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Cutting-edge technology

A ContiTech innovation is among the strongest timing belts in the world Steel cords keep products by the ContiTech ­Conveyor Belt Group especially stable Editorial_3

Dear reader,

Around the world, technological achievements drive economic and social about. ­‘Engineering Next Level’ is also the motto of our exhibition stand at the development. They enable us to make progress and improve our lives. ­HANNOVER MESSE trade fair. Come and see us in Hall 6! ­Gutenberg gave us the printing press; James Watt gave us steam engines; Thomas Edison invented electric light, and Carl Benz started the success When we talk about ‘Engineering Next Level’, we are referring to the high- story of the automobile. But did all these inventions simply come about by quality innovations we bring to market as quickly and efficiently as possible, coincidence? No. Innovations don’t happen by chance; they come from a pio- but also to the superlative service we provide for our customers at locations neering spirit, materials and process expertise, and outstanding teams in around the world. organisations. And that’s exactly how things work at ContiTech. This is how we became the world’s leading specialist in natural rubber and plastics. We One factor designed to support us in this is the merger we’ve initiated between give our 28,000+ employees plenty of scope to take responsibility, and in the ContiTech Group and plastics specialist Veyance Technologies. This will doing so we stimulate them to develop a culture of ideas that is as yet in allow us to complete our presence in countries such as the USA and South a league of its own. This is true not just true of ContiTech but of the whole America, where we are currently under-represented. Moreover, by extending of the Continental Group. Across our divisions and business units, we work and enhancing our product and service range, we will be in a position to offer together closely to find the best product or system solutions. our customers even more advantages – all from a single supplier.

Often ideas generate innovations. But for an innovation to be a success, it I hope you enjoy this edition of ContiTech initiativ. must be needed. This is why we closely observe technological and social Happy reading! trends. What is it that moves people – today and in the future? And what will our next important steps be if we want to continue working with our Best regards partners to develop innovations that meet people’s needs and are ready for the markets? In this edition of ContiTech initiativ, we take a closer look at what our company is doing to encourage purposeful innovation manage- ment. We also find out how foresight can help us develop efficient products with special material characteristics that meet the most specialised chal- Heinz-Gerhard Wente lenges. That’s what our guiding principle of ‘Engineering Next Level’ is all CEO of the ContiTech division In this issue

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ContiTech. Engineering Next Level The ContiTech Group’s new guiding principle Innovations made by ContiTech Under the guiding principle of Engineering Next Level, the The experts that make up the ContiTech innovation team ContiTech Group is working more consistently than ever to encourage development and push forward innovation across meet the needs of customers today and in the future. The the company. Frank Stünkel, Head of International Sales and technology leader in natural rubber and plastic products keeps Communications, spoke to three innovation managers from a close eye on the individual requirements of clients in the the team to find out what ContiTech is doing to drive progress various markets.______Page 6 in this area. ______Page 16

Teamwork for peak performance Research for progress Extreme performance and impressive dimensions make the Around the world trends in production and methods, such as ContiTech Transmission Group’s CONTI® SYNCHROCHAIN lightweight construction, downsizing and safety, are placing CARBON a top player among timing belts. At almost five metres new and ever tougher demands on materials. ContiTech is long and 22 centimetres wide, it transmits 315 Kilowatts of capitalising on its comprehensive expertise in natural rubber power onto the drivetrain of a high-performance shredder by a and plastics technologies and inspiring a wide variety of company called UNTHA. ______Page 8 industries. ______Page 22

Inner warmth Engineering dreams straight down the line An innovative heating system based on a conductive paste by To offer its customers the best possible solutions, the Benecke-Kaliko has numerous advantages over conventional ContiTech Conveyor Belt Group is setting new standards in alternatives. Being especially fast and efficient at heating up, belt development. Its specialist conveyors can now transport this covering material is ideal for incorporating into electric glowing furnace slag at up to 600°C. ______Page 36 cars, where power reserves need to be used sparingly. ______Page 14 16

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People and markets Dynamic economic partnership Right up to the limit The Netherlands are the home of famous artists such as Le Dakar is by far the best-known and most treacherous long- Rembrandt and Vincent van Gogh, and famous for their tulip distance rally in the world. It’s a tough test of endurance for fields. But that’s not all. For companies like the ContiTech human and machine. Both must stand up to the rigours of the Group this partner country of the HANNOVER MESSE 2014 9,000-kilometre journey for the entire 14 days of the race. It’s trade fair is an important strategic business partner. ______Page 26 an adventure ContiTech customer Iginio Voorhorst was not about to miss. He followed his teams at Le Dakar 2014, with

Rooted in Germany, at home in China ContiTech Air Spring Systems as a sponsor. ______Page 40 International manager, experienced engineer and long-standing China expert Uwe Wüst has taken over the helm of the Benecke- Kaliko plant in Zhangjiagang, eastern China. ______Page 32 Et cetera The latest from the world of ContiTech ® Technology and trends Conti Thermo-Protect conquers the seas ______Page 35 High-performance 20,000 times a week ______Page 35

Nanotechnology – present and future Acquisition to strengthen industry business ______Page 45 Written by Professor Andreas Leson, Deputy Director and Head of Department at the Fraunhofer-Institut für Werkstoff- und News in brief

Strahltechnik in Dresden, Germany, this edition’s guest article Other stories from the world of ContiTech ______Page 45 offers a glimpse into the world of nanotechnology. ______Page 24 Imprint ______Page 45 ContiTech. Engineering Next Level The ContiTech Group’s new guiding principle

Open for new perspectives: Advancing technologies through trend-watching ContiTech. Engineering Next Level_7

he guiding principle of Engineering Next Level will see the ContiTech Following the principle of locality, ContiTech is establishing its research Group with its eight divisions focus more closely than ever on the and development knowledge directly in the relevant markets through increasing demands of its customers and the individual needs of decentralised facilities that allow it to cater to cultural differences when Tpeople in markets around the world. And the company knows exactly which configuring products. For instance, ContiTech is able to help car manu- social changes and technical trends it needs to respond to. As an innovation facturers develop global platforms on virtually every continent. This too and technology leader in rubber and plastic products, ContiTech is commit- is a key step up, a next level of progressive thinking and acting, and deliv- ted to developing and supplying innovative products and services. In doing ers high-tech products for current and future generations that really are so, it often comes up with cutting-edge technologies, which are rooted in the needed locally. group’s long-standing materials expertise in developing components and sys- tems that suit the markets and will help ensure the future viability of partners. The ContiTech Group is now a global player, who, as a driver and source of ideas and inspiration, stands for new technologies and progress. It is “We aim to deliver first-class quality and sustainable solutions for the current consequently growing in the relevant markets – in two main ways: first and future needs of our customers and of people around the world. Innova- by cultivating these markets with great skill, and second by entering tive strength, technological know-how and materials expertise are corner- into partnerships, making acquisitions and establishing joint ventures. stones of our work as we actively operate in partnership with each other. We In addition, all of its divisions are consistently expanding their services want to grow profitably in relevant markets and industries, and that means in close proximity to the customer, for more intense and better-quality striving to be the best, not the biggest! To make sure that happens, we’re partnerships. investing in new plants and sites around the world, but also in research and development and in training for our staff. We are right where our customers “Doing the right thing at the right time for people, together – that’s what need us,” says ContiTech CEO Heinz-Gerhard Wente explaining the vision drives us and makes us a successful team,” says Heinz-Gerhard Wente. << behind Engineering Next Level.

