Polymer Technology

Polymer Technology Ireland 2020 Strategy Polymer technology: the backbone of Irish manufacturing Contents 1 Chair’s foreword 2 Director’s welcome 4 Polymer Technology Ireland strategic pillars 7 Polymer Technology Ireland organisational chart 8 Model of Substance 9 Business case studies 29 Categories of company in the polymer industry 30 Mapping Ireland’s polymer technology industry 32 Talent and skills 40 Gateway to growth 44 An eye on the EU Chair’s foreword

In the late 1950s Ireland’s industrial take-off was bolstered by manufacturing output growing 6% annually, 1958-1963. Manufacturing played a major role in the development of the Irish economy at a time when it was a predominantly agrarian economy. And in these early years the Federation of Irish Manufacturers, a precursor of Ibec, played an important role leading the business agenda and driving growth.

he manufacturing as agri-food, automotive, vision for the future in this industry in Ireland medtech, ICT and biopharma. special publication. has expanded The polymer technology While the sector continues significantly since industry is the backbone of to be ambitious with 4.2% then. The sector now Irish manufacturing with world- growth forecast for the Irish Tcomprises 4,000 enterprises class processors, suppliers economy in 2018, we must employing 230,000 people, and service providers continue to work with our making it the second largest employing nearly 7,000 people members to ensure they employer in Ireland and across 230 businesses with are adequately equipped to accounting for nearly a quarter exports of €1.62 billion. face challenges and seize of economic output. Polymer technology opportunities in the years Irish manufacturing has businesses are manufacturing ahead. evolved from traditional autoinjector devices for Polymer Technology Ireland, industries such as textiles and diabetes treatment, plastics as part of Ibec, will continue steel to a higher technology, components for Jaguar to provide industry foresight higher value businesses, such and Land Rover cars, and business services to as ICT, biopharma, medech, engineering materials for use our members to help them agri-food and automotive. in cardiovascular stents, and compete and thrive. Polymer Technology designing packaging to extend Thank you to our member companies, represented by the shelf-life of food products, organisations and expert Polymer Technology Ireland, as well as leading the way in colleagues who helped us have played a major role using recycled materials for develop our 2020 strategy. in the growth of these high use in the automotive industry. technology manufacturing We’ve brought together industries. These companies some of these leading John Wallace are driving growth and companies in a series of Chair, Polymer creating jobs across Ireland interviews to outline their Technology Ireland and across key sectors such strategies for success and

2020 Strategy 1 Director’s welcome

The Irish polymer sector continues to evolve as one of Ireland’s premier manufacturing and technology industries. It has been very rewarding for Polymer Technology Ireland to be part of this success story and to watch companies from across Ireland mature, win new customers and invest in their technology and people. Many of the member companies of Polymer Technology Ireland have developed beyond recognition over the last ten years to become world class providers of the most advanced polymer solutions.

2 Polymer Technology Ireland “ Polymer Technology Ireland will continue to be the voice of the sector in Ireland. We will work with our colleagues in Ibec to deliver a high-quality environment where businesses can grow and prosper.”

olymer Technology of the Polymer Processing to tackle challenges arising Ireland is developing Technologist Apprenticeship from the evolving policy and alongside its that is delivered in conjunction regulatory environment. With membership. We with Athlone Institute of the support of our colleagues have changed our Technology and IT Sligo. The across Ibec, PTI promotes Pname from Plastics Ireland Apprenticeship is geared industry best practice through and we continue to develop towards providing the polymer working groups on Operational our services. Our focus industry with an attractive Excellence, Advanced has traditionally been on long-term career path for Manufacturing, EHS/OHS, developing skills and on new employees who can Skills, Employer Relations promoting the industry. The become apprentices in the and Gender Leadership First Polymer Training Skillnet knowledge that they will work Development. centre in Athlone continues to towards a level 7 qualification The European Union plays go from strength to strength and a rewarding career in a vital role in the evolution and is consistently adding to polymers. With a growing of the industry particularly its offering of training courses industry and extremely strong through its regulation of the for the sector. In this fast- demand for skilled people, industry, the EU Plastics moving world, it is essential the apprenticeship will play Strategy and its work in the that our training centre adapts an important role in attracting area of the circular economy. to the needs of industry the highest calibre of young PTI’s memberships of EuPC and stays up to speed with people into the polymer and Plastics Europe enable the latest technologies and sector – this is fundamental us to effectively represent techniques. First Polymer to the future development the industry’s interests in Training Skillnet is highly of our industry. these areas. regarded by the industry Polymer Technology Ireland Polymer Technology because of the quality of will continue to be the voice Ireland will continue to deliver training that it provides, its of the sector in Ireland. We a strong, industry-specific cost effectiveness and its will work with our colleagues offering to the polymer ability to meet the industry’s in Ibec to deliver a high- industry and we look forward requirements. There is no quality environment where to growing our organisation doubt that First Polymer businesses can grow and further and to supporting the Training Skillnet has made an prosper. Skills and training will continuing evolution of the enormous contribution to the remain core elements of what polymer sector in Ireland. skills profile of the polymer we do whilst we continue to industry in Ireland and Polymer bring companies together to Technology Ireland is proud to make connections, develop Mark McAuley continue to support this. business links and identify Director, Polymer Polymer Technology opportunities. PTI enables our Technology Ireland Ireland is also the backer members to work together

2020 Strategy 3 Polymer Technology Ireland

Polymer Technology Ireland is part of Ibec, Ireland’s leading business organisation. |t represents the polymer industry including suppliers of raw materials and technologies, polymer processors and support services. Vision for the industry The polymer industry in Ireland is a dynamic, innovative and competitive industry where technology-led firms provide high quality products and services and give employees excellent careers in a sector where firms are growing and prospering.

4 Polymer Technology Ireland Strategic pillars: 1. Represent the polymer sector n Represent the Irish polymer industry sector to key stakeholders including the Government, state agencies, the EU and partner manufacturing sectors. n Advocate for policies and conditions that support a competitive business environment where polymer companies can prosper and grow. n Support an ambitious national planning strategy which invests in infrastructure to address the needs of all regions of the country.

2. Build awareness of the value of the polymer industry to key stakeholders n Build awareness of the scale, diversity and value of the polymer industry to the Irish economy by showcasing end market application across manufacturing sectors. n Promote the polymer sector as an innovative high-tech industry. n Publicise the environmental credentials and initiatives of the polymer industry and ensure that the correct information about plastics is fed into the environmental debate. n Provide information about the positive contribution of plastics to the health sector and the environment.

3. Deliver high quality information to Polymer Technology Ireland members n Improve awareness of policy and market developments affecting members. Identify key areas for specific focus such as skills, the circular economy, health and safety and trade. n Establish appropriate forums to enable industry leaders to share knowledge, discuss the impact of changing business models and prepare for the future. n Collaborate with the Technology Gateways which provide close-to-market technology solutions and work closely with centres, such as APT in Athlone IT and PEM in Sligo IT. n Encourage businesses across the polymer sector to become early adopters of new technologies in areas such as additive manufacturing.

4. Support the development of a world class talent pool for the polymer sector n Promote policies and conditions that will make Ireland a leader in talent development for the polymer industry. n Continue to develop Ibec’s First Polymer Training Skillnet Centre in Athlone which upskills and reskills talent for the sector. n Grow the Polymer Processing Technologist Apprenticeship in line with global best practice and evolving industry needs. n Publicise job opportunities and raise awareness of the exciting career development in the sector. n Support the development of skills required for new business models and emerging technologies.

5. Provide opportunities to maximise B2B engagement and support business development n Facilitate interactions with relevant sectors which offer business-to-business opportunities. n Help members to identify opportunities and new markets in the light of changing market and economic trends. n Host events and collaborate with strategic partners to provide opportunities for networking.

2020 Strategy 5 Polymer Technology Ireland will: + Be the voice of the polymer industry in Ireland. + Further the objectives of the polymer industry through Ibec. + Promote skills supply and development in the sector, grow and develop the First Polymer Training Skillnet Centre and the Polymer Processing Technologist Apprenticeship. + Connect member companies to exchange views, develop business links, address industry concerns and identify opportunities. + Provide members with industry relevant information, expertise, knowledge and insight. + Support industry best practice through working groups in the areas of Operational Excellence, Advanced Manufacturing, EHS/ OHS, Skills, Employer Relations, Gender Leadership Development. + Support the industry across Europe through EuPC and Plastics Europe.

6 Polymer Technology Ireland Organisational structure

Polymer Technology Ireland Chair

Polymer Technology Ireland Council

Innovation Skills Business Excellence

Advanced First Polymer Operational Manufacturing Steering Group Excellence Working Group Working Group Polymer Apprenticeship Gender Leadership Consortium Development Taskforce The Council and working groups allow Polymer Technology Manufacturing Ireland members to work on Apprenticeship strategic issues for the industry OHS/EHS Forum and share best practice. Consortium

IR/HR Forum

To find out more about business trends, Ibec member supports, and how to get involved in initiatives like this special publication, contact Polymer Technology Ireland Executive Ciara Finlay by emailing [email protected].

2020 Strategy 7 Model of substance

The business environment in Ireland is characterised by substantial activity in key areas, which means opportunities and a bright future for the polymer industry.

he Irish economy is favourable to the polymer the problems of too much markets are becoming more now in a very new industry – is the fact that of a good thing. In order and more sophisticated. phase. While it may Ireland is bang in the centre of to deal with the emerging They are moving away from feel similar, nothing the latest industrial revolution, challenges, we need to mass manufacturing and that went before known as Industry 4.0, McCoy move quickly to ensure we commoditisation. The capacity Tcan be compared to what notes. This is concerned with have the right infrastructure of their workforces to deliver we are experiencing now, automation, the interoperability to sustain prosperity,” he sophisticated solutions has according to Ibec CEO Danny of machines and devices says. “This includes modern increased,” he says. “In order McCoy. “I don’t believe we and the ability of information housing solutions, maximising to stay competitive with these have ever had a better set of systems to virtually represent interconnectivity and countries we need to keep circumstances in terms of the physical world. broadband and modernising going further and further up the business environment,” “Historically, Ireland missed the education curriculum to the value chain and continue he says. previous industrial revolutions. be geared towards artificial to embrace new technologies A report released by Ibec What is driving innovation in intelligence and robotics.” in manufacturing.” recently shows how the Irish manufacturing now are not Seen by many in the Looking to the future, business environment is built natural resources such as business world as one of McCoy believes it is very on what the OECD terms iron ore, but rather computer- Ireland’s biggest challenges in bright for the polymer industry “substance”. In McCoy’s view, aided design, technology the coming years, Brexit may because of globalisation the polymer industry is well and intellectual property. A well be more of an opportunity as well as Ireland’s access placed to take advantage of lot of substance in terms of for manufacturing and the to European markets and the immense opportunities for these intangible assets has polymer industry, according talented, skilled workers. Ireland that this represents. been moving to Ireland,” says to McCoy. “We have no idea Entitled ‘Ireland: A Model McCoy. of the impact of Brexit or of Substance’, the report “I believe the polymer the form it will take. It could points out that economies industry has a unique be disastrous but equally of substance have depth, advantage in this regard as manufacturing could actually diversity, and years of it is in the vanguard in terms benefit from it. This is because tactical policy planning and of manufacturing. It doesn’t it is involved in global value implementation behind them. have to deal with the legacy of chains and is not affected in In contrast, insubstantial post industrialisation and the the same way as agri-food, for economies don’t encourage baggage of Brownfield sites.” example, which is dependent a diversity of industries; While Ireland’s economy on the British consumer they don’t do research and of substance presents huge market,” he says. development (R&D) or high- opportunities, it brings with it Low cost, but highly value manufacturing and don’t certain challenges. However, productive, jurisdictions such generate indigenous firms of in McCoy’s view these as China, Indonesia, Malaysia scale or outward investment. challenges are a function of and South Korea present One of the reasons that success not failure and should much greater challenges to the economy is in a new be viewed as largely positive. Irish manufacturing than Brexit phase – which is particularly “We are grappling with does, McCoy adds. “These

8 Polymer Technology Ireland Business case studies From plastics processors, suppliers and service providers, the industry in Ireland is leading the way. Get to know some of these businesses here.

2020 Strategy 9 Business case studies Over 30 years ago, JL Goor started out as a supplier of of machinery and later moved into supplying polymer raw materials.

