ng prepregs l ke CM11 wh ch s one of the fastest-cur ng press prepregs n the market, to support customers 200,000 for su table mater als for automat c process of p ck ng, deformş ng and plac ng prepregs/text les to manufacture ready-to-mold 100,000 pre-forms (essent al mater als for metal stampers), Source: JEC Market Report 3. Structure: ntroduc ng CM11 prepregs, carbon fabr cs, mater als - l brary tests and solut ons n order to be able to follow the programs 2005 2010 2015 2020 2025 2030 of large ndustr al automot ve corporat ons, 4. Goal: to create closer relat onsh ps w th automot ve plants and Table 3: Carbon fiber composites for industrial and automotive applications are the T er 1 manufacturers n Europe and n future to follow up w th fastest-growing markets today, especially in mid-segment cars where there is the need to produce large volumes of geometrically complex structural/aesthetic parts at an affordable price. growth n the Far East (Ch na) and U.S.
4. Cl ent Road Map and Carbon Componants
Supplier Competition-CARBON FIBER COMPONENTS For Major OEMs -EU (CFRP Components Automotive - Sport Car)
ACE FORMAPLEX Riba Most of CFK Benteler SGL Prodrive Carbotech Creative HP compositi C2i Sparco A-Class Exterior Exterior A-Class Clear Carbon parts are made RTM Clear (Pre-Preg Clear RTM Chassis & Compsites Clear Pre-Preg Clear Carbon Painted A-Class and structural Pre-Preg panels Pre-Preg inside ACRC in Carbon Parts Carbon Parts) Exterior SMC Parts Carbon Parts Pre-Preg Pre-Preg RTM Autoclave Press Components: Lamborghini Components Components Exterior Parts and Autoclave Hood Interior trims Die Wethje C2i Mitras Riba 3C Celbo A-Class Painted Pre-Preg Clear CPC SMC Parts Exterior A-Class Carbotech Carbotech Clear Carbon Gurit SMC Parts Exterior Parts Carbon Parts A-Class Exterior Pre-Preg RTM Chassis RTM Clear Autoclave Clear Carbon Carbon SMC Components Carbon Exterior Moulding Press Moulding Adler Plast Autoclave Painted Parts (Class-A) Pre-Preg Roof Pre-Preg Roof Clear Carbon press (A Class carbon (Jaguar F-TYPE) Pre-Preg CBS look) Die Wethje Components CPC Fritzmeier FORMAPLEX Exterior A-Class A-Class Painted A-Class Exterior Glass SMC Parts Exterior A-Class Pre-Preg Exterior Parts Pre-Preg panels Components Re Fraschini Adler Plast Autoclave Press Cobra Painted Exterior A-Class A-Class Painted Prodrive and Autoclave Clear Carbon Pre-Preg Exterior Parts Sparco (Pre-Preg Clear Trim Suppier Components Carbon Parts)- Painted A-Class (interior/exterior ACE 3C Painted SVO special Pre-Preg -spoilers) Riba A-Class Exterior Clear Carbon series Exterior Parts A-Class Clear RTM Autoclave Gurit PENSO uk Exterior A-Class Carbon Pre-Preg Gurit Moulding Exterior Parts Pre-Preg Roof Exterior A-Class Pre-Preg Hood Exterior A-Class (S Class) Pre-Preg panels (vacuum) ....end CBS Pre-Preg Hood Press Molding Prodrive of program Exterior A-Class (press molding) PENSO uk Sparco (Pre-Preg Clear Pre-Preg primer Carbon Parts) Exterior A-Class Painted A-Class Components Benteler SGL outer/carbon Pre-Preg panels Pre-Preg Painted RTM Clear look inner Press Molding Exterior Parts ACE FORMAPLEX Carbon Parts A-Class Exterior Exterior A-Class RTJ Crosby composite UK Pre-Preg panels Novation A-Class Carbon Autoclave Press A-Class Painted look autoclave Interiors Parts
PENSO uk Exterior A-Class PENSO uk Pre-Preg panels Exterior A-Class Press Molding Pre-Preg panels Press Molding
Table 4: The main Tier 1 and OEM road map is shown here. Kordsa focuses on supporting every step of this OEM supplier chain.