All the while environmental and climate protection, responsible use of resources and social responsibility remain key elements of our corporate policy. ­ContiTech at the HANNOVER MESSE Around the world demand for a higher quality of life is escalating, which in turn heaps more pressure to innovate onto leading companies in the automo- Under the slogan “Integrated Industry – NEXT STEPS”, 7 to 11 April tive and many other core industries. The rapid growth of cities, for example, 2014 will see the HANNOVER MESSE present future-oriented tech- represents a challenge to the global economy, and by keeping a close eye nologies from the world of industry and solutions for the intelligent, on change as it happens, ContiTech is often able to implement innovations networked factory. early on. We respond not only to the need for safety, function integration or lightweight construction but also to legal guidelines, which every country “Engineering Next Level” will be the theme of ContiTech’s campaign specifies individually. When it comes to environmental and climate protec- in Hall 6, booth F18 at this year’s event. The innovation leader in rub- tion, rubber and plastics specialist ContiTech has already come up with many ber and plastics technology will be showcasing its products and ser- perfectly tailored solutions. vices for its partners from industry and for the needs of people and markets on over 500 square metres of floor space. As the name suggests, Engineering Next Level will see ContiTech systemati- cally and judiciously using its materials and process expertise to take things Visit us at the HANNOVER MESSE. up a notch – in every respect. One keyword here is composite materials, To sign up for your personal e-ticket go to: which vastly improve product characteristics. Extensive expertise in this http://www.hannovermesse.de/ area is just one of the reasons why the company is often a preferred devel- ticketregistration?Rfrqxcds9ywz4g opment partner. Teamwork for peak performance When ContiTech teams up with customers to develop a product, the result is usually something quite special – like the strongest PU timing belt in the world. The TR3200 shredder is as powerful as a semi-trailer truck. That’s why it is absolutely vital that the ContiTech Power Transmission Group’s timing belt is perfectly adjusted 10_ContiTech. Engineering Next Level

hen it comes to heavy-duty polyurethane timing belts, the culated the position, length and thickness of its integrated carbon-fibre ten- CONTI® SYNCHROCHAIN CARBON is in the top league. With sion members. The first prototype belts soon made their way to Austria – but tension members from carbon, it can transmit extreme trac- it was perfectly clear to everybody involved that this was just a first important Wtion forces, with outstanding performance and durability guaranteed. But an and positive step on the road to series maturity… enquiry from Kuchl, in the Austrian state of Salzburg, presented the ­ContiTech Power Transmission Group with a new challenge: A company called UNTHA, Highest specifications which produces industrial shredders, was looking for a drive belt for its high- A conversation with Christian Lanner provides clarity over why UNTHA performance flagship model, the TR3200. The belt would have to transmit chose ContiTech to supply the heavy-duty belt it needed. Describing the 315 kilowatts to the enormous machine’s drive train to enable it to process incredibly tough requirements on industrial shredders like the TR3200, up to 15 tonnes of domestic waste per hour. the company’s Head of Product Management says: “Most of our machines work in the open air or unheated halls across various continents around Teaming up for development the world. In Guatemala temperatures can reach 45 degrees Celsius or At five metres in length and 22 centimetres more, while in Scandinavia our machines have to across, the belt they were looking for “was way work at 20 degrees below zero.” But irrespective beyond anything we had in our portfolio at the “In a project like this of climate differences, shredders have to be sure time,” recalls Axel Thor, Sales Manager with it’s essential for everybody to deliver the tremendous forces needed to tear ContiTech Austria in the town of Wiener Neudorf. to pull together.” materials of any kind into pieces no larger than Responsible with trading partner ­Synchrotech 30 millimetres – small enough to fall through Antriebstechnik GmbH for taking care of cus- Axel Thor, ContiTech the perforated screen in the machine. In prepar- Sales Manager, Wiener Neudorf, Austria tomers in the Alpine republic, Thor passed the ing household refuse for heat recovery, materi- request from Kuchl on to the team at the Power als are first pre-shredded and sorted. The next Transmission Group. stage of processing falls to secondary shredders like the TR3200. “After that, granulates can be used as fuel,” Lanner explains. As a source of The first part of the task was in itself a hefty challenge – in the truest sense power, granulates from waste are particularly beneficial to more energy- of the word: The mould used for making the belt weighs in at a respectable intensive industries, such as cement production, as they save oil, gas, five tonnes! Used to manufacture the full length and width of the belt in one coal and other fossil fuels, and consequently help protect the environ- single piece, the steel form had to be created especially for the purpose. It ment. Treated waste of this kind also benefits waste management compa- was then taken to Dannenberg, in the German state of Lower Saxony, where nies, as EU landfill guidelines coming into force in many European coun- an experienced team devised appropriate production methods, defined the tries allow domestic refuse to be deposited in landfills only in exceptional ideal formula for the polyurethane (PU) from which the belt is made, and cal- cases, or indeed not at all. >> A well-rehearsed team: (from left to right) Manuel Spanner Sales Engineer with SynchroTech Antriebstechnik, Paul Gschaider, Head of Purchasing & Quality Management with UNTHA, Christian Lanner, Head of Product Management with UNTHA, and Axel Thor Sales Manager with ContiTech Austria 12_ContiTech. Engineering Next Level

Absolute precision for extreme loads – that’s the concept behind the CONTI® SYNCHROCHAIN CARBON >> ContiTech. Engineering Next Level_13

Before the new high-performance belt could finally go into operation, it had to undergo rigorous testing. The specialists in Kuchl and Dannenberg used all their expertise to ensure the CONTI® SYNCHROCHAIN CARBON belt was able to resist the forces it is subjected to.

Fine-tuning for top results To protect the belt during prolonged use, the engineers at UNTHA decided to modify the drivetrain of their shredder. “While we were testing, we decided to replace the shear pin couplings we’ve used until now with a shift segment coupling,” Christian Lanner explains. “The new coupling is far more precise, so if the machine is operated incorrectly or overloaded, it prevents the belt from being damaged.”

When it came to putting the finishing touches to their product, the spe- cialists in Dannenberg remained ambitious. “During this final stage our people managed to make the tension members even stronger and inte- grated additional carbon fibres into them,” says sales expert Axel Thor. Along with Synchrotech’s Manuel Spanner, he was in constant contact with both the customer and production at ContiTech throughout. After months of testing and fine-tuning, the world’s strongest PU timing belt finally reached series maturity.

Good prospects Collaborative development work for this product has been a worthwhile undertaking for all sides. Our ContiTech belts are currently driving 35 machines around the world – and numbers are rising all the time. “At the moment our most important markets are the UK and Poland,” announces UNTHA’s product manager Christian Lanner with delight. He is also look- ing ahead to a bright future, as the product is expected to sell especially well in eastern and southern European countries, where the implementa- tion of EU landfill guidelines is firmly on the agenda.