Going a step further

he polymer industry Recognising that there was in Ireland started in a modest way in the 1980s. It was an opportunity to add to the made up of injection Tmoulding companies, sheet knowledge of polymer materials manufacturers, film and rotomoulders and, until about ten years ago, there was a in the growing medtech sector predominance of relatively basic products,” says JL in particular in Ireland, Dublin- Goor’s sales director Joe Wall. Injection moulding is the most widely used plastic process, based JL Goor decided to make producing high volumes from all polymers in every shape and this a point of difference for it size while rotomoulding is used for products with larger hollow sections, such as oil tanks. as a distributor and become “The medtech sector really began to grow and more more proactive in this area. research and development was happening in Ireland. Our approach on this was to meet market demand but go a step further,” says Wall.

10 Polymer Technology Ireland Image supplied

“We decided to be a Administration approval,” Based in Co Waterford, such films are made before resource for customers or notes Wall. Mima Films, one of the they decide to make major potential customers in the Over 30 years ago, JL Goor country’s leading suppliers capital investments,” explains medtech sector and guide started out as a supplier of of stretch film for the Wall. “Cheese packaging them on the most appropriate machinery and later moved containment of pallets, is also needs to protect the cheese materials to use to begin initial into supplying polymer raw a client of JL Goor, as well and extend its shelf life for as product approvals.” materials. In addition to the as Boran Plastic Packaging long as possible. Many cheese Currently employing a team medtech sector, it serves in Co Kildare – a company packs may have up to seven of nine people, in recent years clients in the automotive, which invested heavily in layers to control the barrier JL Goor hired two polymer aerospace, pharmaceutical, innovation through the properties. This design it is scientists and also invested in general packaging and food economic downturn to ensure driven by a mix of commercial logistics expertise to ensure and beverage markets. No its packaging keeps food reasons and the desire to it is offering added value. It one sector accounts for more fresher longer. reduce food waste.” has two strategic warehouses than 30% of turnover. Food JL Goor’s partnership JL Goor has also worked in Dublin, one in Cork; one and beverage is the largest approach in sharing polymer with Irish Custom Extruders in Belgium and another in followed by pharmaceuticals expertise extends beyond in finding the right materials Singapore. and automotive. the medtech sector. In food for its unique comfort slat “The logistics process In Northern Ireland, JL Goor packaging, it has worked mats for cows and Oral-B for medtech products can works closely with Denroy with a number of customers in coming up with a material be complicated and time Plastics in supplying injection which were looking to do for toothbrushes that was consuming. It is very important moulded components to a things differently, for example, resistant to biting and to ensure the right amount of wide range of customers in modifying cheese packaging could withstand being in a materials is held in stock at the aerospace industry and using layering of different dishwasher. the right time so companies with coachbuilder and pioneer materials. can quickly ramp up once of the low-floor bus Wrightbus “We work with these clients they get US Food and Drug International. to help them to indentify how

2020 Strategy 11 Business case studies Proactive partners

As the demand for more cutting-edge plastic products has increased, distributors of polymer materials based in Ireland have become more focused on engaging with clients at the research and development phase.

ith offices in 27 “Where we are trying to Jeff Hobbins, Ultrapolymers countries and step in is by getting involved 50 warehouses at the start of a research across Europe, and development process polymer by proposing new and/or Wdistributor Ultrapolymers alternative materials produced Group brands itself as locally in Europe that are “a partner from design to fully medically accredited production”. with a notification of change In Ireland, the healthcare process which is critical sector has become a for that industry,” says Jeff particularly strong focus Hobbins, managing director of recently as local medical Ultrapolymers Ireland. device manufacturers “By utilising tools such engage in the material as Moldflow we can offer selection process for new guidance on topics such product designs and/or seek as common issues in alternatives for materials which component design, design can often be specified on other features to avoid when continents and converted at using certain materials as plants here. Ultrapolymers well as trade-offs between hired a business development aesthetics and mechanical manager dedicated exclusively performance.” Moldflow for medical applications two simulates the injection years ago. moulding process in order to Ultrapolymers’ philosophy improve plastic part designs, is to work in partnership injection mould designs and with designers, converters manufacturing processes. and original equipment “Moldflow allows us to make manufacturers, providing material recommendations, a significant competitive pre-empt problems and advantage through effective suggest doing something material selection, improved different,” Hobbins adds. part performance and process Headquartered in Belgium, optimisation. Ultrapolymers employs

12 Polymer Technology Ireland 250 people. In 2002, it was curve and Ultrapolymers now consumer packaging and becoming a one-stop shop acquired from BASF by the has offices all over Europe, also rotomoulding. It works for our customers,” says Ravago Group, a service including South Africa and with around 15 major polymer Hobbins. “We have chosen provider to the plastics Turkey,” notes Hobbins. “We manufacturers, including global to be exclusive with each of industry founded by Raf have always maintained a leaders such as LyondellBasell our suppliers and not to offer Van Gorp in 1961. Ravago strong presence in the Irish – which Ultrapolymers works the same resin type from Group was one of the first market because we firmly exclusively with in supplying competing manufacturers. companies in the world to believe that a local supplier Polyolefins to clients – and This allows us to work get involved in the recycling has a better understanding of the world’s largest Styrenics closely with suppliers whilst of plastics. Since becoming customer expectations so we manufacturer INEOS simultaneously providing part of Ravago in 2002, can adapt and continuously Styrolution. support to and being Ultrapolymers’ footprint has improve our service level to all “We work very closely more innovative with our grown beyond Ireland and customers.” with our suppliers. That customers.” UK to now having a pan- In terms of market allows for penetration into Ultrapolymers also acts European presence. segments for Ultrapolymers, multiple markets around as the Irish agent for Romi “Ever since then we have these include healthcare, Europe through our large Moulding Machines (formerly been on a steep growth automotive, construction, customer network whilst also Sandretto).

The polymer industry has an annual turnover of €2.1bn

Each year the 77% Irish polymer of sales in industry pays out the industry €314m are exported in wages

2020 Strategy 13 Business case studies Global grasp

nnovative Polymer drying, dosing and dispersing Spotting a gap Compounds (IPC) was technologies. It is currently set up in Kilbeggan, evaluating putting its current county Westmeath product range of around 2,000 for the supply of in 2008 as a joint different polymer compounds Iventure between polymer into 3D filament format. polymer compounds compounding company In each instance, a special Associated Plastics of Ireland formulation is made for and polymer and chemicals medtech clients in volumes to the medtech distributor National Chemical ranging from as small as 5kg Company (NCC) – each of for engineering trials up to 5 sector in Ireland which has over 30 years’ track tonnes for mass production. record in the polymer industry. The compounds processed The joint venture partners by IPC end up in products in 2008, Innovative saw an opportunity to supply in a number of key areas: compounded materials cardiovascular tubing/stents; Polymer Compounds to original equipment neurovascular treatment; manufacturers (OEMs) intrauterine devices; and first- and second-tier orthopaedics; gastric balloons has gone on to suppliers serving the and surgical tools. medtech sector in Ireland. “We take the basic successfully grow “NCC had been supplying engineering polymer and then polymer raw materials to put additives into it to improve the medtech sector as far its performance. These its export business back as 1996 so it knew the include radiopaque materials customer base well. Instead – which allow clinicians to around the world. of just selling raw materials, see devices inside the body the aim with IPC was to work on x-rays – specialist colours with clients such as Boston or antimicrobial materials,” Scientific, VistaMed and explains Howard. Teleflex by adding capability “From the outset we and value,” explains sales recognised that it was and marketing director of IPC imperative that IPC is involved David Howard. at the very beginning of a “Until IPC was established client’s product life cycle so not a single granule of we can recommend materials compounded materials was and ensure they are suitable supplied from within Ireland – for application. Once a historically it all came from the specification is written by US. We wanted to compete engineers and materials are with the American companies validated on a product, this on the basis of local service, cannot be changed without faster lead times and research huge cost and revalidation.” and development [R&D] IPC is unusual in Europe for support.” its medtech specialisation and IPC’s state-of-the-art white in 2010 decided to leverage room facility in Kilbeggan this to extend its footprint features the latest in material outside Ireland.

14 Polymer Technology Ireland “Historically in Europe its European agent IPC won Stuttgart and Compamed in Avenues is an initiative industrial materials contracts with a number of Dusseldorf. “We are also very funded by the EU aimed at compounders have been large clients in Germany, well supported by Enterprise helping European companies focused on electrical or France and Italy. It has since Ireland across Europe as well to establish long-lasting automotive applications. We built up a customer base as in the US. We recently business collaborations in are a small unit employing nine of over 100 clients in 23 won a client in South Korea Asia. Selected companies get people, purpose-built to only different countries. having visited the country to participate in a one-week serve the medical technologies A key driver of IPC’s there as part of the EU business mission focused sector,” notes Howard. business has been attendance Gateway/Business Avenues on a specific sector in South Further to taking on at major medical tradeshows programme,” says Howard. Korea, South East Asia, German distributor Velox as such as MedTech Europe in EU Gateway/Business China or Japan.

“ IPC won contracts with a number of large clients in Germany, France and Italy. It has since built up a customer base of over 100 clients in 23 different countries.”

David Howard, Marketing Director, Innovative Polymer Compounds (IPC)

2020 Strategy 15 Business case studies Achieving process perfection Andrea Cawley, Director of Sales and Marketing, Automatic Plastics The pace of process innovation is accelerating in manufacturing and Irish-owned companies are making sure to adapt to compete.

ased in Tinahely, improve pricing or quality,” incorporated a mentoring strength to play to,” she says. county Wicklow Cawley explains. “This requires partnership with Waters “It has been transformational since 1972, expertise not only on the Technologies in county for us in terms of reducing Automatic Plastics design side, but also on the Wexford involving reciprocal waste as well as staff differentiates itself technical side – as frequently site visits and the sharing of engagement and up-skilling.” Bfrom other injection moulding visits on-site to see the client templates for lean tools. Automatic Plastics recently companies through its lines identifies root-cause “The mentoring partnership launched its APL2020 vision focus on improving product problems that design tweaks fast-tracked our lean which includes, for example, design for manufacture for its can eliminate.” implementation. The further up-skilling of its 90 staff clients in the pharmaceutical, Once the design is agreed, whole area of lean is really and aiming to have all staff medtech and food packaging Automatic Plastics builds the collaborative in Ireland. trained to lean manufacturing sectors. custom-made tool or mould Other companies such as white belt in 2018, with a “Clients come to us with for its injection moulding Rottapharm and Depuy core team of 12 accredited to a design for food packaging machines to make the client’s Synthes have been happy green belt. with specific requirements, for product or parts. Having to open their doors to us The company has served example. We give feedback started out as heavily focused and show us what they have the UK market for many on a better way to go about on the automotive sector, the achieved,” notes Cawley. decades, mainly focused on the design to avoid quality company gained certifications Automatic Plastics has also the medical technologies and issues – this could be the such as the 13485 (ISO) worked closely with Enterprise food packaging sectors. It use of different materials or quality management standard Ireland on lean manufacturing represents a significant part of slightly different processes for medical technologies, programmes. Richard Keegan, its portfolio. to reach the finishing line,” which allowed it to diversify in head of the competitiveness Since the Brexit vote, the explains director of sales and the past five years. department at Enterprise family-run company has marketing Andrea Cawley. An increased emphasis Ireland – who has led over realigned its strategy with the In food packaging or on operational excellence 1,500 best practice lean aim of targeting the French pharma, Automatic Plastics’ has been a major driver of missions to Toyota’s Deeside and Benelux markets. “We clients might be making Automatic Plastics’ success. plant in the UK – visited believe that the larger injection millions of units to run down During the past 12 months it Automatic Plastics and said moulding companies in fast filling lines. This can has used the Mór Benchmark it was “like a little piece of Europe are not as agile and require precision down to +/- Model devised by members Japan” in county Wicklow, flexible as we are. Our aim is 0.10 of a millimetre. of Ibec’s Irish Medtech Cawley points out. to always come up with new “Our clients come with a Association to measure “We recognise that if we ideas,” says Cawley. product design, but small the company in areas of can be lean and efficient in changes can drastically lean manufacturing. This our processes, this is a major

16 Polymer Technology Ireland 2020 Strategy 17 Business case studies

Embracing automation Over the past year family-owned business Gem Plastics Ltd has undertaken a number of key measures as part of its continuous pursuit of general process innovation at its 10,000 square metre plant in Regaskin, county Cavan.