29 THE REINFORCER Body-in-White Closures & Fenders Powertrain Suspension & (22%-25%) (7%-8%) (24%-28%) Chassis (22%-27%)
CM 11 CM 11 CM 11 CM 11 • Passenger • Front & Rear Compartment • Seats Door • Engine • Chassis Frame • Instrument • Hood / Bonnet • Exhaust System • Wheels • A, B, & C Panel • Fenders • Fuel Tank • Steering Pillars • Insulation Key Applications Key • Tailgate / • Transmission Brakes • Airbags Liftgate • Roof Structure • Windows • Floor Structure • Glazing • Steel • Aluminum • Steel • Trim • Steel • Aluminum • Iron • Aluminum • HSS/AHSS • GFRP • Magnesium • CFRP • Plastics • Aluminum • CFRP • Magnesium • CFRP • GFRP Key Materials Key • CFRP
Table 5: Lightweight materials options in various applications and weight reduction percentages
5. Carbon F ber Automot ve Prepreg Sales Growth as a Result of a L ghtwe ght Ma n Components Program: the Boom n
Electr cal Cars and CO2 Em ss ons Restr ct ons In electr c veh cles, the payo for reduc ng we ght s even greater due to secondary cost sav ngs from us ng smaller, l ghter batter es. However, alternat ve methods of reduc ng gasol ne use such as hybr d zat on and us ng alternat ve fuels l ke natural gas, hydrogen, and b ofuels, are gradually becom ng less costly as the r underly ng technolog es cont nue to advance. Current trends st ll strongly nd cate s gn f cant automot ve adopt on of CFRPs n the m d-2020s, and compan es throughout the value cha n must pos t on themselves to take advantage of the com ng sh fts. However, those develop ng these technolog es should cons der that there could be a l m ted long-term w ndow for penetrat ng the automot ve ndustry.
220 9 200 8 180
160 7 Mexico 2016: 145 Brazil 2017: 138 140 6 Japan 2020: 122 China 2020: 117 120 5 India 2021: 113 S. Korea 2020: 97 US 2025: 97 4 EU 2021: 95 Canada 2025: 97 80 3 per kilometer, normalized to NEDC to normalized kilometer, per 2 60 historical performance 2 40 enacted targets Liters per 100 kilometers (gasoline aquivalent) (gasoline kilometers 100 per Liters Grams CO Grams proposed targets or targets under study 20 1
0 0 2000 2005 2010 2015 2020 2025
Source: http://www.theicct.org/info-tools/global-passenger-vehicle-standards Table 6: This graphic clearly shows how drastic gasoline consumption and CO2 emissions reductions in the automotive industry will be. Companies like Kordsa will offer new lightweight materials and engineering solutions every year to produce lightweight cars and lightweight solutions for future hybrid electrical cars as their sales boom in future. (Composite materials will help to compensate for the extra weight of installing batteries and electrical engines.)