Axel Thor is among those who are highly satisfied with international col- laborations on this project. He is full of praise for cooperations with the customer. “For ContiTech this is a success story, without doubt,” he says. Not least because “UNTHA has already indicated that they intend to fit more machines with our belts – wood shredders, for example.” <<

Contact: Axel Thor, [email protected] Inner warmth Benecke-Kaliko is developing a polymer-based based paste that can be integrated into surface coverings and used to heat cars ContiTech. Engineering Next Level_15

e’ve all been there: It’s the middle of winter, you get into and other components. It is applied by simple screen-printing. “In principle, your car – and you freeze! It takes a good, cold while before applying this paste is like printing a motif onto a T-shirt. It’s applied to the the engine actually manages to blast some warmth into the material with a roller and in whatever pattern or thickness is required. The Wair system. For combustion-powered passenger cars all this is perfectly customer is free to choose exactly which sections should be heatable and normal. But for state-of-the-art, super-efficient electro-mobiles it’s a prob- to what degree. Our developers have managed to come up with a substance lem – because an electric motor doesn’t generate the usual waste heat of that hardens after it has been put in place but loses none of its elasticity,” a combustion unit. “The fact is that in an electric car the heating is the explains Bühring. greatest additional power consumer. It normally takes up to three kilo- watts of power input to heat the car at all. In one where the battery pack Plenty of extra comfort in the car has an average capacity of 16 kilowatts and is susceptible to the effects The potential of this innovation extends far beyond the realms of electric of the cold anyway, heating will exhaust energy supplies in the blink of an mobility. Drivers of diesel and petrol-powered cars also stand to benefit from eye. Anyone driving off on their skiing holiday in a reasonably warm car it, as conductive covering materials are just as useful for conventionally pow- will need to stop for a re-charge after just 80 kilometres rather than the ered cars. What’s more, vehicle buyers can choose exactly which parts of usual 200,” explains Dr Alexander Jockisch, Head of Business Develop- their car-seats they want to have more heat in – a real blessing for anyone ment & Marketing with Benecke-Kaliko, describing the challenge of finding with a back problem. And not just in winter. Controls and mobile apps mean an innovative solution. settings can be adjusted very easily.

So drivers face a choice: Either they do not heat their car, or they stop to Technology ready for take-off charge it up more often. Automotive producers are working flat out to find Already developed to series maturity, the new technology is now ready for a solution but have not yet managed to develop one to series maturity. use. Because it is integrated directly into the covering material, no extra pro- More­over, all the approaches that have been tried until now only reduce cess is needed to apply it. Instead it is integrated straight into the covering energy consumption, meaning many current solutions consist of fuel-pow- material during manufacturing. Unlike the solutions on offer so far, the new ered supplementary heating systems, which have a negative impact on the paste also requires no modifications or additions. It is wired up to the circuit car’s CO2 credentials. by conventional means and connected to the onboard network via a standard plug. “The advantages for automotive producers are obvious. They get an Simply ingenious – ingeniously simple innovative feature that not only supports energy efficiency in electric cars but Benecke-Kaliko has now come up with a solution: a conductive, spread- also satisfies occupants by delivering the comfort and wellbeing they need – able, polymer-based paste that is easy to integrate into the kinds of sur- which is a key point when it comes to buying a car.” face materials found in car interiors. What’s special about it is that it is conductive and can produce heat without even an inch of heating wire. Much more than just warmth in the winter This innovation has three major advantages over conventional systems: Given the fact that this integrated heating material is suited to any size of First of all, it uses far less energy to reach pleasant, warming temper- vehicle, its market potential is excellent. In 2013 alone more than 60 million atures. Rather than requiring three or more kilowatt hours of energy, it new cars were registered around the world. The innovative paste is just about takes just 300 Watts and heats only those surfaces that come in direct set to be piloted – and already the team at Benecke-Kaliko are researching contact with vehicle occupants. Second, it responds immediately. Being other potential applications that capitalise on the product’s qualities. These directly beneath the surface of the covering material, it takes just a few include touch-sensitive sensors and switches that are integrated into covers seconds to radiate heat a distance of two or three centimetres. Third, the and surfaces – in cars or elsewhere. “Trucks, agricultural and construction paste can be applied to any shape of heatable covering material – unlike machinery, trains, planes… this technology can be used in a very wide range conventional heating mats based on metal wires and carbon fibres, which of contexts. And who knows? Some day you might even find it where you have a fixed shape. In fact, Benecke-Kaliko’s heatable paste can be used would least expect it. There are plenty of ways our surface heating could be to warm almost any interior component, from seats, steering wheels and used in a domestic context,” says Alexander Jockisch, considering another armrests to door trim panels and foot mats. possible step towards a simpler life. <<

“For us the challenge was to find a material that conducts electricity, uses minimum power and is flexible enough not to break,” says research man- ager Dr Jürgen Bühring, describing the project. At the end of the develop- Contact: ment process the team had come up with a paste-like substance that can Dr. Jürgen Bühring, [email protected] be applied like a thin foil to the reverse side of covering materials for seats Dr. Andreas Gerken, [email protected] Innovations made by ContiTech When it comes to advancing ideas and developments, innovation managers from the various ContiTech business units provide important inspiration hen Wilhelm Conrad Röntgen dis- Responding to gold-diggers in western America So how do innovations work at ContiTech? Through covered X-rays in 1895, it was a who needed robust clothing, Strauss produced close collaborations, a methodical approach, cre- milestone in medical diagnostics. trousers from tarpaulin before going on to use a ativity and – more than anything else – the knowl- WThe physicist made his far-reaching discovery as cotton fabric called denim. With rivets added in to edge and skills of the company’s various business he was setting up an experiment to investigate reinforce the pockets, his new garment became units. cathode rays. When a beam of light happened to a hit. fall onto a piece of paper, the effects of an as yet To find out more, Frank Stünkel, Head of Inter- unknown type of ray made it glow. Röntgen called These discoveries demonstrate not only pio- national Sales and Communications, interviewed it the X-ray. neering spirit but also the degree of persistence three innovation managers: Hubertus Gawinski needed to make continuous enhancements to from ContiTech Air Spring Systems Research and More than twenty years earlier a different inno- innovations. They happen either by coincidence Development, Benjamin Hübner from ContiTech vation had brought real revolution to the global or in response to a concrete desire for technologi- Power Transmission Group and Markus Linzmaier, community: Levi Strauss’s invention of jeans. cal change. from ContiTech Fluid Technology. >> 18_ContiTech. Engineering Next Level

Stünkel: Why, in your view, are innovations so vital for the commercial success of your business unit? Hübner: Simply creating a product that meets to- day’s standards isn’t enough. We have to keep pace with changes and think one step ahead all the time. We’re curious and think about challenges and op- portunities that are as yet unanswered. We aim to offer our customers products with uses that extend far beyond the solution they were originally looking for – products that enable them to tap into new po- tential and succeed with us by their side.

Stünkel: Can you give us an example? Linzmaier: First of all we keep a close eye on what’s going on around us. We look into any changes in legislation there might be and antici- pate any trends that are emerging. We look at the norms and standards that are expected and observe how the markets are developing. Our pri- ority throughout is our desire to give our custom- ers the edge in their market. That way both sides stand to benefit.