18 Polymer Technology Ireland “ With turnover now in excess of €21 million and employing 90 people, Gem Plastics supplies a full range of industrial containers that are used across a spectrum of industries in the UK and Ireland.”

his general process “We supply the largest has given Gem Plastics the Over the past 12 months innovation is focused chemical distributors in ability to monitor the dosing Gem Plastics undertook on implementing the UK and Ireland. We of polymer materials into the a Sedex Members Ethical improved production also supply the Irish and machines to an accurate level. Trade Audit (SMETA), which methods through the UK manufacturing sites of “With blow moulding there involved a deep investigation Tuse of different techniques, top global pharmaceutical are so many variables and and holistic review of its equipment and technologies companies as well as serving variability impacts cost and plant focusing on labour such as new ways of global brands in beverages,” quality. Every shot is unique. standards, health and safety, measuring data and an says Burke. This smart piece of kit allows environment and business upgraded material handling Investment in automation us to monitor dosing in terms ethics. A global not-for- system. and achieving the quality of the weight and volume profit organisation, Sedex is Alec Milligan established management system standard of the materials going in, home to the world’s largest Gem Plastics in 1988 as a (ISO 9001) and the food safety which will then be converted collaborative platform for sister company to his lubricant system certificate (FSSC to produce the containers,” sharing responsible sourcing distribution company Gem 22000) in recent years led explains Burke. data on supply chains. Oils, which was founded in to the company’s focus on Gem Plastics’ process “The SMETA audit 1962. He started out with high-end food, chemical and involves three materials being started as a key customer one blow moulding machine beverage packaging. mixed at all times: virgin requirement but since then making plastic drums to “The nature of our work resin, colour masterbatch we have used it as a positive supply the oil industry. Blow has changed largely because and regrind (material that selling angle. More and more moulding mainly produces of investment in high-tech has undergone at least companies have requirements hollow products, such as equipment and automation,” one processing method). for their suppliers in this area,” bottles, drums and ducts. says Burke. “There used The company has adopted says Burke. “The company grew rapidly to be one person to every blending and control systems Gem Plastics recently from there to have a life of its blow moulding machine and from TSM to ensure a hired a full-time HR manager own,” says managing director a lot of heavy lifting. Now, consistent mix. It is piloting a focused on skills development Maura Burke. With turnover there is one person running system which measures the and team building. “We have now in excess of €21 million multiple machines and the skill trend of weight of containers a rigorous training system and employing 90 people, needed to do an entry-level and alerts engineers if there in place. Presently we are Gem Plastics supplies a full job has moved on quite a lot. is a variation outside of the rolling out a new food safety range of industrial containers Traditionally, we had general specification. In addition, it has programme to all operations from 1-litre to 220-litres in maintenance people to fix invested in a vision system unit staff building on good size that are used across things when they broke down; used for measuring containers manufacturing practices a spectrum of industries now we have skilled electrical, as they are produced and (GMP) training which they had in the UK and Ireland. electronic, design, quality and spotting any malformations. previously completed.” Containers include anything project engineers. We are “All of our own data from wholesale washing-up recruiting further for 2018.” combined with TSM systems liquid bottles to rigid packs Re-investment in a gives us an advanced picture to contain highly dangerous sophisticated material handling of the true performance of a chemicals. system in the past 12 months machine,” says Burke.

Gem Plastics was established in 1988

2020 Strategy 19 Business case studies

From its base in county Cavan, fibre specialist Wellman International has addressed commoditisation and competition by carefully targeting four key market segments and focusing on R&D.

Staying well ahead

20 Polymer Technology Ireland Donal Breen, CEO, Wellman International

n October, Wellman fibre with a capacity of 88,000 then cooled and spun into Recent product International announced tonnes, it mainly exports to a continuous fibre. At the developments for the a new research mainland Europe. Ireland Wellman International plant, automotive market from collaboration with the accounts for about 3% of the fibres are then collected Wellman International have Royal College of Surgeons sales. in special containers and put included bespoke hollow Iin Ireland (RCSI). It is the latest At its plant in Mullagh, through a second process. and coloured solid fibres for step in the county Cavan- county Cavan, it started out “We elongate the fibres aesthetically critical parts such based company’s strategic making fibres for domestic under tension to improve as carpets, door panels and R&D programme to deliver bedding and home furnishings the tensile properties. This parcel shelves and black and higher value added fibre- – which have become allows us to do things to white fibres for acoustic and based products to the market. increasingly commoditised the fibre to engineer it to a thermal insulation in cars and Together with RCSI clinical in recent years due to specific application, such as light trucks. researchers, Wellman competition from the Far East. specialised crimping or adding “We supply tier 1 and tier International will develop To address this challenge, attributes such as inherent 2 suppliers to the original a novel bedding material it diversified into specialist antimicrobial properties,” equipment manufacturers of with the aim of preventing solutions for the hygiene and Breen explains. Ford, BMW, Mercedes, Audi, pressure ulcers by controlling healthcare and automotive Wellman International Volkswagen, Volvo, Hyundai, moisture levels on the skin’s markets in the past ten years. has several unique fibres Nissan and General Motors surface and evenly distributing It has also evolved from being undergoing trials with key and work as a development pressure while a person is a mainly a polyester fibre customers at the moment partner with them,” says Breen. seated or lying in bed. provider to providing multiple in areas such as moisture Back in its early days, “Otherwise known as bed polymer and fibre types. management, microbe Wellman International was one sores, pressure ulcers cost the It is continuously learning inhibition, skin health of the first companies in Ireland NHS in the UK £4-6 billion a how to further enhance and promotion, blood flow to use recycled materials year. As people get older and improve the performance and enhancement and optimum to produce polyester staple living standards continue to efficiencies its fibres can offer, comfort. The type of products fibres and this ethos has been rise, healthcare systems and according to Breen. which may result from these maintained ever since. care homes could potentially “We are focused on using unique fibres include special “At least 75% of our face more problems like engineered fibre design to bandages for people with polymer base now comes this,” says CEO of Wellman solve specific problems in conditions like diabetes. from recycled materials. International Donal Breen. our four key segment areas: Drinking bottles are turned “We are looking at designing hygiene and healthcare; into flakes at Wellman fibres that can facilitate the technical fibres; automotive; Automotive advances manufacturing units in absorption of much larger and home and apparel,” says France and the Netherlands volumes of fluid compared to Breen. “This has required The automotive market is and shipped to our plant in those used in baby diapers capital expenditure every going through quite a change Mullagh, where we convert and other care products.” year in order to upgrade our at present as it moves more them into fibres,” says Breen. Founded in 1973, Wellman plant to meet the needs of the towards hybrid and electric “For our home and apparel International is owned by products of the future.” vehicles, notes Breen. “Weight segment, we have recently global chemicals company In order to be turned into becomes even more critical produced fibre from plastic Indorama Ventures and fibres, polymers go through a with these new types of reclaimed from the sea which employs around 270 people process where they are heated vehicles and we have focused will eventually be transformed directly. The largest European into a liquid and extruded on designing lightweight fibres into fabrics for T-shirts and producer of polyester staple through small capillaries, for that purpose.” other types of clothing.”

“ At least 75% of our polymer base now comes from recycled materials. Drinking bottles are turned into flakes at Wellman manufacturing units in France and the Netherlands and shipped to our plant in Mullagh, where we convert them into fibres.”

2020 Strategy 21 Business case studies Bang on trend

urrently employing Technologies became one of Trend Technologies’ 175 people, Trend its major suppliers and, by the Technologies’ state- early 2000s, the computer of-the-art facility in giant accounted for 40% of plant in county Mullingar, county its business. Nowadays, the CWestmeath is the centre medical technologies and Westmeath has of excellence for injection automotive sectors make moulding for the whole group. up the lion’s share of Trend Since it was set up in 1981, Technologies’ output, although constantly adjusted the facility has come through it does still supply inkjet a number of phases of cartridge mouldings to HP. to changes in reinvention to enable it Most of its clients are in Ireland to adapt to the needs of and the UK. different industries. “In order to be able to serve the marketplace, The most widely used the medical technologies and plastic process, injection automotive industries, we had ensuring it has moulding produces high to develop a lot of expertise volumes from all polymers and achieve certifications, in every shape and size; this including, the standard to the expertise and was Trend Technologies’ core supply the automotive industry technology from the outset. (ISO16949) and the standard capability to stay “We started out to supply the medical manufacturing and supplying technologies industry (ISO products to the young 3485),” says Murtagh. competitive. computer industry at the Trend Technologies built its time, such as tape reels and first clean room in Mullingar in floppy disk boxes,” explains 1997, mainly geared towards Brendan Murtagh, business HP. It now has three Class development manager at 7 clean rooms, with one Trend Technologies. “Within dedicated to post-moulding a few years, this business operations. was declining so we decided “In order to work with to become a sub-contract medical technologies manufacturer of plastic companies, we had to have components for the an area like an operating computer industry.” theatre – the products have From the mid 1980s to be produced in a very to the late 1990s Trend clean environment and are Technologies’ Mullingar packaged and sealed before operation supplied global they leave the clean room,” companies such as IBM, says Murtagh. “The next time Apple, 3Com and Dell with the package is opened is in outer housings for desktop a similar clean room at the computers, keyboards and client’s manufacturing site.” mice. “By 1999 there was Trend Technologies invested none of that type of computer €3 million in upgrading the manufacturing left in Ireland site and adding clean-room – one by one the companies capacity in 2017. “We want moved it to the East,” to be able to add as much says Murtagh. value as possible to the raw When Hewlett Packard plastic component and have (HP) arrived in Leixlip, Co introduced new technologies Kildare 20 years ago, Trend such as digital printing and

22 Polymer Technology Ireland laser welding specifically for of plastic components every ensure that a good product is that purpose,” notes Murtagh. day to Draexlmaier in the UK, consistently made, regardless Medtronic, Cook Medical, which then converts them of any kind of variation in Olympus Medical and KCI are into complete car interiors for the environment (such as among Trend Technologies’ Jaguar and Land Rover. “The a change in temperature medical technologies components we supply are or moisture in the air) or in customers. It supplies used for everything you see in material supply,” Murtagh the sector with wound the front of a car, including the explains. care products, diagnostic dashboard, heater controls, Typically, when a client laboratory consumables, glove box and Sat Nav,” notes comes to Trend Technologies ventilator housings, surgical Murtagh. they have the general concept handles and stent delivery Trend Technologies uses of a product developed and systems. moldflow analysis to develop know how it is going to work. From 2000 to 2007, tooling before it is built. This What they don’t know is how Trend Technologies built simulation technology allows to move the design on so up capability in serving the engineers to assess how that it can be manufactured in automotive industry and by the polymer material will volume at the lowest possible 2007 Donnelly Mirrors in flow through the tool and to cost. Naas accounted for 50% of predict and eliminate potential “We provide a huge amount its business. When Donnelly problems. It has also built up of advice and support in this Mirrors closed its Irish particular expertise in product area,” notes Murtagh. “We operation and moved much and process validation after a would usually be involved of the business to Slovakia, tool is built and in advance of six months to two years with Trend Technologies replaced production start. a client during the product that business with other “Customers expect development stage onwards automotive clients. production processes to be to manufacture.” It now ships two containers validated to the highest level to

“ Trend Technologies now ships two containers of plastic components every day to Dräexlmaier in the UK, which then converts them into complete car interiors for Jaguar and Land Rover.”

Brendan Murtagh, Business Development Manager, Trend Technologies

2020 Strategy 23 Business case studies

The path to industrial 3D manufacturing

3D printing is now viable for large scale manufacturing

24 Polymer Technology Ireland HP is investing heavily in industrialising nylon based 3D technology to transform manufacturing industry. The HP Multi Jet Fusion Technology allows for final part production economically in volumes of up to 110,000 small parts when compared to traditional injection moulding techniques. This along with design improvements and single process production for complex parts means that many industries can make better parts whilst reducing inventory and total cost of production.