THE REINFORCER 30 Electric-Car Boom Models by style and range available through 2020
VW I.D.* Land Rover Toyota Trumpchi Jaguar Tesla VW I.D. CROZZ Defender GS4 I-Pace pickuo* RAV4 BMW i5 SUVs/Trucks Mitsubishi eX Volvo 40.2* Tesla Tesla M-B EQ VW Model Y* Model X Audi E-tron Budd-e Chehejia M-B B-Class BYD e6 NIO ESB* SUV* Quattro Porsche E-sport Sports cars Renault DeZir Qianto Q50 Venturi Fetish Tesla Roadster Tesla Model S Tesla Roadster* M-B SLS eDrive Hyundai loniq Aston Martin GLM G4 NIO EP9 Audi R8 E-tron RapidE Exagon Furtive Mahindra eVerito Geely Emgrand NIO EVE ChangAn SAIC E-Lavida Tesla Model 3 LeEco LeSEE Eado Mullen 700e Lucid Air Sedans CODA EV Audi E-tron Faraday Honda Clarity BAIC EU260 Sportback JAC iEV4 Renault Fluence BYD e5 FF91 Kia Ray BMW i3 Hyundai M-B E-Cell BlueOn VW e-Golf Chevy Bolt VW I.D. Hatchbacks Chevy Spark Honda Fit Renault Zoe ZE Ford Focus Nissan Leaf Nissan Leaf 2* BMW mini e Fiat 500e VW Mitsubishi i-MiEV Runabouts e-Up Seat Mii* Kandi Mahindra e2o Smart Panda Bollore Renault Twizy ForTwo Bluesummer Ford Transit VW e-Bulli BYD T3 Nissan NV200 Tata Smith Edison Small vans IRIS ChangAn EM80 Peugeot Partner M-B Vito Renault Kangoo VW I.D. BUZZ 0 50 100 150 200 250 300 350 Miles of electric range
Source: Financial Times April 28, 2017 by Patrick McGee
6. The CM11 FastCur ng Res n System: the Carbon • The Future: one piece will be produce at the takt time (30 to 120 Prepreg Kordsa solut on for H gh Volume Product on seconds) Feature: Benef ts and Value Propos t on: Qu ck cure compress on moldable prepregs w th class A surface propert es: • Tg ≥ 170oC • Kordsa is a local supplier and will produce custom designed • Low color fastening (ΔE≤2) and gloss loss at 1000 hours of prepregs for local customers, wh ch s unheard of for prepreg Xenon-Arc weather ng and env ronmental cl mate chambers compos te producers. • Compression molding cure profile suitable for isothermal curing • New resin systems will have oxidative and thermal stability, at 120 to 150 °C, 10 to 50 Barr, hot-demoldable, 3-to-5 m nute wh ch customers demand. Kordsa has already has except onally cur ng good-look ng carbon fabr c weav ng and customers are exc ted Demand: Automot ve ndustry takt t mes are usually 30 to 120 about the dea of a new res n compos t on w th class-A surface seconds exclud ng luxury cars. qual ty. • The Past: Cutting patterns, preforms, and compression molding • Right now, Kordsa delivers CM11 pre-preg to produce complex are consecut ve processes. It s poss ble to produce one p ece 3D shape parts wh ch are su table for automat c cont nuous every 10 m nutes. preform and sotherm cont nuous mold ng systems (150C) to • Now: With current bleeding-edge resin technology one piece can meet h gh product on volume targets w th h gh d mens onal be produced every 3–5 m nutes (w th Kordsa CM11, the stab l ty and a class-A surface f n sh. fastest-cur ng prepreg n the market)
31 THE REINFORCER Laminate Heat Preforming Charge Compression De-Molding CM11 pre preg
Automatic preforming press molding
Future Kordsa Mater als Evolut on: T er 1 metal stampers prefer to use a sem -f n shed product wh ch can be placed d rectly n a press, l ke metal sheets. In compos tes, such product are ready-to-mold pre-forms, and metal stampers prefer t n order to avo d hav ng to relearn the lam nat on process from zero. The manufactur ng and sales of ready-to-mold pre-forms (storable at room temperature) allow a company l ke Kordsa to reduce the t me to market by del ver ng a sem -f n shed product that metal stampers can use as a reference for room temperature storage pre-form res n systems. Kordsa, follow ng these requests, w ll develop a mold ng solut on n future that works very closely w th all the b ggest T er 1 metal groups.
THE REINFORCER 32 Just like the automatic e-mail replies we have today...
33 THE REINFORCER ”Currently I am travel ng and w ll get back to you next week when I am back.” Just l ke the automat c e-ma l repl es we have today...