So to give you the example you asked for: Long before what’s called the Euro 6 norm came into force to restrict emissions of particulates and ni- trogen oxides from agricultural machinery, we were already developing special high-performance often a direct part of the team, out on-site with the sions, and the engine casing have a combined ef- hoses for SCR catalytic converters. SCR stands for customer, looking into possible technical solutions. fect: they cause temperatures around the units to selective catalytic reduction, which is the process But getting involved also gives us a knowledge ad- rise, which puts an extra strain on the rolling lobe that converts nitrogen oxides into water (H2O) and vantage, which we can put to good use. At the mo- air springs. That’s why we got together as an in- nitrogen (N2). In the meantime we have developed ment we’re carrying out a field test with 50 buses novation team to exchange experiences, and we our SCR hoses to series maturity. A development with a partner in Israel. The buses are equipped finally came up with an especially heat-resistant process like that requires a sound knowledge of with spring systems incorporating especially heat- elastomer compound. engineering, professional partners and, most of all, resistant rolling lobe air springs that were devel- time and patience. oped specially for use in hot climates. Hübner: Things work in much the same way at the ContiTech Power Transmission Group. We have Stünkel: How often do customers come to us In hot countries like this air-conditioning is used all sorts of different development partnerships, with an enquiry for a completely new solution to keep passengers comfortable. This means that including customer-driven developments that we or a really acute problem? very often the air-con and engine run all day long, support as well as a lot of innovations we’ve ini- Gawinski: It happens all the time – and we’re al- both when the vehicle is on the move and when it’s tiated ourselves. Though the vast majority of our ways delighted when they involve us in their de- stationary. The restrictive size of the engine bay, development work is carried out in response to velopment processes early on. Our engineers are catalytic converter operations to clean up emis- customer enquiries. ContiTech. Engineering Next Level_19

Innovators united: (from left to right) Hubertus Gawinski from Research and Development with ContiTech Air Spring Systems, Benjamin Hübner, Innovation Manager with the ContiTech Power Transmission Group and Markus Linzmaier, Innovation Manager with ContiTech Fluid Technology in an interview with Frank Stünkel, Head of International Sales and Communications

the knowledge needed to combine a broad spec- trum of materials with each other and to define hy- brid materials for the widest range of applications. This could involve diverse material combinations that incorporate plastics and elastomers along with textiles and reinforcing materials made from metal, for example. Our extreme expertise is all- important, especially when it comes to future gen- erations of engines because this is an area where requirements are getting tougher.

Stünkel: Markus, in what ways does this expertise in materials affect what you do? Fluid Technology has such a diverse palette of hoses and hose lines for so many different industries. Which ones are you keeping a particular eye on at the moment? Linzmaier: We look to technological and social trends for orientation, but most of all we take note of our customers’ needs.

Let’s take an example: our fibre-reinforced silicone hoses for the automotive industry. We developed our latest solid silicone for hose lines specially so they can be produced efficiently by means of extru- sion. The material we use is extremely resistant to temperatures and coolants as well as to the effects of aging, and these are some of the other proper- Stünkel: When you’re developing a new of making an impact in the market. Sometimes we ties that add value. product, what procedure do you follow? What even pick up on ideas we have talked about before. are the premises for deciding whether or not to For example, many years ago we were toying with In our commercial vehicles business we’re looking pursue an idea? the idea of launching a belt drive for bicycles with a at the issue of the moment: saving CO2 emissions. Hübner: In a first step we work as an interdiscipli- toothed belt to replace the chain. But the time was We’re working on package solutions here, one ap- nary team often with our clients to collect ideas. not yet quite right back then. Today, though, elec- proach being weight reduction. This is something Innovations aren’t knocked up in a garden shed tric bicycles are breaking through into the market we are already realising successfully with our tur- somewhere; they come into existence when people and becoming a real hit – and taking innovative con- bo-oil hoses. Developments like these are always from different backgrounds get together and ex- cepts like our belt drive with them. made in collaboration with the customer and the change ideas. Often we’ll send out enquiries to all relevant specialist departments. the business units and work on joint projects with Stünkel: When it comes to all-new develop- other Continental divisions. We frequently work ments and enhancements, what role do mate- Hübner: I’d like to add at this point that the Power with other cooperation partners too – universities, rials play? Transmission Group has developed an oil-resistant for example. We evaluate and prioritise our pro- Linzmaier: As a specialist in natural rubber and toothed belt. Our Belt-in-oil can be used to replace posed solutions based on indicators such as cus- plastics technologies, our expertise in materials is chains and in the future it will drive oil pumps and tomer benefit, economy and the product’s chances fundamental to our lasting success. We contribute camshaft controls. It has now reached series >>

ContiTech. Engineering Next Level_21

maturity, and one of the advantages is that it’s easy treme demands we have built our own unique test know-how and test rigs belonging to the Continen- on the environment: toothed belts have lower fric- rig, which has cold and hot chambers. This allows tal Group. But we also offer our facilities to others tion levels, so they save fuel. They’re also as quiet us to test our air spring systems in extreme tem- within the company to use. In addition we regularly as a whisper and comparatively light. peratures of less than minus 40 degrees Celsius exchange ideas with others on trends and oppor- and more than plus 50 degrees Celsius. That way tunities and support each other. We are currently Gawinski: Our innovativeness is reflected in our we can be sure millions of passengers will stay working on a Group project to develop intelligent ATEX certified air actuators. These are suited to a safe and comfortable. transport solutions for tomorrow’s mobility. And variety of applications in industry wherever there’s then, of course, there are our joint activities to cut a risk of explosions. Developments like this prod- CO2 emissions in vehicles. uct allow us to tap into potential new customers. “We leave absolutely We’re working to make our actuators usable in pa- nothing to chance because Electric mobility is another issue we’re working on per production or even steel works, for example. in rail travel passenger as part of the Group. We work in cross-divisional These are completely new areas for us and we’re teams and want to deliver single-source solutions getting active in them. safety is paramount.” for hybrid drive technologies as well as for two- Hubertus Gawinski, Head of Research & wheelers. Hübner: We’ve succeeded in creating a polyure- ­Development, ContiTech Air Spring Systems thane belt for lifts. It replaces the heavy cable pull Linzmaier: I can only agree with Benjamin on that systems, is non-flammable and needs neither oil Stünkel: What role do our lab and R&D depart- point. With us it’s the share of electric sensors and nor maintenance – which is good news, given the ments play in all of this? Rather than being actuators in our hose line systems that’s increas- increasing urbanisation we’re seeing right now. It’s centrally organised, we’re spread across all ing – and the technical requirements of our prod- making high-rises safer and helping people feel markets now. ucts are rising with them. Continental produces a less at risk. Gawinski: We leave absolutely nothing to chance large number of the most diverse sensors for pas- because in rail travel passenger safety is para- senger cars and commercial vehicles. We aim to Stünkel: That’s an important point. ContiTech mount. This is especially true of the extreme strains capitalise on exactly these areas of potential within is not alone in its efforts to manufacture sus­- that take our components to their limits. We have the company for our hose line systems of the future. tainable products that are good for the envi- an excellently equipped test lab for validating air ronment, health and the well-being of society. spring systems for railway vehicles. It has several Stünkel: Gentlemen, thank you very much for In a bid to improve people’s standard of living, DIN and special accreditations, which is important giving us an insight into the different activities our teams work to meet new needs all the time for underpinning our trusting collaborations with that are going on. When it comes innovative- and stay a step ahead throughout. Hubertus, customers. Train manufacturers often demand test ness and the future viability not only of our what are you working on at the moment? data from an accredited lab – and we can deliver company but also of our partners across the Gawinski: At the moment we’re involved in a major exactly what they need. continents, this is the way forwards. Thank you project with Siemens to renew the Russian rail and very much for taking the time to talk to us. << transport network. So we’re working on air spring Stünkel: As technology leader in the natural systems and other products that are specially rubber and plastics industry, we’ve made it Contact: designed for extreme conditions. Our air springs our mission to be the benchmark in innova- Hubertus Gawinski, [email protected] have to work in temperatures of less than minus tiveness, among other things. In what areas do Benjamin Hübner, [email protected] 40 degrees Celsius and handle maximum speeds collaborations across the company help? Markus Linzmaier, [email protected] of 350 kilometres an hour. To simulate these ex- Hübner: Essentially we use research facilities, Frank Stünkel, [email protected] 22_ContiTech. Engineering Next Level