D printing is one of and the ability handle larger Today, HP also announced strength, versatility, and the most disruptive quantities of 3D printing the further expansion of its flexibility, but only one of them technologies of our materials, while significantly industry-first Open Materials is going to space (for now). time, spearheading lowering production costs with Platform, a collaborative The new HP 3D High a new 4th Industrial reduced pricing on HP’s 3D development and distribution Reusability PA 12 Glass 3Revolution that will radically materials and shared service model where HP and its Beads, an innovative new change the way we conceive, contracts. growing ecosystem of 3D nylon material filled with tiny design, produce, distribute, When put together with partners work together to glass beads, was used to and consume pretty much HP’s industry-leading Multi drive materials innovation, make one of the most complex everything. Jet Fusion technology, reduce costs, and create new parts in a specially-designed But until now, 3D printing those enhancements double applications and markets for HP ENVY Zero-Gravity printer hasn’t been a viable means the existing “break-even Multi Jet Fusion technology. developed with NASA that’s of large-scale industrial point” at which 3D printing There are already over 50 being sent to the International manufacturing (think big remains cost-effective to an leading companies actively Space Station this February. factories) because of unprecedented 110,000 parts, engaged on the platform. The printer’s output tray prohibitively expensive and drastically reduces the Materials companies can use needed to be particularly production costs and limited cost-per-part, up to 65% less HP’s Materials Development lightweight, watertight, and technology. In order to than other methods. Kit to quickly test compatibility durable for its journey to realize HP’s vision of digitally “The new 3D 4210 with Jet Fusion printers. space, and 3D printing with PA transforming the $12 trillion Printing Solution enables Materials companies 12 Glass Beads provided the global manufacturing industry, our customers to mass- can use HP’s Materials perfect solution. the economics of 3D printing produce parts using HP’s Development Kit to quickly HP continues to unlock the needed to be completely Multi Jet Fusion technology test compatibility with Jet economics and technology rewritten. for significantly less than Fusion printers. of 3D manufacturing, with At the end of 2017, HP other processes, and fully It was announced that a deeply-engaged network announced that it has benefit from the economies leading chemical companies of partners committed to smashed that economic of scale,” said Ramon Dressler Group and Lubrizol accelerating the digital barrier and paved the way Pastor, General Manager of have joined the growing HP industrial revolution. for cost-effective, industrial- Multi Jet Fusion for HP’s 3D 3D partner ecosystem, and Says Corey Weber, co- scale 3D manufacturing with printing business. “HP’s Jet also that three new three founder of leading printing the new Jet Fusion 3D 4210 Fusion 3D systems have now new engineering-grade 3D service bureau Forecast 3D, Printing Solution. reached a technological and printing materials are coming “It has never been more The new solution increases economic inflection point that to the open platform: PA clear to us that HP’s Multi Jet production volume for HP Jet combines the speed, quality, 11, PA 12 Glass Beads, and Fusion represents the future Fusion 3D printers by enabling and scalability needed to Polypropylene. of digital manufacturing.” continuous operation, greater accelerate manufacturing’s The new materials raise overall system efficiency, digital industrial revolution.” the bar on production quality,

2020 Strategy 25 Business case studies Expanding operations through manufacturing excellence

global manufacturer a new 60,000 sq ft building With contract of packaging facilitating the manufacture components and of medical devices with delivery systems electronic component manufacturing for injectable drugs integration to meet the Aand health products, West increasing global needs of operations in Pharmaceutical Services customers and patients for has built up its presence in connected devices. Today, Ireland significantly since around 500 people are Dublin since 1998 acquiring the Tech Group, employed at West’s Dublin which included a contract facility. and following its manufacturing operation in The Dublin site is to produce Mulhuddart in Dublin 13 around 35 million devices years ago. and 2 billion components acquisition of ‘The Tech Now West’s largest this year to support its contract manufacturing site medical technology and Group’ in 2005, West globally, the Dublin facility pharmaceutical customer started out in 1998 with 17 base, according to senior employees in a 40,000 sq director Tom Clarke. These recently expanded its ft facility, initially serving the devices will be shipped all over consumer electronics sector. the world. operations in Ireland, By 2004, when a further “We have 95 injection 40,000 sq ft was added, it moulding machines in Dublin was 100% focused on serving supporting 14 high-volume both in Dublin and medical technology and assembly lines,” says Tom pharmaceutical customers. Clarke, senior director, at with a new site in Demand for autoinjector West. “Currently processing devices for the treatment almost 6,000 tonnes of of diabetes drove further polymer resin per year, we Waterford. expansion in 2014 and in expect this will grow even 2016, the ribbon was cut on more in 2018.”

26 Polymer Technology Ireland In recent years, West has specific to Dublin, is going for multiple product lines and has 28 sites around the invested in the digitisation to enhance our efficiencies in the future. It was built in world employing a total of of its Dublin contract and make us an even leaner a campus layout to ensure 7,300 people. The Waterford manufacturing facility to operation.” flexibility to grow in all facility currently employs allow real-time process and West recently expanded directions. 80 people, with plans to product monitoring across its global manufacturing “Waterford will be a continue hiring in 2018. the machines and automation operations to include a new centre of excellence for Commercial production is systems that produce the site in Waterford on the our proprietary elastomeric planned to begin there by devices. back of increased demand sheeting, which is used the end of the year. “This has significantly from pharmaceutical and to package insulin for use West won the inaugural enhanced our biotech customers. The in pen injectors,” explains Partner/Supplier of the competitiveness and new facility will produce Clarke. “It will also offer high- Year 2016 at the Medtech business growth. 2018 will packaging components for value finishing for West’s Rising: The Irish Medtech see us embark on another insulin injector cartridges and elastomer products, such CEO Conference and enhancement of the facility, other high-value packaging as stoppers and plungers. Awards hosted by Ibec’s as we are going to look at components. These capabilities include Irish Medtech Association, automation from the receipt Situated at a 44-acre site, washing, vision inspection Enterprise Ireland and of orders right through to the the facility is around 20,500 and sterilization.” IDA Ireland. shipping of products,” notes sq m in size and is designed Founded in 1923, West Clarke. “This pilot project, to accommodate expansion is headquartered in the US

“ [West’s] Dublin site is to produce around 35 million devices and 2 billion components this year to support its medical technology and pharmaceutical customer base.”

Tom Clarke, Senior Director, West Pharmaceutical Services

2020 Strategy 27 Business case studies The test of time Over the past 24 years Anecto has evolved from being an electronics device test laboratory to having a state-of-the-art test facility serving multiple sectors including 80% of the world’s top 20 medtech companies.

ne of the standard, Medtech and life sciences the case by looking at plastic packaging of a medical device and perhaps now account for 60% of performance. If the packaging was causing it not to seal surprising, tests Anecto’s business, followed is problematic, we figure out properly. Rather than the Anecto carries by energy and power, which what we can do about it in a company having to reengineer out for automotive makes up a quarter of its cost efficient manner.” everything, we found that a Omanufacturers is to see what turnover. Electronics and On the product side, small formula change to the happens when sun tan lotion mechanical and packaging are medtech companies face adhesion component meant is put on the internal plastics its other main areas of focus. a range of challenges and the problem was solved.” in a car. “The size of the medtech issues involving polymers and Anecto won Partner/ “Plastic can discolour in industry in Ireland – with plastics. Anecto assesses Supplier of the Year 2017 at instances when you put sun key players having a base everything from making sure the Medtech Rising: The Irish tan lotion on it,” says Mike here, including nine of the Luer fittings don’t crack and Medtech CEO Conference Connolly, sales director and world’s top ten medtech leak to testing the bendability and Awards hosted by Ibec’s director of testing services at companies – was perfect of catheters. “We always Irish Medtech Association, Anecto. “The performance of for a company such as ours look at performance issues Enterprise Ireland and IDA a product largely depends on to develop expertise. It gave against standards but can also Ireland. the stresses plastics are going us a competitive advantage evaluate against a database to get, including vibration, to expand throughout of similar products,” says heat, cold and compression. Europe,” says Connolly. “In Connolly. Our job is to establish how a some European markets the He believes where Anecto product made out of plastic medtech industry was too is of real value to clients will perform in real life.” small to concentrate on, while is in understanding why The Galway-based company in others, such as the UK and something happens, offers a full range of services Germany, there was so much rather than just reporting that support companies in their testing going on in so many what has happened – it efforts to increase product areas that it wasn’t important is the expertise beyond reliability and reduce the risk of to specialise in medtech.” the test. failure throughout the product Regarding polymers, there “For example, we lifecycle. are two strains to Anecto’s identified that the Currently employing over work with medtech companies interaction between 90 people, its 40,000 sq ft – packaging and products. three components facility contains over €2.5 “The challenge for medtech in the million worth of equipment, companies is to deliver their including vibration systems devices sterile at points of use and specialist medical device anywhere in the world. The systems. “Our engineers will product may have a five-year design and build specialist shelf life, but still has to be test equipment to meet a sterile,” explains Connolly. specific need if it is not already “We work with medtech Mike Connolly, Sales available,” notes Connolly. companies to ensure that is Director and Director of Testing Services, Anecto

28 Polymer Technology Ireland Categories of company in the polymer industry

Processors Suppliers

Injection moulding: The most widely used plastic Raw materials: Any company involved in process, producing high volumes from all polymers supplying raw materials into the polymer sector. in every shape and size.

Tool and mould: Create and/or design tools and Blow moulding: Predominantly produces hollow moulds for the polymer industry. products, such as bottles, drums and ducts.

Machines and ancillaries: Suppliers of Rotational moulding: Used for products with polymer processing equipment and ancillaries larger hollow sections, such as oil tanks. to the industry.

Thermoforming: Products are formed by shaping Compounds and pigments: Suppliers flat sheets with heat and vacuum to form 3D of polymer compounds and pigments parts such as shower trays, blister packs and car to the industry. dashboards.

Tube extrusion: Polymer is extruded into a thin circular tube. Used in variety of medical devices Services including catheters and electrical cable wrapping. Design: Providers of polymer engineering solutions, Pipe extrusion: Polymer is extruded into a thick prototyping, polymer conversions and part/product circular tube. Used predominantly in construction, development solutions. drainage and packaging. Other: Companies supplying services to the Film extrusion: Polymer is blown or cast into a polymer industry, such as recycling, packaging thin film for products such as plastic bags, cling and clean room validation. film, silage wrap and bin liners.

Sheet extrusion: Polymer is extruded into sheet, which can be used in signage and bathroom products, or thermoformed as described above.

Foam moulding: Foaming agent is added in the production process to give lighter products for insulation and packaging.

Non-woven/fibre: Fibres extruded from polymer are used for textiles and in the fashion industry. Non-woven fibres are found in upholstery and bedding products.

2020 Strategy 29 Mapping Ireland’s polymer technology industry

30 Polymer Technology Ireland PIPE EXTRUSION TOOL AND MOULD

ROTATIONAL MOULDING

104 114 224 013 053 96 Proxy Biomedical Ltd | Galway 085 091 099 99 Shadow Creations Ltd | Dublin 100 Smallwares Ltd | Louth 196 105 112 134 059 Suppliers 102 Steripack Ltd | Offaly ATHLONE 109 Thormac | Clare 205 DUBLIN 135 136 139 MACHINES AND ANCILLARIES 114 Trend Technologies Mullingar Ltd | Westmeath 102 047 074 180 117 Verus Precision Ltd | Sligo 159 VistaMed Ltd | Leitrim 067 149 150 152 153 GALWAY 142 204 228 183 J L Goor Ltd | Wicklow 160 169 175 184 Modular Automation | Clare OTHER 087 092 042 175 181 Nelipak Healthcare Packaging | Galway 179 183 186 185 Sys-Pro Ltd | Limerick 178 Total Plastic Solution Ltd | Kerry 219 Athlone Institute of Technology 195 190 191 192 186 Tritech Precision Ltd | Dublin (Research) | Westmeath 031 187 TSM Control Systems | Louth 228 Boran | Kildare 117 Verus Precision Ltd | Sligo 193 199 200 221 Bruss GMBH Dichtungstechnik | Sligo ENNIS 019 222 LC Packaging | Donegal 43 028 065 083 201 202 203 RAW MATERIAL Filtertek – An ITW Medical Company | Limerick 191 Irish Farm Film Producers Group | Dublin 223 Kayfoam Woolfson Ltd | Dublin SHANNON 212 215 220 150 MacFarlane Packaging | Wicklow 11 Allsop Europe Ltd | Waterford 138 188 Mima Films | Waterford LIMERICK 223 BASF Ireland Ltd | Cork 181 Nelipak Healthcare Packaging | Galway 189 Delta Q | Westmeath 194 137 190 Retech Processing Ltd | Cavan Distrupol Ireland Ltd | Dublin 195 Roc Recycling Solutions Ltd | Laois 191 Irish Farm Film Producers Group | Dublin 130 192 Shabra Group | Monaghan J L Goor Materials Ltd | Dublin 197 Shabra Recycling | Monaghan 193 National Chemical Company | Dublin 102 194 Steripack Ltd | Offaly Retech Processing Ltd | Cavan 224 Taconic International Ltd | Westmeath 144 146 195 Roc Recycling Solutions Ltd | Laois 225 032 030 196 ThermoSafe Brands Europe Ltd | Cork Scott Bader Company Ltd | Meath 226 Wellman International Ltd | Cavan 130 Shabra Group | Monaghan 227 197 VitaBond Ltd | Westmeath Shabra Recycling | Monaghan 229 Zenith Adhesive Components | Westmeath WATERFORD 198 TCL Plastics | Dublin 199 Total Polymer Solutions | Dublin 011 022 046 080 200 UltraPolymers | Dublin NON-WOVENS/FIBRES 075 124 201 Univar Ireland Ltd | Dublin 122 138 176 209 229 Zenith Adhesive Components | Westmeath 226 Wellman International Ltd | Cavan CORK COMPOUNDS AND PIGMENTS 227 VitaBond Ltd | Westmeath 131 132 FOAM MOULDING 188 218 202 Baxter Healthcare (Deansgrange) | Dublin 203 Baxter Healthcare (Sandyford) | Dublin While the coordinators have made every effort to ensure 204 Clariant Masterbatches Ireland Ltd | Kildare 227 VitaBond Ltd | Westmeath that the information in this map is accurate, we do 189 Delta Q | Westmeath apologise for any inconsistencies. Stakeholders who wish 205 Innovative Polymer Compounds – IPC | Westmeath to amend map, please contact Polymer Technology Ireland 206 MICAM Ltd | Cork EDUCATIONAL INSTITUTES on 01 605 1562 or [email protected]. It is anticipated 207 Saint Gobain Performance that updates will be supported on an ongoing basis and completely at the discretion of Plastics Ireland. Plastics(Chemfab) | Clare 219 Athlone Institute of Technology © 2018, Polymer Technology Ireland (Research) | Westmeath 230 IT Sligo | Sligo 231 First Polymer Training Skillnet | Westmeath 2020 Strategy 31 Talent and skills Continuous industry improvement