Serv ng the Customer I had been at the company for just 2 months, when our Sales D rector called me nto h s room. He was together w th the Purchas ng Manager of an mportant cl ent from Eastern Europe. The door was closed, so I knocked and entered. To my surpr se the two gentlemen were s tt ng at the meet ng table and on the table there were var ous examples of colorful lad es’ underwear. Maybe th s s not very unusual for a l ght text les or garments branch, but for us t was qu te nterest ng, as we were produc ng t re cord fabr cs. The d rector’s secretary, who came n to ask f we wanted any dr nks, was even more shocked. I not ced that she seemed to want to leave the room to these perverts as fast as poss ble. After a few m nutes t all became clear. Our guest the Purchas ng Manager had a fr end n h s country who was try ng to mport text les for h s underwear product on fac l ty. He was ask ng for pr ces for the text les part of the underwear. As a jun or salesperson, my task was to check w th var ous text le producers about the ava lab l ty and pr ce of the mater al. A l ttle b t ashamed, I put the p nk, blue and red sl ps n my pockets and went VAHE HANAMİRİAN around Istanbul to carry out the research. All the t me, I was pray ng that there would be no nc dent n wh ch pol ce had to check people Global Accounts and Marketing Director and would f nd the underwear n my pockets.
The Manager Hard at Work! For salespeople, travel ng s a b g part of the job. Allthough we l ke travel ng, one problem we have s tackl ng work at the o ce n paralel to our tr ps. Today th s s not too d cult w th all the electron cs we carry w th us, but n earl er days we d d not have the chance to work remotely. When arrang ng our tr ps n the sales department, we usually tr ed not to all leave the o ce at the same t me; n order to be able to replace each other for urgent customer commun cat on and serv ce. Th s was usually not too d cult as there were three of us n the sales department n my jun or days. We had d erent accounts, but knew some bas cs about each other’s customers so that after a short br ef before leav ng, other colleagues could replace us. Rarely d d all of us had to travel n the same week. In one case, wh ch was probably dur ng the negot at on per od n October or November, we were unable to avo d a s tuat on n wh ch all three of us had to travel n the same week. To repeat, those were t mes w th no mob le phones, no nternet and not even computers. If you wanted to commun cate w th the o ce, you had to use a hotel or a publ c phone. To reach the travel ng sales people was even more d cult, as you needed to have exact nformat on about where they were n order to get n touch. So, we were worr ed, but were unable to f nd a solut on, as t seemed that all of us had good reasons to travel. We dec ded to consult our manager. After all, the managers are there to f nd solut ons. Our manager was a very calm and relaxed person and, as expected, he relaxed us. He sa d that for one week there would be no problem, as he was n the o ce and could reply to all the commun cat ons. We were not so sure, but there was no other solut on—and he had the author ty n any case. Back n the o ce next Monday, we were a b t worr ed, but our manager welcame us w th h s usual calm and sm l ng face. He sa d, “as you can see, there were no problems at all. I managed to respond to all the commun cat ons for all three of you.” We went to our desks to check the commun cat on bundles. Nearly all the outgo ng fax/telex messages from our dear manager were very s m lar:
THE REINFORCER 34 WE REINFORCE LIFE
I REINFORCE LIFE I REINFORCE LIFE As a member of composite We Reinforce Life by delivering team, I’m strongly believing the best fabric to our customer, that Kordsa will keep and which will transport our loved further improve its success ones in safety everywhere they story by touching every want to go. But our job doesn’t aspect of life, listening their finish there. We carry out the customers and employees reinforcer value in every aspect thanks to its open of our lives. To protect life innovation culture. itself.
I REINFORCE LIFE I REINFORCE LIFE Being a reinforce requires I’m working in construction sector. constant development and Buildings are at the center of life. improvement as an individual. Finding a shelter and being safe… Like the fabric that we use for I believe reinforcing construction reinforcing tires, as reinforcers is to reinforce the life itself. always have to act open mindedly, Providing safer buildings with accept differences and create a increased durability is the key point. world with no segregation That’s why we highly associated and discrimination. with reinforcing life itself.