Research for progress Expertise in materials is a major driver of ContiTech’s success

hether hard as steel, light as plastic or flexible as rubber, mate- are the birthplace of many a crucially important compound material with rials and their special properties are fundamental to techni- improved and sometimes even unprecedented properties. cal innovation. For new developments and the technological Wadvancement of society, they are indispensable. But when it comes to char- Expertise in materials: a driving force acteristics, there’s “hard” and there’s “hard” – and in this respect caoutchouc More than almost any other company, ContiTech has been producing rubber has a lot to offer. As well as the unique interplay between stiffness, moldability and plastics-based solutions for a wide variety of industries around the world and elasticity, natural rubber has two other important advantages to offer. for more than 140 years. Its comprehensive expertise stems from decades of research and development work. “Our expertise in materials is pivotal to our The first is that it can be mixed in an almost unlimited variety of material lasting success – because trends in global production and methods, including combinations. Depending on what function it will need to fulfil, it can be lightweight construction, downsizing and safety, are placing new and tougher amalgamated with other substances to become hard or flexible, resistant to demands on materials all the time. We bring to the table the knowledge that’s heat, cold or aggressive substances or to environmental influences such as needed to combine different materials like natural rubber and plastics with UV light. It can even be made electrically insulating or conductive. metals, textiles and fabrics. This area of work, which we call “hybrid materi- als”, is one in which we have developed significant know-how, and our skills Its second strength is that, as one of the most universal materials of all, are finding increasing application,” points out Dr Wolfram Herrmann Head of natural rubber can be coupled with other substances, allowing its versatility R & D Materials at ContiTech. and efficiency to really come into their own. Hardly any other material can be mixed and combined with such a wide range of different substances to Advances through nanotechnology create something new. ContiTech’s­ Research and Development labs, then, When it comes to creating elastomers with increasingly specific properties ContiTech. Engineering Next Level_23

High-tech combined: ContiTech Fluid Technology’s charge air lines for passenger cars are made from natural rubber, polyami- de with fibre glass, a resonator and a holder welded into place to make the best possible use of the space available and save weight.

that meet the requirements of their potential applications, nanotechnology only very, very slightly. High temperatures and pressures like this push our has a key role to play. Working with the German Institute of Rubber Technol- current materials to the limit. That’s why we’ve developed new ones that are ogy, ContiTech is currently carrying out a fundamental research project sup- really proving their worth in these extreme conditions,” says Dr Herrmann, ported by Germany’s Federal Ministry of Education and Research. Entitled describing the potential of extremely heat-resistant elastomers. ENEFEL – Energy-efficient Elastomers, the project explores the degree to which the properties of elastomers can be enhanced through targeted adap- Combinability: the opportunities are endless tation of fillers and additives. Its primary focus is on optimising three aspects ContiTech manufactures thousands of rubber-based products – all thanks in particular: temperature resistance, rigidity and durability. The team is look- to the material’s complex qualities and the virtually endless possible com- ing for new applications for elastomers. “We aim to develop elastomers that bination with other materials, such as plastic, steel, aluminium and textiles. do not become brittle and that are good conductors of electricity, malleable These countless hybrid combinations are throwing up more and more new and consequently durable. Another example is materials that heat up less applications. In addition, ContiTech Phoenix Compounding Technology has under extreme dynamic strain and are especially resistant to abrasion. This rubber compounds to hand for a broad spectrum of applications. Its standard would prolong their service life and allow more energy-efficient operations,” range alone includes more than 700 different formulae for the most diverse Dr Herrmann adds. uses, specially created to deliver the properties required. The business unit also develops new production procedures that can themselves generate new Extreme heat-resistance is especially vital in today’s turbo-charged engines, material properties. So when it comes to research, ContiTech is in the front where the right elastomers can save energy and cut CO2 emissions. “This a line – right beside its customers. << context where, compared with plastics, elastomers can really play to their strengths. They are resistant to the heat found in engine bays and deform Contact: Dr. Wolfram Herrmann, [email protected] 24_Technology and trends

Nanotechnology - present and future Guest article by Professor Andreas Leson, Deputy Director and Head of Department at the Fraunhofer-Institut für Werkstoff- und Strahltechnik in Dresden, Germany

ince physicist Richard Feynman gave for example. He also suggested that computers time believed technology would ever develop far his milestone lecture entitled “There with nanometre-sized structures (a nanometre enough for it to come true. But we now know is plenty of room at the bottom”, fifty being one thousand millionth of a metre) and cor- that’s not the case. Today nanotechnology has Syears have passed. Speaking to a delegation of responding performance would be technologi- become part and parcel of our everyday lives in fellow US physicists, Feynman presented a bold cally feasible as well as commercially extremely many respects. Countless products we take for vision: to create things on the minutest scale. viable. He envisaged future materials being pur- granted are produced using nano-scale methods pose-made, atom by atom, to achieve completely or have properties based on nanotech processes. He explained that according to the laws of new properties. physics, nothing at all would stand in the way Nowadays our PCs, tablet computers and smart- of such an undertaking. In his view it would At the time most of Feynman’s colleagues viewed phones are also our videos, cameras and music be possible to write the entire contents of the his vision as being possible in theory but certainly devices. They work by using amounts of comput- Encyclopaedia Britannica on the head of a pin, not realisable in practice. Hardly anybody at the ing power that would have been unimaginable not Technology and trends_25

long ago. And it’s all been made possible by tre- ments. Moreover, unlike chemical UV filters, mod- weight. This opens up major opportunities for mendous advances in the field of microelectron- ern-day sunscreens are even suitable for children lightweight engineering. In addition their con- ics, specifically in the production of the integrated and allergy sufferers. The functions they offer far vincing electrical properties make them highly circuits these products are based on. State-of- exceed those of conventional products – and are attractive for use in displays and photovolta- the-art circuits made in today’s semiconductor typical for innovations in nanotechnology. ics, and over the longer term they could be factories incorporate structures of a mere 22 applied in microelectronics. As a replacement nanometres. Strictly speaking, then, we should There are also great expectations for completely for the silicon used today, they would offer actually be referring not to micro but to nanoelec- new nano-scale materials. Carbon nano-tubes even greater, vastly improved performance. tronics. As structures grow tinier and tinier, they and graphenes are just two of the most notable But until now the astonishing properties these not only enhance computing performance but examples. Both are a product of modified carbon materials display at nano-level have only sel- also require less energy. It is this that makes our and have fascinating properties. Their tensile dom been transferred successfully to real- devices – especially the mobile ones – possible strength is one hundred times greater than that life macroscopic components. Over the next at all. And as we move into the future, forthcom- of steel – even though they are extremely light in few years realising their full potential will take ing generations of gadgets will incorporate even quite some research and development work. more powerful circuits with even smaller struc- tures. The question of how to produce them is cur- Nanotechnology also offers promising new rently the subject of investigations by industry and approaches in the world of medicine. One research institutes. Working together as an asso- new technique for treating brain tumours, ciation, they are exploring the use of short-wave for example, is based on the use of nano- UV light with wavelengths of just a few nanome- particles. These are inserted directly into the tres to manufacture such minuscule components. growth and heated up by means of an alter- nating magnetic field, which damages the And: who would ever have thought nanotech- tumour cells without harming the healthy tis- nology could protect us from the effects of UV sue around them. There are also plans over light? When used in sunscreen, nano-scale zinc the medium term to administer medications oxide or titanium dioxide really come into their via nano-scale container systems. These will own. Years ago sun creams used micro-sized pig- take active ingredients directly to the centre of ments to block out harmful UV rays. This made the disease, where they will unfold their phar- them comparatively thick and difficult to rub in. maceutical potential selectively and gently. They also left a white film on the skin that most people found unpleasant. Nowadays, though, Andreas Leson, physicist, is the Deputy Director of the These examples show very clearly just how reduced pigment sizes of nano-scale dimensions Fraunhofer Institut für Werkstoff- and Strahltechnik and broad the spectrum of possible applications have made both zinc oxide and titanium dioxide Head of the PVD and Nanotechnology department. He is is in which nanotechnology could have an also an honorary professor and lecturer at the Technical invisible to the human eye, more fluid and con- University of Dresden, where he and his team are working important role to play. Much has already made sequently easier to spread on skin. Sun protec- on a number of research projects in the field of nanotech- its way into our everyday lives, but plenty still tion levels have also increased dramatically, and nology. He is the Association of German Engineers (VDI) remains under development or in its infancy. the sunscreen products we know today offer representative for nanotechnology and speaker for the What new developments and products ulti- Nano in Germany initiative, a federation of more than 100 high degrees of protection against the sun’s rays companies and research organisations that are active in mately emerge over the next few years still that would be impossible without nano-scale pig- the field of nanotechnology. remains to be seen. <<