The training provided through First Polymer Training Skillnet has been crucial in supporting the growth of Litec Moulding over the past ten years.

hen Jonathan “We employ 70 people and this year, the number of him on three years ago. He Read joined and operate on a 24-seven components it has processed is currently studying for his Litec Moulding basis. The training modules has increased from 2 billion to Bachelor of Engineering in Sligo as are essential for understanding 5 billion. in Polymer Processing at managing the baseline technologies and “In the past ten years we Institute of Technology Sligo Wdirector in 2007, one of his processes in this setting,” says have more than doubled our with the company’s support. priorities was to review the Read. Injection moulding is a output, while only increasing “Technical skills are vital training and development widely used plastic process, staff numbers by 20%. This to us as we are dealing with needs of personnel to support producing high volumes from could only be achieved thin-walled, high precision the company’s growth plans. all polymers in every shape through ongoing continuous components with a very fast He decided the following and size. improvement and having a cycle time. We measure our year to establish a relationship Founded in 2000, Litec team that understands the parts in microns. Producing with First Polymer Training Moulding provides high injection moulding process,” 5 billion components means (FPT) Skillnet as the precision components used notes Read. you can’t rely on traditional company’s baseline training in the making of aerosol The team includes inspections; it is our people provider. Initiated by Polymer valves and dispensing engineering facilities manager and our processes that Technology Ireland, FPT solutions. It is the in-house Ray Fox who completed the deliver quality.” Skillnet’s objective is to moulding operation of Lindal FPT Skillnet injection moulding provide technical training to Group, which is a leading module 4 in October. polymer processors, both at manufacturer of the valves, Meanwhile, newly appointed First for skills its centre in Athlone and in- serving global clients including continuous improvement First Polymer Training (FPT) company as required. Unilever and Biersdorf. “About leader Jonathan Pugsley and Skillnet was one of the first Since then, Litec Moulding 30% of the global volume production supervisor Enda funded Skillnets when it was has used FPT Skillnet of aerosol valves, actuators Dineen did module 2 as part established nearly 20 years consistently every year so and spray caps contain of their induction. ago. This was driven by that now every manager components manufactured Ronan Collevy did the Polymer Technology Ireland and technical person on out of Sligo,” says Read. first three FPT Skillnet in1999. It is one of only the operational side of the Litec Moulding has been modules off his own bat three Skillnet networks from business have gone through on a continuous growth after leaving school and was the very first cohort still in FPT’s injection moulding path since it was set up, recommended as a good existence and is managed modules 1, 2 and 3. notes Read. Between 2007 hire, so Read agreed to take by Catherine Collins.

32 Polymer Technology Ireland FPT Skillnet injection moulding modules

Module 1 This course starts with a full overview of injection moulding from the moulding parameters/mould opening and closing parameters, up to injection pressure curves and why troubleshooting issues occur.

Module 2 This course starts by covering the cycle with an indepth review of each of the parameters making up the stages in the cycle. Theory sessions include parameters and their control, setting up a mould with no setting sheet, plastic materials, mould design and troubleshooting – with an emphasis on troubleshooting during all sessions. The remainder of the course is practical, focusing on setting up moulds from scratch, selecting pressures, speeds, times and strokes before building the shot up and dealing with defects as they arise. Jonathan Read, Managing Director, Litec Moulding Module 3 This course focuses on techniques used to understand and ‘map’ the injection moulding process, reducing moulding inconsistency by understanding its causes and effects. A strong emphasis is placed on giving participants the practical skills to apply both statistical Since then, the network has achieve its early objectives. process control and troubleshooting techniques. been successfully developing FPT has a dedicated and delivering technical polymer training facility in Module 4 training to the polymer industry Athlone, which houses four and driving the upskilling injection moulding machines, This course focuses on the polymer engineering and agenda for the sector with an extruder, thermoformer and processing principles related to achieving the optimum more than trained 6,500 purpose built maintenance injection moulding process. Strong emphasis is placed participants trained to date. training boards. on giving the practical skills to achieve optimum FPT’s voluntary steering A wide range of courses performance but supported by engineering principles. group is made up of leading is offered at the centre It includes an element of home study to reinforce the figures from the polymer exclusively and companies principles applied throughout the course. industry who oversee the can benefit from Skillnets management of the network funding on these programmes and give strategic direction which are tailored to and guidance. Companies specifically meet their needs. represented on the group FPT is currently the sole include the Spectrum Plastics provider of many of these Group, Polymer Technology QQI accredited polymer Ireland, Irish Micro Mouldings, programmes (including Trend Technologies, JL injection moulding, extrusion Goor, MFP Plastics, Nypro and part & tool design) and Healthcare, West Pharma, originally developed these as Athlone Extrusions and a career progression route for Medtronic. those working in industry. This group has been FPT is an integral part of fundamental to the network’s the sector and continues success to date and has to work as a partner with driven its development to be a industry. Current network real partner to industry with a membership of 78 companies very strong enterprise focus. At includes leading plastics the beginning, Chair Pat Whyte processors in a range of played a key role sharing his sectors, medtech companies expertise to help the network and suppliers to the industry.

2020 Strategy 33 Talent and skills Practical career progression

y the end of this year According to Aisling Nolan, New apprenticeship around 110 people general manager of Mergon will have started on International and chair of the two apprenticeship Polymer Technology Ireland programmes are programmes which Apprenticeships Consortium, Bmark a new departure for this apprenticeship fills a gap helping to create a training and skills development that has been in the industry in the plastics industry for a long time. in Ireland – the Polymer “There was a route for pipeline of talent in Processing Technologist qualification for people who Apprenticeship and the will work in maintenance and the area of polymer Manufacturing Engineer on the tooling side, but we Apprenticeship. always had a gap in terms of a Based on the ‘earn and practical route for qualification processing and learn’ principle, these new on the side of processing the industry-led apprenticeships plastic in the blow moulding manufacturing. involve a work placement or injection combined with studying for a moulding level 7 degree. They are part machine,” of a general Government push she says. to expand apprenticeship into “As long as new sectors of the economy, I have been in which was initiated in 2014 the industry [20 with the establishment of the years], this has Apprenticeship Council. been a topic of Polymer Technology conversation. Ireland, the Ibec association I took on the representing the sector, position of chair developed the Polymer of the consortium Processing Technician as I have a vested Apprenticeship with a interest to ensure consortium of 14 companies we ended up with and Athlone Institute of a programme that Technology (AIT) and Sligo truly met industry Institute of Technology (Sligo requirements.” IT) as education providers. An Irish-owned At the end of the three year company established programme, successful in 1981, Mergon apprentices will have a International employs Bachelor of Science in Polymer 270 people in Processing Technology. Castlepollard, County

Pictured at the launch of new manufacturing and polymer technology apprenticeships (l-r): Chair of Polymer Technology Apprenticeship Consortium and Mergon International General Manager, Aisling Nolan; Chair of the Manufacturing Apprenticeship Consortium and CEO Cambus Medical, Barry Comerford; and Apprenticeship Project Manager Denise Carthy.

34 Polymer Technology Ireland Westmeath and also has “My experience so far has operations in the Czech been of blow moulding. The Republic and the US. apprenticeship opens up the The role It serves clients in the opportunity to learn about all automotive and healthcare aspects of plastics processing, sectors, designing, including injection moulding manufacturing and assembling and extrusion,” he says. of SOLAS components using both “The end goal for me is blow moulding and injection to know the machines inside moulding. Blow moulding out, be able to manage There are formal requirements for approval of an mainly produces hollow the moulding process from employer’s suitability to train apprentices and for products, such as bottles, scratch and eventually run the registration of apprentices as part of the national drums and ducts while the production line. I couldn’t apprenticeship system. SOLAS, the Further Education injection moulding produces have afforded to take time and Training Authority, is responsible for delivering on high volumes from all polymers off work to do a degree. As I these requirements. in every shape and size. had done an apprenticeship Its network of over 40 authorised officers (AOs) Last May, the company before I jumped at the chance located in the 16 Education and Training Boards around hired two polymer processing of doing this one as it really the country work on an ongoing basis with employers, technician apprentices from interests me.” apprentices and the consortia engaged in rolling out within as part of the first Other companies that apprenticeship programmes. intake to the apprenticeship took part in the first intake of They carry out site visits to employers’ premises programme of a total of 15 the polymer apprenticeship to assess their suitability in terms of their ability people. They have completed programme like Nypro to provide quality, relevant, on-the-job training to their phase 1 work element Healthcare in Bray, County apprentices. AOs are also tasked with supporting and started their college Wicklow. apprentices during their training. training at AIT in September. “Through this new “The Irish polymer industry is well established and Twenty nine year old tool programme, we get to offers a broad range of career opportunities,” says setter Allan Devine is one train people to industry Martin Carrigan, development officer at SOLAS. “The of the Mergon International standards,” says Nolan. “The Polymer Processing Technologist Apprenticeship allows apprentices. Having grown apprentices learn how we do people to learn in a real working environment, generally up in Castlepollard, he served things and get to understand in state-of-the-art, high-tech production facilities.” his time as a carpenter and the company culture. We joiner before being hired as are very focused on talent an operator with the company management and look to in 2010. promote people from within.

2020 Strategy 35 Talent and skills

Our aim is to develop the Boston Scientific Clonmel, amount of experience, which Institute of Technology, Cork skills people have so they can County Tipperary and Key will make them very valuable Institute of Technology and move into more senior and Plastics, Bray, County to the company they’re Galway-Mayo Institute of management positions. The Wicklow. placed in. It offers them a Technology. There will be a apprenticeship is a key way of “It is significant that SMEs career path,” she says. “It second intake in November doing this.” are taking a leap forward takes at least 12 months for that will include Sligo IT. Nolan expects more and getting involved in the companies to see the benefits “If a company is generating existing employees of Mergon programme. This gives of recruiting engineers through polymers, this apprenticeship International to be trained confidence to others to do the the normal routes. Once hired, programme allows it to as polymer processing same,” says Denise Carthy, it takes a while for them to acquire a hybrid skill-set with technicians under the apprenticeship manager at understand the industry and manufacturing focused on programme and will also hire Polymer Technology Ireland. start giving back.” tooling. Employers need to new people as apprentices in “Smaller companies often Once apprentices graduate assess where their talent gaps the coming years. have a loyal and committed with their Bachelor of Science are when weighing up the “In our industry, we are core team that has been in Polymer Processing apprenticeship programmes,” certainly back to an acute with them for years. The Technology, they can then says Carthy. level of shortage in the apprenticeship facilitates such springboard to level 8 and 9 For anyone interested engineering area, including people to stay working and qualifications to take them in pursuing a career as a quality, process, automation, upskill. Those that take part down the path of tooling polymer engineer, AIT now mechatronics and robotics can then become mentors to precision, notes Carthy. offers a combined mechanical engineers,” she notes. others and there is a cycle of “Polymer processing and and polymer engineering level “We hope that the new talent to build on.” tooling precision combined 8, four-year honours degree. programmes will lead to Carthy points out that is a very sought-after set of The entry requirements are the development of further while polymer processing is skills. Companies want people higher than for the three-year apprenticeship models, quite a niche area, there is a who understand how materials apprenticeship (295 points particularly on the automation demand for polymer engineers perform and behave and can versus 250 and two honours and mechatronics side where across the country as so many make sure the production subjects are required where they are much needed.” larger companies – such as process is consistent; the apprenticeship requires Twelve people started medtech giant Medtronic in the downtime is kept to a only a pass Leaving Cert). their induction as polymer Galway for example – have minimum and the quality of the Sligo IT and First Polymer processing technician moulding capability within their output is good.” Training Skillnet offer apprentices for the second organisations now. There is a polymer combined programmes in intake in October. Companies She believes this type of module in the third year of the polymer space. There taking part include BD Medical model is the best way to turn the Manufacturing Engineer is a programme that offers Technology in Dublin, Litec out high quality engineers. “A Apprenticeship which a level 7 polymer degree, Moulding in Sligo, West standard engineering degree incorporates a lot of learning delivered online, but a level Pharma in Dublin, Delta Q in takes three years. During around tooling precision. Last 6 qualification in a relevant Athlone, County Westmeath, the same timeframe, the June, 52 people started on discipline is required for entry. Tool and Plastic in Longford, apprentices will gain a huge this programme at Limerick

“ A standard engineering degree takes three years. During the same timeframe, the apprentices will gain a huge amount of experience, which will make them very valuable.”

36 Polymer Technology Ireland Getting on the road to polymer technology careers

Oleg Aleksandrov, Kingspan

What is your job title? Divisional Polymer Engineer for Kingspan Light and Air Division What was your previous role (3 roles) n Polymer Engineer for Kingspan Insulated Panels Division n Process Technician for Tool and Plastic n Trainee Process Technician, Nypro

What did you study and what educational qualifications do you hold? n Diploma in Automotive Manufacturing, Riga Valsts tehnikimums, Latvia n BSc Business and Finance, University of Ulster, Northern Ireland n BEng Polymer Processing, IT Sligo n MSc Polymer Science and Technology, Loughborough University, UK

What first attracted you to working in manufacturing? Having moved from manufacturing to a career in business and finance, after a number of years I realised that the manufacturing was the area that interested me the most. It is a very rewarding career that gives you an opportunity to be involved in a process that will produce a tangible product, which will make somebody’s life easier, help to cure somebody’s illness or build a better building. As well as that the pay rates are quite good too.

What do you like about your job? Working for a company with a global presence and an opportunity to apply polymer materials knowledge to improve manufacturing process and develop new products, ultimately making our planet a better place.

How has manufacturing changed since you started working in the industry eg new technologies, processes, business growth etc? I can remember operating a Metalworking Lathe to produce a part for a complex assembly that took me 4 hours to complete, now the same part can be produced by CNC machine within minutes and then assembled by a robot to a much greater accuracy. In the last 20 years manufacturing has been transformed with the help of Information Technologies making it a leaner process. Many widely used polymers did not exist 20 years ago, bringing a whole new range of opportunities for innovation and product development. Polymers and technology have made it possible for processes like 3D printing to emerge, opening a whole new industry.

2020 Strategy 37 230 polymer companies in Ireland Nearly 7,000 people are employed in the polymer sector €1.62bn annual value of Irish polymer exports

38 Polymer Technology Ireland Getting on the road to polymer technology careers

Clara Bracken, Nypro

What is your job title? Senior Process Engineer, Nypro What was your previous role (3 roles) n Senior Site Moulding Engineer, Bausch & Lomb n Injection Moulding Engineer, Bausch & Lomb n Moulding Technician, Greenbank Plastics

What did you study and what educational qualifications do you hold? n BSc Polymer Technology, Athlone Institute of Technology n Diploma Applied Project Management, University College Cork n Master Molder I & II through Nypro University

What first attracted you to working in manufacturing? In school I was more interested in science and engineering rather than manufacturing, I picked polymer on CAO form because I’d covered some of this in leaving cert chemistry and it caught my interest. My first job was in Mallinkrodt Medical in Athlone and this led me to where I am today. I think when you start off in a certain area you tend to stay in it, which in my case was injection moulding, some of my classmates ended up in quality, extrusion, R&D and even sales.

What do you like about your job? The fact that you’re helping make medical devices that can enhance people’s lives, plus the diversity. No two projects are the same in terms of design or materials used so while it is very challenging it is great to get this exposure.

How has manufacturing changed since you started working in the industry eg new technologies, processes, business growth etc? Ireland has a good history when it comes to medical device manufacturing, but I think the design of parts and their functionality are getting more complicated, with that equipment and materials are constantly evolving. Processing itself has developed a lot, use of scientific injection moulding is now the norm, 20 years ago it was a bit more ‘unscientific’ and most people thought it was a black art. Now it’s easier for a process engineer to come in and develop or match a process by following basic principles.

2020 Strategy 39 Gateway to growth The innovation ecosystem for the polymer industry stepped up a gear in 2016 with the formation of EMD Ireland, a cluster group of six technology gateways focused on engineering, materials and design.

unded by Enterprise Institute of Technology Carlow. SEAM in 3D metal additive has become exemplary of Ireland, EMD Ireland Specialised research manufacturing to study the why Ireland is recognised as a provides a broad resources are leveraged from porosity of materials used model of business substance,” range of expertise within the six participating in the manufacture of 3D says Ibec’s Medtech and to companies of all institutes of technology and printers. It also worked Engineering Director Sinead Fsizes, effectively becoming an applied to industry problems. with APT to assess how Keogh. important extension of their The gateways send work a new coating to facilitate “The world-class research and development around between each other over-moulding would work ecosystem here includes (R&D) capability. and companies regularly in an injection moulding key sectors such as The cluster connects with access the expertise of more environment. polymer technology, over 300 industry researchers than one gateway for specific EMD Ireland can assist which has 230 companies in areas such as precision projects. companies with Enterprise in Ireland collaborating engineering, biotechnology, For example, chemical and Ireland funding mechanisms with industries such as polymers, protective coatings, consumer goods company in the form of Innovation agribusiness, automotive, prototype design, medical Henkel’s operation in Tallaght, Vouchers, Innovation construction, medtech, and imaging technologies and 3D County Dublin worked with Partnerships and Innovation pharmaceuticals.” metal additive manufacturing. three different gateways Partnership Feasibility Studies. The immediate gains of The six gateways that make recently as part of its R&D into Companies can also directly working with Technology up the cluster are: Applied novel adhesive solutions for fund their work with the Gateways are obvious for Polymer Technologies (APT) at 3D printing. gateways. Irish-based companies, Athlone Institute of Technology Ahead of the Since 2013, €23 million according to Enterprise Ireland (AIT); the Centre for Research announcement of a new worth of innovation projects Technology Gateway manager in Engineering Surface partnership with HP to have been completed Paddy Byrne. Technology (CREST) at develop 3D material solutions between over 900 Irish-based “Nearly two thirds of Dublin Institute of Technology last May, Henkel engaged companies and a total of 15 companies report the (DIT); South Eastern Applied with CREST to carry out Technology Gateways funded development of new products Materials Research Centre a colorimetry test – an by Enterprise Ireland. while more than a third have (SEAM) at Waterford Institute essential quality control test “Manufacturing exports accessed funds to develop of Technology (WIT); Precision for which Henkel didn’t are worth nearly €103 their business,” he says. “In Engineering & Manufacturing have a suitable instrument billion, and the sector now the long term, the fact that (PEM) at Institute of at the time. Colorimetry is a employs more than 230,000 seven out of ten said that Technology Sligo (IT Sligo); technique used to determine people across the country. working with these gateways Medical & Engineering the concentration of coloured Thanks to our dynamic talent has helped them foster a Technology (MET) at Galway- compounds in solution. pool, supportive business culture of innovation will help Mayo Institute of Technology In addition, Henkel environment and collaborative these companies to scale and and Design + Gateway at accessed the expertise of ecosystem, manufacturing grow.”

40 Polymer Technology Ireland APT Gateway moulding and blow moulding. Dr Sean Lyons who worked their own staff in new areas, Used in a variety of medical as the centre manager from Lyons adds. “Sometimes Over the past 20 years, devices including catheters 2013, before becoming the companies have the expertise AIT has grown the polymer and electrical cable wrapping, Athlone Institute of Technology in-house but don’t have the research area into an pipe extrusion involves Acting Dean of Engineering bandwidth or time to try things interdisciplinary hub, polymer being extruded into in 2018. out. In other cases, they don’t connecting with the plastics a thin circular tube. Blow “This could be anything have the specific skills or industry across multiple moulding mainly produces from developing materials equipment required, and this platforms on thousands of hollow products, such as for production to working on is where our unique, state-of- projects. bottles, drums and ducts while new production methods and the-art facility really comes into The APT Gateway is injection moulding produces devices. Our facility is based its own.” an important part of the high volumes from all polymers on a factory setting which APT works across all hub, providing polymer in every shape and size. is easily translated into an industry sectors on developing and technology solutions Housing the only dedicated industrial setting. Companies parts for a wide range of for industry in the medical, pilot and industrial-scale can try out ideas using our applications. One of the key composite, recycling and polymer processing R&D pilot production lines without sectors it serves is medtech pharmaceutical sectors. facility in Ireland, APT is having to make a capital where the use of injection APT was funded by equipped with sophisticated investment.” moulding components is very Enterprise Ireland as a analytical equipment as Industry partners gain not common, for example in the gateway in 2013. Last year well as a variety of pilot- only the knowledge they its team of 16 full-time staff scale processing equipment need, but also worked on over 150 projects including injection moulders, the ability with industry ranging from extruders and blow moulders. to train two-hour problem solving “We work hand-in-hand to an 18-month project with industry partners costing €300,000. Areas throughout a project and our covered include design for researchers become part of manufacture, simulation their teams, helping them prototyping, small-scale to solve the problems production, compounding, they are facing,” says pipe extrusion, injection

“ In the area of polymers, PEM is engaged in a lot of work around tool design and tooling for injection moulding for a wide spectrum of industries. Johnson & Johnson, and Abbott Nutrition Dr Sean Lyons, Acting Dean of and Avenue Mould Solutions Engineering, Athlone Institute in Sligo have been partners in of Technology this area.”

2020 Strategy 41 Pictured (from left to right): Dr Brendan Duffy, Centre Manager, CREST; Dr Alan Hernon, Centre Manager, PEM; and Dr Ramesh Raghavendra, Centre Director, SEAM.

development of catheters or parts or getting polymers to interventional devices. stick together better – which “We work with a lot of can often be a problem with large medtech companies on these materials,” says centre improving the performance manager Dr Brendan Duffy. and reliability of components, “We have just finished a or on altering the way project with Sherwin-Williams, they perform for different one of the biggest industrial applications,” explains Lyons. suppliers of paints and “In many cases, we may coatings in the world. But see foreign matter in the equally, we work with small, production process which local companies which have the company can’t identify or come up with an idea and there may be issues in terms want to use an Innovation of the stability of the product Voucher to explore it.” over time.” One such small APT has engaged with company is Dublin-based numerous original equipment Smarter Surfaces, which is manufacturers in the areas of manufacturing and distributing lightweighting and strength paint which turns any optimisation of parts supplied surface into a white board. to the aerospace and CREST carried out a material automotive industries. development investigation Otherwise, APT has on its paint with a view to and trialled on conducted a lot of work on enhancing its functionality and machine parts at APT,” behalf of industry partners capacity to be used with a says Duffy. manager Dr Alan Hernon. in the use of recycled variety of visual aids. “Researchers from the “Projects are focused on not materials in their products and In the automotive sector, Biomedical Manufacturing just embedding a sensor into processes. For example, it CREST has licensed a Technology Centre in South a process, but also trying helped Condron Concrete in technology to C&F Automotive Korea have visited us twice to make sense of the data Tullamore, county Offaly with in county Westmeath, which recently as they are so and how it can bring down the testing and manufacturing is coating trim parts for Volvo, impressed with the Enterprise manufacturing costs.” of recycled plastic for use in its Daimler Benz and Porsche. Ireland Gateways model for Last year, PEM worked on underground piping. “The trim surfaces on car polymer research. There are 26 industry projects ranging in parts in the new Volvo XC60 other examples of research cost from €5,000 to €20,000. are made out of our patents,” centres trying to replicate the It has conducted a total of 100 CREST Gateway notes Duffy. model in South East Asia.” industry projects since it was Through an Enterprise established in 2013. Based in Dublin Institute Ireland Innovation Partnership PEM has a fully equipped of Technology since 2004, project CREST and C&F PEM Gateway engineering tool room further CREST provides coating Automotive developed a sol- to acquiring a high-end five- solutions for industry in the Funded as a gateway by gel coating technology called axis CNC machine, which engineering, construction, Enterprise Ireland last year dualion that was applied to provides more precise and healthcare and biomedical due to its strong track record the company’s aluminium trim. exact cutting capabilities sectors. with industry projects, PEM It is already being used on than the standard three-axis The only dedicated provides a unique industry Volvo’s 2017 models. Volvo is machine used in precision surface coatings laboratory support offering in precision sourcing parts from up to ten engineering. in Ireland, CREST offers engineering, manufacturing other Irish companies. In the area of polymers, expertise in areas such and materials. A spin-out company PEM is engaged in a lot of as protective coatings for Its expertise spans has emerged from CREST, work around tool design challenging environments, precision engineering and which is projecting multi- and tooling for injection surface treatment of metal design, manufacturing million euro revenues over moulding for a wide spectrum components, coatings for process modelling and the next five years. Kastus of industries. Johnson & environment applications and simulation, advanced process creates antimicrobial coatings Johnson, and Abbott Nutrition biomedical devices. monitoring and control and and additives proven to and Avenue Mould Solutions Working on 60-70 projects advanced material synthesis provide 99.9% resistance to in Sligo have been partners a year with industry partners and characterisation. superbugs like MRSA or E. in this area. PEM also covers in various sectors, CREST “While these capabilities Coli. design for manufacture and employs a team of 30 people, are listed individually, we “Kastus’s unique early stage product design. including 14 full-time staff, aim to offer the full suite technology was developed Last year, PEM researchers postgraduate researchers and to partners as industry here at CREST; then was completed an EU-funded academic colleagues. moves more towards the tested in a lab at Shannon project entitled Bio-PolyTec, “A lot of our work is development of smarter tools Applied Biotechnology Centre which has cut the cost focused on coating metal that collect data,” says centre