Dynamic economic partnership The innovative capacity of the Netherlands is the focus of the 2014 HANNOVER MESSE industrial trade fair The Netherlands has an outstanding network of highways totalling 2,360 kilometres in length People and markets_29

his year the Netherlands is the partner country of the HANNOVER ContiTech – diversity in the Netherlands MESSE industrial trade fair – a welcome reason to take a closer look For the ContiTech Group, then, the Netherlands is a key strategic economic at Germany’s north-western neighbour. At the fair in Hanover, north- partner. For many decades the company has had direct and indirect links Tern Germany, "Global Challenges, Smart Solutions" will be the slogan under there, with many customers in both the OEM and aftermarket sectors. The which the Dutch present their trend-setting solutions for the industrial chal- organisation and distribution channels of German rubber and plastics spe- lenges of the future. And when it comes to innovation, they know what they’re cialists are as diverse, flexible and open as the Dutch people themselves. talking about. “Our ContiTech Belgium BVBA subsidiary, which is based in Berchem, looks One example among many is the technically outstanding feat of the Delta after sales partners in a variety of market segments, from mounting elements Works. The ambitious flood defence system, comprising a huge artificially and drive belts right through to printing blankets and air springs – for all kinds raised island, is considered by many to be the “Eighth Wonder of the World” of applications,” says Managing Director Tobias Mahrenholz. “We have long and a benchmark for similar undertakings. In a country where 40 percent been highly active with Eeltink, our biggest export customer for air springs for of the land is below sea level, the population needs special protection from use in commercial vehicles. Eeltink was our customer of the year in 2013,” he floodwaters and storm surges. adds, emphasising the closeness of the relationship.

The Netherlands is often thought of as the realm of tulip fields, bicycles and The Belgian subsidiary has had traditional links with the free importer Conti- the famous Dutch cheese. Tourists in their millions flock to the canal city of nental Banden Groep B.V. via ContiTech’s parent company Continental since Amsterdam – the “Venice of the North” – with 1946. There are also direct contacts between its many museums, or to the 19 windmills of the ContiTech divisions and their customers Kinderdijk, declared a World Heritage Site. “For the ContiTech Group, in the market. ContiTech’s business partner the Netherlands is a key strategic Phoenix Vibration Controls B.V. have been But looking at its economic performance, economic partner.” active with an representative office in Stel- the Netherlands is just as much a guarantor lendam in the Netherlands since 1996. Their Tobias Mahrenholz, Managing Director of for innovation in both mechanical and plant technical sales office supplies customers and ContiTech Belgium BVBA, Berchem engineering, and in power engineering. We partners in the Benelux countries with air are talking about a uniquely strong coun- springs for industrial applications and rubber- try in global export and an extremely important trade partner of German metal products for vibration insulation under the MEGI® and Schwingmetall® industry. brands. “We offer our partners in industry and shipping products we have developed and manufactured ourselves. We even have test beds and we’re in Although its agriculture is high-tech, only two percent of jobs in the most a position to present a suitable solution in the shape of a custom-made pro- densely populated country in Europe are in grain, fruit or vegetable produc- totype within a few weeks,” points out Marco Wilmsen, Managing Director of tion, cut-flower and tulip cultivation or dairy farming. Nevertheless the Neth- Phoenix Vibration Controls. One example is the MEGI® rubber-metal mount erlands is the world’s third-largest exporter of agricultural produce. ALIVIO 2000. This component intelligently combines the properties of air and rubber to meet the high standards of vibration control required for generator Around a quarter of all Dutch exports ends up in Germany. And conversely, mounts in luxury yachts so passengers can enjoy smooth, low-vibration sail- Germany is the biggest exporter to the Netherlands, with annual exports ing on high seas. “We have always concentrated on finding the right individual totalling €54 billion plus. With a goods turnover of some €130 billion in bilat- solution to suit our partners and help them succeed. It’s all based on mutual eral foreign trade, this supposedly small state is Germany’s second-largest loyalty: Our customers remain loyal to us, and our motivated team put their partner country. heart and soul into resolving our partners’ requests”. >> 30_People and markets

For DAF Trucks in Eindhoven, for example, Air Springs Systems are regarded unloading goods from all over the world, industrial belts in moving stairways, as a reliable partner for hard-wearing air springs, especially because of the hoists and equipment, hydraulic, transport and fuel hoses galore, air suspen- ongoing support they offer in the aftermarket. Suspension manufacturer sions and air bellows, and mounting elements in ships, machines and engines, Weweler also relies on ContiTech Air Springs Systems. lifeboats, robust fire-fighting suits and innumerable types of membranes. A myriad of products reliably do their job in port operations, where annual Another important player from ContiTech’s point of view is the Dutch automo- turnover amounts to more than 400 million tonnes – and all with due regard tive industry, where NedCar is one of its primary customers. Based in Born to environmental and climate protection. ContiTech contributes by provid- in the province of Limburg, NedCar is the country’s main series automobile ing expertise and experience in the different areas; always state-of-the-art, plant, which has seen models from brands such as DAF, Volvo, Smart and always customised, need-based and low-maintenance. For a service location Mitsubishi roll off the production line. And in 2014 MINI is expected to join like the Netherlands, which has another major port in Amsterdam and one of the customer list. the biggest international airports Schiphol, benefits like these are essential for coping efficiently with huge volumes of passengers and, above all, freight. Meanwhile Edelbüttel & Schneider and Oil & Marine – both segments of ­ContiTech Fluid Technology – supply oil hoses and highly innovative pipes As well as major goods-handling sites, the Netherlands has an efficient for liquid gas to firms in the energy sector. A prominent partner here is Blue­ infrastructure and well-built road and railway networks. Both are among the water, who specialise in technologies for FPSOs (Floating Production, Stor- densest and best-developed in the world. Shipping is ideal for the country, age and Offloading units). These production ships incorporate built-in storage because it lies at the mouths of several major rivers (the Rhine or Waal, Maas, tanks and collect crude oil or natural gas that has been extracted at sea Lek and Scheldt), and many waterways of the canal network are navigable from offshore drilling platforms. The oil and gas are processed in their own for large ships. on-board facilities. These floating refineries also provide living quarters for the workers on board. Another major customer for industrial hoses is Angst So, thanks to the foresight of trade fair organiser Deutsche Messe AG, the & Pfister in Rotterdam. choice of the Netherlands as a partner country for HANNOVER MESSE means we have plenty to look forward to. When Dutch Prime Minister Mark Rutte Service arena: port and airport was recently honoured with the Ludwig-Erhard commemorative medal, he This takes us to Europe’s biggest and most important port. Stretching for specifically highlighted the close relations between his country and Ger- 42 kilometres right up to the North Sea, the port of Rotterdam is expected many – a relationship that must be among the most dynamic in the world in to continue growing considerably by 2030 and is currently being extended the field of commerce. << in line with strict sustainability guidelines. Considering how many products are used here every day, a concern like ContiTech sees countless high-tech Contact: Tobias Mahrenholz, [email protected] applications from its own ranks pass by in its mind’s eye: conveyor belts for Marco Wilmsen, [email protected] Amsterdam is an international hub. With more than 50 million passengers a year, Schipol Airport is an economic driver in the region Uwe Wüst, Director of Benecke-Changshun, in the new TPO production hall at the facility in Zhangjiagang People and markets_33