42 Polymer Technology Ireland of production of medical SEAM Gateway is of particular interest to high weight but high quality.” implants using bioresorbable value added sectors such as In 2015, SEAM formed polymers by a quarter, An Enterprise Ireland funded medtech where implantable a unique collaboration with according to Hernon. gateway since 2012, devices can be made Boston Scientific, precision Bioresorbable polymers SEAM provides innovative customised to the patients engineering company Schivo have key advantages over materials engineering specific needs, for example in and tool manufacturer metal. These include improved solutions for a wide range of orthopaedic applications. Lisnabrin to work on a patient recovery and fewer sectors, including medtech, Each year SEAM’s team of ground-breaking metal 3D follow-up operations. They pharmaceuticals, micro- 15 people work on more than printing additive manufacturing also break down naturally into electronics and industrial 200 industry projects ranging research programme. the body’s system when they technologies. It has served in size from those costing a “We were collaborating with are no longer needed. The over 150 companies to date, few hundred euros all the way the three companies on the main obstacle to wider use 45 of which came from the up to €1 million. emerging 3D metal printing of the material up to now has medtech sector. “Around 30% of our work in technology to understand how been high processing costs. Technological expertise the polymer area is focused on far it would be of benefit to The two-year Bio-Polytec unique to SEAM includes x-ray product design optimisation, them,” says Raghavendra. initiative involved partners microtomography (XMT), finite which involves identifying The project completed in from five nations and was element analysis and metal failures in the process and June of this year with each funded by the EU’s Seventh additive manufacturing. XMT coming up with solutions company finding significant Framework Programme. is used in design verification to prevent problems,” says merits of this technology to “Our contribution involved of product components while centre director Dr Ramesh their business. SEAM began using soft sensors to assess finite element analysis is a Raghavendra. “For example, another 24-month project with whether filler was being computer-based technique a couple of years ago we Boston Scientific in September evenly distributed in the used to analyse engineering used finite element analysis to on metal 3D printing bioresorbable material used in applications and sealing investigate vial integrity and the technology applicable more a device supporting arthritic components to understand factors that influence sealing.” specifically to its business and joints,” says Hernon. their behaviour under a variety SEAM recently entered products. “The new instrumentation of conditions. into an innovation partnership “The new technology and technology we developed This analysis involves finite with APT which is exploring we are developing offers allowed this to be done online, element modeling, which is material identification selection enormous potential to rather than having to wait often used for new component and characterisation for manufacturing industries in until the medical device was design, or to refine an existing gaming mice devices on Ireland,” says Raghavendra. finished to be taken away for product design. The virtual behalf of technology company “It allows streamlining of the microscopic analysis and then environment allows engineers Logitech. “A lot of the time manufacturing process by scrapped if it wasn’t right.” to predict how sealing the selection of materials removing multiple process components will perform in for injection moulding steps, reducing materials real-life applications. components lead to the failure handling and the number of Metal additive of the product identification,” components in an assembly manufacturing enables says Raghavendra. “In the as well as enabling rapid engineers to produce complex case of the medical devices, prototyping of functional customisable components and the materials have to be low metal components.”

2020 Strategy 43 An eye on the EU

Brexit: challenges with solutions

The departure of the UK from the EU represents a profound change for Ireland and Irish businesses.

Ireland’s unique Service exports also play the future could adversely compared to the a central role in the Irish impact on the economy and previous year. exposure economy. These exports are particularly on indigenous This weak export Any change in the EU-UK also exposed to Brexit as the sectors. performance meant trading relationship, either UK accounts for almost 20% that output in traditional through the introduction of of service exports. This is the manufacturing fell by 2% in tariffs or non-tariff barriers, third highest share in the EU, Export performance the second half of 2016, while would impact Ireland more after Spain and Malta. The UK food output fell by 4.3%. than any other EU27 country is the most important market down If this continues it will have due to its unique trade and for transport services, 60% Exports played a huge role in severe impacts on the overall business exposure. The UK of total exports. It is also an our economic recovery, but economy as these sectors accounts for 14% of Irish important market for travel 2016 saw a slight slowdown spend a higher proportion goods exports, the highest and financial services exports, in this growth. In 2016 the of turnover on wages and share of any European country which represents roughly 30% exports of goods and services intermediate purchases than and double the exposure of of these exports. grew by 2.4%, the weakest other sectors of the economy. the EU as a whole. performance since 2008. Ireland’s exposure to the Headline figures do not, UK is even higher for imports, The impact of Brexit however, capture the more Brexit toolkit – as 32% of goods imports Is already being felt significant impact of Brexit What’s ahead in come from the UK. This is to date on exposed sectors, more than three times the Given that Ireland is so even before the application of manufacturing? share of the next highest exposed to the UK, the any potential tariff or non-tariff Irish manufacturing in 2015 country, and much higher than weakening of sterling that trade barriers. had a net sales value of the EU average of only 4%. If happened in the later part While goods exports €52.6 billion, excluding tariffs were placed on these of 2016 had a significant increased by 5%, if chemicals the pharmaceuticals and imports, it would put upward impact. While sterling has and electrical equipment are food sectors, contributing pressure on the overall price strengthened in 2017, the excluded, exports actually to 21% of Irish GDP. There level and would increase negative movements at the fell by 3%. Food exports in are 14,600 manufacturing business costs as many of end of last year highlight particular saw a significant businesses in Ireland these imports are used as just how exposed Ireland is decline, as these exports to employing 230,000 people. intermediate goods. and how greater volatility in the UK fell by 5.3% in 2016 Indigenous manufacturers

44 Polymer Technology Ireland account for 23% of total Irish Key Brexit manufacturing turnover. Certain Irish sectors impacts for the are over-reliant on the UK manufacturing market. Cheaper sterling sector has already increased competitive pressure for Irish Weak Sterling: Weak sterling manufacturers exporting to the makes Irish goods more UK. In 2015, Ireland exported expensive in the UK and UK €15.6 billion (13.9%) of substitutes are more attractive goods to the UK. The largest to UK businesses. three manufacturing sector goods exported to the UK Interlinked supply chains: were: medical products (€1.5 Non-tariff barriers will billion); organic chemicals introduce new costs and time (€1.0 billion); and essential delays for Irish manufacturers oils, perfume materials with interlinked supply chains (€0.8 billion). UK and Irish across the UK and Ireland. manufacturing industry supply chains are tightly integrated, Capability gaps: The both between the Republic introduction of trade barriers and Britain and north-south on will require Irish manufacturers an all-island basis. to invest in capabilities to fill Pictured above: Ibec CEO Irish manufacturers have gaps in trade experience. Danny McCoy met with British already undertaken extensive These capabilities may be Prime Minister Theresa May as scarce and in high demand part of a delegation of key EU cost-cutting over the last 10 businesses federations. years and continue to operate following Brexit. on tight margins. Irish SME manufacturers rely heavily on Investment decisions bank funding and particularly paused: Investment decisions short-term funding. are being put on hold as a result of Brexit uncertainty

2020 Strategy 45 An eye on the EU

Access to finance: Brexit- to switch to notified bodies in The voice of n Ibec CEO Danny McCoy based uncertainty may other EU countries to retain meets British Prime cause a slowdown in the UK Single Market compliance. Irish business Minister Theresa May economy, reduce demand Ibec has been working to and Brexit Secretary for Irish exports and in turn Over-reliance on UK ensure that Irish business David Davis in Downing make lenders less inclined to market: Some Irish concerns are heard at both street, as part of a support Irish business. This manufacturing sectors domestic and EU level as delegation of key EU risk is particularly relevant for are overly reliant on the well as providing support to business federations, 13 Irish SME manufacturers. UK market. This makes members while navigating November 2017 them more prone to Brexit Brexit uncertainty. n Ibec hosts the House FDI opportunity: The UK’s impacts and makes business Ibec’s Brexit campaign loss of Single Market access planning harder. Irish SME of Commons Foreign recent engagements and Affairs Committee as may make Ireland a more manufacturers are more activities include: attractive location for FDI. exposed to this risk than part of their Brexit international businesses with n Brussels launch of Ibec fact-finding mission to Financial trade barriers: The Irish operations. Brexit priorities paper Dublin, 17 November introduction of tariff and other ‘Brexit: challenges with 2017 tax barriers may increase the New market entry: With solutions’, 12 July 2017 n Ibec CEO Danny McCoy cost of Irish manufacturing so many uncertainties in n Meetings with Task addresses the House exports to the UK. It may the UK, Irish manufacturers Force 50, the EU of Commons Select also increase the cost of UK are assessing how they Commission Brexit Committee on Exiting imports into Ireland, impacting could enter new EU and negotiating team and the EU, 25 January both finished and unfinished international markets. Irish the Irish Permanent 2018 products. business, particularly small representation in n Ibec CEO Danny McCoy firms, have limited experience Brussels, 13 July 2017 Divergent standards: in developing other channels addresses the House of Regulatory divergence from in new markets, and it can n Ibec hosts a breakfast Lords Select Committee EU standards may require typically take 3-5 years. at the Irish embassy on the EU, 30 January Irish manufacturers to meet London with Political 2018 new UK standards. This could Competitiveness: Irish and business increase costs and complexity manufacturers are assessing stakeholders to highlight to produce for Irish business. whether operating in both the key concerns of Irish Divergences could include the UK and the Republic will business, 20 October new content, labelling and remain viable following Brexit. 2017 process requirements specific Moving production to the UK n Launch of the Ibec to the UK. may limit heightened currency Brexit tracker, providing and trade risks of serving the a quick snapshot of Switching notified body: UK market. This will be more progress in negotiations Medical devices must adhere difficult for SME businesses to date in key areas, 23 to stringent EU regulations. as the investment and skills October 2017 Regulators, known as notified required may not be easily bodies, ensure products meet accessed. required European standards. Irish producers with approvals from UK regulators may need

46 Polymer Technology Ireland Medtech regulations, a landmark for EU manufacturers

his marked a new With the new regulations After five years of phase for medtech come significant changes for and contract these sectors not least among manufacturing them changes to vigilance negotiations, the businesses with the and post market surveillance Ttransition period commencing where manufacturers will now European Commission and the new rules coming fully be required to collect post- into effect by the end of May market clinical data as part 2020 for medical devices and of their ongoing assessment published the Medical May 2022 for IVDs. of potential safety risks and Over the coming years, there will be reduced reporting Device Regulation smooth implementation of timeframes. the new regulations is a top The new regulations will priority for these sectors be much more prescriptive (MDR) and In vitro which have already begun about the required content to collaborate with key of technical documentation, Diagnostic Medical stakeholders to achieve this. particularly as there are more Resources are the key detailed requirements for issue of the moment, in quality management systems. Device Regulation particular, the need to apply The new MDR will require new resources to support more clinical evidence and (IVDR) in 2017. designation of notified bodies clinical evaluation in proportion under the new MDR/IVDR as to the risk associated with a early as possible during the given device. transition period.