Rooted in Germany, at home in China Last year an experienced manager, engineer and China-connoisseur took the helm at the Benecke-Kaliko Group facility in Zhangjiagang, eastern China. His name is Uwe Wüst.

ith 18.1 million new vehicles regis- weight, low-emissions compact and foam foils for foam foils, we can offer them high-quality, low- tered last year, China is one of the instrument panels, door trim panels and a host of emissions, ultra-lightweight materials to cover most important markets worldwide other applications in vehicle interiors. ContiTech the dashboards, storage spaces and door trim Wfor ContiTech’s Benecke-Kaliko business unit, initiativ spoke to the China specialist about the panels in their cars. The new TPO line is pivotal a renowned supplier and producer of high qual- goals and potential of ContiTech in the People’s to the development of our activities in the Chi- ity covering materials for car seats, centre con- Republic. nese market. We want to support our customers’ soles, door panels and dashboards. But China is business success by offering them the most com- also home to the Benecke-Changshun Auto Trim prehensive range possible of locally produced joint venture, which has been operating since “We want to support goods. 2006. Last year 58-year-old Uwe Wüst took over our customers’ business as director. success by offering them CTi: What was the greatest challenge you faced while you were building the new TPO Since graduating as a process and industrial the most comprehensive production line? engineer, Wüst has held a variety of positions range possible of locally We set up a completely new production hall on including head of production with a range auto- produced goods.” some 9,000 m² of space and got the TPO systems motive suppliers and another industrial corpora- running in just ten months. The entire operation Uwe Wüst, Managing Director, tion. Whilst plant director with ITT Fluidhandling, was carried out in compliance with the strict en- Benecke-Changshun which is a major producer of pipes, hoses and Auto Trim, Zhangjiagang vironmental standards that are in place here in quick connectors for the automotive industry, he China and was a masterstroke, albeit one that completed his MBA. In 2006 he became project entailed a number of challenges for us to tackle. manager for restructuring projects in Slovakia CTi: Benecke-Changshun has increased Our success was made possible purely by close and Portugal with Continental. Three years later production capacity of its existing facilities by collaborations between us here in Zhangjiagang he took a job in China, where he spent four years adding a new TPO system. Why right now? and our colleagues at the German Benecke-Kaliko managing a plant in Shanghai for ContiTech’s Demand for our interior materials is very strong facilities. For several months our Chinese special- Hydraulic Brakes Systems business unit. In his here in China because our Chinese customers ists and managers developed their skills by working current capacity as director of Benecke-Chang- are becoming more and more discerning when it with German colleagues in Germany – in produc- shun, he has already been involved in the launch comes to eco-friendliness, aesthetics and hap- tion, plant engineering, and materials and product of the new TPO production system for extra-light- tics. With our TEPEO® and TEPEO 2® compact and development. >> 34_People and markets

Benecke-Kaliko’s low-emissions, light- weight compact and foam TPO foils for instrument panels, door trim panels and centre consoles are now being produced in China as well

CTi: Why do Chinese customers choose CTi: What are the current trends in the CTi: Is there a Chinese proverb of some sort ­materials by Benecke-Changshun? Chinese market? that really encapsulates your view of life? Our materials expertise is unique, and we’re highly Sustainability and “green-ness” are pressing issues ‘‘Ye chang meng duo” It roughly translates as “The innovative and offer top-class production quality. in politics, business and society at large. Last year longer the night, the more our dreams”. The un- Together, these factors mean we have the best pos- the government in Beijing launched a legislative ini- derlying message is that the longer you take over sible setup for developing bespoke solutions with tiative to limit in-car emissions. Its guideline values making your decisions, the more uncertain the out- our customers. We also advise them on the applica- are designed to protect vehicle occupants’ health come will be. tion of our materials and provide customer service and they have to be adhered to in every respect. Be- and support. This, in turn, helps them to achieve ing especially health-friendly and low in odours and CTi: Finally I’d like to ask you a personal particularly good results. So that we can deliver emissions, our Acella® Eco green covering material question: What do you do in your free time this level of service, we have a team of Benecke- is being used more and more widely to ensure vehi- here in China? Changshun application specialists at every major cle interiors meet the latest requirements. I occasionally relax by taking out my motorbike automotive production centre. and my Chang-Jiang sidecar. It’s a replica of a CTi: In what ways do the wishes of Chinese BMW motorcycle that was made in Germany in the CTi: What development demonstrates the inno- motorists differ from those in Europe? 1930s. Not many Europeans would dare to ride a vativeness and materials expertise you describe? Chinese customers prefer their vehicle interiors to motorbike in China, but I love to go out with my TEPEO® Protect and TEPEO 2® Protect are two ex- be light in colour, so shades of beige, cream and sidecar and bike. When I have the time I also enjoy amples of materials we’ve developed to satisfy the pale grey are in especially strong demand at the exploring new places on short city breaks or going high expectations of Chinese customers when it moment. They also value a harmonious atmos- to the mountains on holiday. << comes to exclusive designs for vehicle interiors. Be- phere inside the car and light, soft materials. Be- ing scratch resistant, they keep the inside of the car cause they associate abundant space with abun- looking new for as long as possible and keep signs dant wealth, Chinese vehicle owners tend to prefer of damage to a minimum. They do it quite simply by cars that have plenty of leg-room, especially for yielding under the pressure of pointed objects that rear seat passengers, which mostly include the ve- Contact: would otherwise damage their surface. hicle owner himself. Uwe Wüst, [email protected] Et cetera_35

Ultra-durable 20,000 times a week

ContiTech Fluid Technology’s ultra-durable fuel For ContiTech Fluid Technology the challenge was they can withstand pressures of up to 35 bars hoses for the latest generation of truck engines are to design an all-new production process that meets and run at operating temperatures of up to 130° making a pivotal contribution to saving diesel and the most stringent standards for quality and clean- Celsius. In flame tests they remained fully intact cutting CO2 emissions – and helping commercial liness and delivers tighter tolerances. This meant for four hours, and their performance was hardly vehicle producers meet forthcoming Euro 6 and establishing an independent production unit and compromised at all. Being copper-free, they can EPA 13 emissions standards in the process. At its investing several million in new machines. also be used with bio diesel, which no longer facility at Karben, Germany, the hose line specialist froths up due to chemical reactions with metal. produces a staggering 20,000 of these high-per- ContiTech Fluid Technology’s latest fuel lines are Moreover, their stainless steel casing even makes formance fuel lines every week and is one of just ideal for use in heavy-duty engines. Their innova- them suitable for use in buses, where particularly a handful of providers to do so in the world today. tive rubber compounds and special braiding mean rigorous safety standards apply.