2020 Strategy 47 An eye on the EU

48 Polymer Technology Ireland Significant changes are 1. Clinical Evaluation and to implement the new also looming for labelling, UDI Clinical Investigation regulations and clarify the new and transparency. Certain (MD), Performance governance system (ii) ensure products have received special Evaluation and the availability of notified consideration in the MDR and Performance bodies early in the transition are subject to re-classification. Studies (IVD) periods and (iii) ensure that all These new provisions will stakeholders have a consistent 2. Scope and apply to cosmetic implants, interpretation for the transition Classification standalone software, products periods, to ensure effective without an intended medical 3. Notified Bodies implementation. purpose, certain spine and Conformity Manufacturers cannot products and reusable Assessment underestimate the time that Class 1 devices. will be required to implement For the IVD sector in 4. Post-Market the new MDR and IVDR. The particular, the new IVD Surveillance and major challenge is that some Regulation represents a Vigilance underlying details are not fundamental legislative change 5. Eudamed and UDI fully defined yet and will only with new or major shifts in become clear as secondary areas such as the classification 6. Market Surveillance legislation emerges over the system, performance 7. IVD-specific Issues coming months and years. evaluation and clinical It is important that evidence and conformity 8. Over-arching and manufacturers closely follow assessment of IVD’s. Cross-cutting these developments and Recently, the European Priorities. the implementing acts. A Commission and competent proactive approach to dealing Pictured at the Global authorities consulted with However, the European with the challenges ahead Access conference: stakeholders to develop trade association, MedTech will be hugely important for Tony Keaveney, Merit an official implementation Europe, has called on the the sector and can help Irish Medical Systems; European Commission Áine Fox, Irish Medtech roadmap. It identified eight manufacturers better compete Association; and Robbie priority areas: and Member States to: (i) by getting a head start. Walsh, Boston Scientific. invest necessary resources

2020 Strategy 49 An eye on the EU Competitive advantage

n order to remain Ireland is putting a lot of effort A strong focus on competitive in light of into helping them to diversify Brexit, companies in the beyond the UK as a way of Irish plastics industry need protecting themselves from any the supply chain to ensure they are as potential ill effects from Brexit. Ilean as possible in terms of “It is very important now that and maximising operations, as well as actively companies carry out a market looking at supply lines and opportunity review and seek sourcing raw materials to their out new opportunities, such operational efficiency best advantage. as in the Nordic countries, the This is particularly true Benelux region, France and will help companies for companies selling plastic Germany,” says Kelly. parts into the automotive He cites Mergon as a sector in the UK, as this is good example of an Irish in the Irish polymer where competition can be company with a well dispersed very strong, according to Tom marketplace and a good technology industry Kelly, Head of the Industrial, differentiation strategy. Life Sciences and Consumer “Mergon is one of Ireland’s division at Enterprise Ireland. leading manufacturers with to navigate their way “The strategy around supply a reputation for excellence, will be very important into the reliability and innovation. It through the Brexit future,” he says. “Companies supplies into the industrial, need to position themselves healthcare and automotive so they are perceived as key sectors. It’s customers include phase. suppliers, for example, by a host of global blue chip differentiating themselves in companies.,” notes Kelly. terms of design or innovation. “Lean business practices They need to actively find are also important for all types the right solutions for the of companies in the plastics Tom Kelly, Head of the Industrial, Life Sciences and Consumer companies they are serving.” industry, from those which division at Enterprise Ireland; As well as encouraging make plastic sheeting, the ones John Power CEO Aerogen and plastics companies to have a that take in polymer material Minister of State Pat Breen, TD. strong proposition, Enterprise in flake form and process it to those that make components or parts,” says Kelly. Enterprise Ireland has supported a total of around 1,000 companies from various sectors through its lean programmes to date. “These programmes have been remarkably successful and the companies that took part have made significant savings as a result of them, as well as establishing practices of continuous improvement. Lean is an important part of Enterprise Ireland’s wider approach to improving the competitiveness of companies.”

50 Polymer Technology Ireland What does the Circular Economy hold for plastics?

The European Commission launched the Circular Economy Package, in December 2015. The circular economy package seeks to maintain the value of products, materials and resources for as long as possible in the value chain.

What is the How will it affect the Circular Economy? plastics sector? The aim of the circular The circular economy package economy package is to move highlights the plastics sector us, as European citizens, from as a priority area. The sector a buy-use-dispose lifestyle will face specific challenges to a society where items are in Europe’s transition to a designed with easy dismantle circular economy, because after use in mind and therefore of the specificities of the the parts can be reused products or value-chains, the again and again. This will be environmental footprint or achieved though changes in dependency on material from product design, consumption outside Europe and waste management. As part of the circular The circular economy economy package, the EU package is a suite of tools is revising the current waste including an action plan, the legislation. New waste development of strategies for directives will be adopted in specific issues, the revision of Spring 2018 which set the the EU waste directives and following targets: the setting of targets up to 2025, 2030 and 2035.

Anne Murphy, Green Business Executive, Ibec

2020 Strategy 51 The Circular Economy

Production

From waste to resources

Waste Consumption management

The aim of the circular economy package is to move us, as European citizens, from a buy-use- dispose lifestyle to a society where items are designed with easy dismantle after use in mind and therefore the parts can be reused again and again.

52 Polymer Technology Ireland n Re-use/recycle 65% n The low rate of reuse review is regarded as one of municipal solid waste and recycling of plastic of the most important with by 2035 (compared to other regards to the success of the waste streams) due to Circular Economy package n Reduce landfill to max. quality issues; as the European Commission of 10% of municipal need to identify how to waste by 2035 n New sources of plastic increase recycling and re-use leakage such as n Re-use/recycle 70% of plastics while protecting microplastics which are of all packaging waste human health, product unintendedly released by 2030 safety, comply with REACH into the air, land and regulations and ensure that water ways; n Re-use/recycle 55% EU producers are not at of plastic packaging n Uncertainty over the fate competitive disadvantage. waste by 2030 of much waste plastic Barriers to increasing exported to the Far East; recycling rates and re-use of In addition to the above materials have been identified targets, in January 2018, n The growing by the European Commission. the European Commission consumption of single- These issues include the published A European use and short life chemical composition of Strategy for Plastics in a plastics; recycled plastics; lack of Circular Economy. The n Unacceptably high information about the possible “Plastics Strategy”, aims to volumes of plastic waste presence of chemicals of help all players in the plastic that end up littering the very high concern; incidental production chain in the environment, particularly contamination during the transition to ensuring that all in sensitive marine recycling process; ensuring plastic packaging is reusable ecosystems. there is a level playing field or easily recyclable in a cost- between EU-produced and effective manner by 2030. The plastics strategy aims imported articles. While recognising the to boost investment in the These uncertainties unless contribution of the plastics plastics sector and promote addressed could discourage industry to Europe’s future well-regulated markets for demand for recycled plastics economic prosperity, the secondary raw materials. in new products with specific plastics strategy seeks to Quality standards and new safety requirements and thus address the inter-related guidance for sorted plastic create a significant obstacle problem areas: waste and recycled plastics to achieving higher recycling n The plastic sector’s will also be developed. rates. An EU wide public continuing high In addition to the plastics consultation seeking views dependence on virgin strategy, the European on the issues identified will be fossil feedstock for Commission is currently open in early Summer 2018. producing polymers; reviewing the relationship Ibec will continue to work with between chemicals, products member companies on this and waste legislation. This important issue.

“ The plastics strategy aims to boost investment in the plastics sector and promote well-regulated markets for secondary raw materials.”

2020 Strategy 53 An eye on the EU Plastics in Europe, contributing to welfare

PlasticsEurope is one of the leading European trade associations with centres in Brussels, Frankfurt, London, Madrid, Milan and Paris.

he European plastics industry makes a significant contribution to the welfare in Europe by competitive Tenabling innovation, creating approach to the challenges PlasticsEurope and its plastics industry, that offers quality of life to citizens and we face today. PlasticsEurope members are committed an impressive range of facilitating resource efficiency is proud to have in Polymer to contributing to achieving suppliers, processors and and climate protection. More Technology Ireland a strong a circular and resource service provides to contribute than 1.5 million people are and reliable partner. efficient economy and we see to make its voice heard at working in approximately This year, the European innovation as being at the core the European level, providing 60,000 companies (mainly Commission launched its of the Plastics Strategy. continuous input into the small and medium sized “Strategy on Plastics in the Innovations made by, from development of EU policies, companies in the converting Circular Economy”, supporting and with plastics account for including the Strategy on sector) to create a turnover a shift to a more circular many of the advances that Plastics. This will be a unique above 340 billion EUR per economy as an alternative society is benefiting from opportunity to recognise the year. The plastics industry to a linear economic model. today. The role of innovation importance of plastics in our includes polymer producers This offers the opportunity becomes more essential than daily lives and contribute to represented by PlasticsEurope to maximise the utility of ever if we want to achieve an address global challenges and converters represented resources by retaining increasingly circular European such as marine litter and by EuPC and machine the value of goods for as economy. We must cultivate waste management. manufacturers - represented long as possible within the the breeding ground that We are confident that the by EUROMAP. economy; describing how encourages, stimulates and ambitious Polymer Technology Throughout the European this can help make Europe’s accelerates innovation to Ireland 2020 Strategy will Union, PlasticsEurope economy sustainable, deliver the desired solutions. highlight how Irelands industry engages with national plastics low carbon, resource To make it happen, innovation will secure its role as important associations to strengthen the efficient and competitive. has to be focused. EU Member State and voice of the plastics industry Plastics are among the key We look to Ireland with contribute to the overall efforts and to ensure a coherent enabling materials. Indeed, its dynamic, innovative and by the European Union.

Pictured above is Kim Christiansen, PlasticsEurope Regional Director

54 Polymer Technology Ireland EuPC the voice for plastics convertors in Europe

The European plastics industry makes a significant contribution to the welfare in Europe by enabling innovation, facilitating resource efficiency and creating jobs.

ith plastics with a priority on plastics. EU wide survey on the “Competitiveness of the converters at This, in turn, has led to current and future use of European Plastics converting the heart of the the revision of the waste plastics recyclates in Europe, industry” together with the plastics industry legislation, comprising the available for all Members. consultant Dr Wieselhuber thanks to their Waste Framework Directive, This first ever EU survey, & Partner (W&P), focused Wadaptability, durability and the Packaging & Packaging initiated during the EuPC on the assessment of the light weight making them a Waste Directive and the General Assembly in Madrid industries’ current and future favourite in the construction, Landfill Directive, together last June, is a very important level of competitiveness so packaging and automotive with the proposal to launch a tool to provide more insights to present issues currently industries amongst others. European Plastics Strategy. for the EU plastics Strategy. faced by the industry. More The latest developments These activities have This survey is the first of a recently, together with other in the field of the European required EuPC to provide larger set of initiatives to get European Associations Circular Economy Package input to relevant institutions more knowledge about the representing all kinds of and the need for a clear by identifying barriers use of rPM in the plastics manufacturing industries, European industrial agenda and challenges to the converting industry across EuPC has signed the Joint have seen many Brussels circular economy in the Europe. Further surveys and Reaction Paper “For an stakeholders active and chain and formulating workshops with national ambitious EU industrial especially EuPC, as the recommendations both plastics associations are strategy: going further”, main interlocutor for policy for the sector operators expected to follow in 2018 in order to call on the makers on behalf of the and policy makers during and beyond. Commission to come up with plastics converting industry all the different moments Moreover, in the context an ambitious EU industrial in Europe. of dialogue with European of economical strategies strategy to maintain industrial The Circular Economy Commission and Parliament. and the need to have a true jobs in Europe and allow the Package has come with In particular, for the EU industrial agenda, EuPC EU to remain a competitive many sectorial actions Plastics Strategy, EuPC has has published in June 2016 global industrial power and regulation proposals, launched a very important an industry study on the playing in a fair world market.

Alexandre Dangis, Managing Director, EuPC

2020 Strategy 55 Notes

56 Polymer Technology Ireland Ibec is Ireland’s largest lobby group representing Irish business both domestically and internationally. Its membership is home grown, multinational, big and small, spanning every sector of the economy. Together they employ over 70% of the private sector workforce in Ireland. Ibec and its trade associations lobby government, policy makers and other key stakeholders nationally and internationally to shape business conditions and drive economic growth. It has over 230 professional services staff in seven locations including Brussels and has 42 different trade associations in the group. Polymer Technology Ireland 84/86 Lower Baggot Street Dublin 2 T: 01 605 1500 E: [email protected] @PolymerTech_Irl www.polymertechnology.ie