Conti® Thermo-Protect conquers the oceans

Bremen-based shipping company Sloman Neptun Schiffahrts-AG has used the ultra-flexible Conti® Thermo-Protect system to insulate the steam hoses of the first of its 22 tankers. Produced by ContiTech Elastomer Coatings, the new insulation replaces the previous material, which had become brittle and soaked with seawater, causing the pipes to corrode. On the upper deck of the tanker more than 100 metres of hose lines have now been fitted with a durable casing in the shape of almost 130 kilograms of Conti® Thermo-Protect. This will provide lasting insulation when the vessel is out on the high seas.

In this new field of application, ContiTech’s protec- tive material will be resistant to intense sunlight, the wash of the sea and mechanical strain. 36_ContiTech. Engineering Next Level

Engineering dreams straight down the line Non-stop high-tech: Future developments by the ContiTech Conveyor Belt Group are setting new standards

ntil 1906, when Richard Sutcliffe first used conveyor belts in Brit- ventional rubber coatings – and all without compromising on the belt’s broad ish coal mines, work at the coalface had been even harder for man spectrum of applications. As well as optimising energy consumption, light- and beast alike. As well as making the physical transportation of weight constructions offer a range of other advantages. Using them to reduce Ucoal and ores easier, the new invention ensured the energy needs of upcom- the weight of mobile systems and installations, for example, can open up ing industrialised nations could be met. opportunities for technical enhancements to be made. It also allows the often complex conveyor belt systems to benefit from optimised system designs. Nowadays conveyor belts have spread not only into mining but across all other branches of industry as well. From rare earths to fish, from excavation But the Conveyor Belt Group has long been investigating a range of other waste to glowing hot slag, when something needs moving from A to B quickly, areas besides the optimisation of rubber. Anyone seeking to have an impact safely and cheaply, conveyor belts are the way to go. Spanning distances in a demanding market environment needs to master the conveyor belt in all of up to 40 kilometres and covering altitude differences of as much as 700 of its complexity. metres, conveyors keep the wheels of global industry turning – and are inno- vative and remarkably easy on the environment to boot. “We mainly source belt components like textiles and steel cables from exter- nal partners. They supply what we need based on the specifications we’ve Unlike the often rough environments in which they operate, modern-day agreed with them. But over time we’ve also strengthened our own in-house caoutchouc-based belts are state-of-the-art pieces of engineering technol- development skills for these materials considerably. This means we can now ogy. A look into the ContiTech Conveyor Belt Group’s “test kitchen” shows create materials whose properties are more holistically balanced with each that the global producer of steel cable, textile and specialist belts still sees other at a deeper level. This way we can make the best possible advances numerous opportunities for optimising the performance of its products to in this field and consolidate our market position over the longer term,” meet current and future needs. explains Wilhelm Schrand, Head of Technology and Belt Components with the ­ContiTech Conveyor Belt Group. Lightweight construction advances into conveyor belts and components Industries around the world face a key challenge: to cut energy consumption. One example of an area where his team is active is the development of ultra-stiff When it comes to textile belts CONTI LIGHTWEIGHT TECHNOLOGY repre- steel cable belts that resolve the conflict between weight and rigidity on a higher sents a universal approach. Based on an innovative rubber compound, the level. As well as questioning materials and designs, the development team goes technology can save up to 30 percent in weight when used in place of con- out in search of new solutions to make conveyor belts even more efficient. >> High-performance products: The ContiTech Conveyor Belt Group is working on the development of a new generation of ultra-robust steel cord belts 38_ContiTech. Engineering Next Level

Super-strength combinations What happens to rubber on contact with extremely hot materials? Normally it melts into a thick, black lump. But not if it is a state-of-the-art rubber com- pound by ContiTech, whose latest conveyor systems are highly capable of transporting glowing furnace slag, iron ore pellets and other such substances that can be as hot as 600°C – safely, without damage and across long dis- tances. The secret of their success lies in their highly melt-resistant textile linings. These are inserted into their rubber carcass or applied as a protective layer over the carrier material, and the type used depends on actual tem- perature requirements. In addition, the new HEAT CONTROL insulation layer reduces temperature transfer from the topside of the belt to the conveyor belt carcass by up to 40°C.

Record-breaking potential Compared with truck fleets, conveyor belts have proven to be a considerably more economical and ecological transport option within certain distances. For this reason, operators are finding new applications for them all the time – and with ever tougher demands. The ContiTech Conveyor Belt Group is addressing their needs through the kind of consistent research and develop- ment work that is unmatched by any other provider.

With the company’s new MegaPipe Conveyor Belt “masses more masses” is the credo. This tube belt technology is making closed conveyor belts of unprecedented dimensions possible. With an outer diameter of 900 millime- tres, the MegaPipe can carry double the quantity transported by conventional tube belts, and after just a single crushing, rough ore, coal and rock are ready to travel up to 10 km. And the MegaPipe is practical too – available in a steel cord version or as a textile variant suitable for more winding routes.

For Wilhelm Schrand and his development team conveyor belts will represent a fascinating challenge for a long time to come: “There’s still plenty more potential. We’re exploring a range of the most diverse areas including acid- resistant and flame-retardant belts, or ones that would be suitable for use in extreme cold. The innovations we come up with will allow us to offer our customers the best possible solution to meet their needs. Conveyor belts are – and always will be – a highly technical field of work for any engineer that loves researching and developing.” <<

Contact: Frank Kantorek, [email protected] Wilhelm Schrand, [email protected] ContiTech. Engineering Next Level_39

In open-cast mines or underground, ContiTech conveyor belts offer extraordinary performance when it comes to transportation – even in the toughestBildunterschrift conditions

Right up to the limit The Dakar Rally – the toughest test of them all for both human and machine

Ready for a cool dip: The desert trail is dusty and sweat-inducing and requires absolute driving skill 42_Technology and trends

earing heat during the day, icy tempera- success was attributable first and foremost to his their air suspension GINAF trucks. Purpose-built tures at night, craggy mountains, soft technical expertise. As a development engineer for off-road racing, these incorporate the kind of dunes and winding jungle trails with with WP Suspension, a chassis developer and advantageous, progressive technology that is per- Ssteep, rocky descents. Contestants in the Dakar producer of world renown, Iginio Voorhorst had mitted in the Dakar Rally for trucks. Rally have to battle their way though an array of become fascinated by his field of work. The tech- tough conditions. By truck, car, quad or motor- nical expertise he acquired during his time with In Iginio Voorhort’s experience, air suspensions bike, the greatest off-road race in the world is the company came in handy when he was setting deliver a definite competitive advantage. Com- the ultimate endurance test for competitors up his car for the Dakar Rally and working to opti- pared with conventional systems, such as steel every year. mise its performance. springs, they respond considerably more gently, enhancing the vehicle’s road contact. They also In the early days, the Paris-Dakar long-distance Genuine all-round talents compensate for uneven road surfaces by smooth- race started in the French capital and went half Since that time he has been putting his heart and ing the effects of stones and potholes more sen- way across the world to finish in Senegal’s main soul into sponsoring and supporting “his own” sitively than conventional systems. As well as city, Dakar, just as its name suggests. The route teams at the Dakar Rally every year. His commit- offering added protection for both the vehicle and came to represent a bridge between two very dif- ment stems not only from his passion for racing: its delicate equipment, air suspensions reduce ferent worlds, as envisioned by the race’s founder “VB-Airsuspension develops and produces air the physical strain on drivers. Being less shaken Thierry Sabine. spring systems for chassis in lightweight vehicles about, they can concentrate more fully on the “road” and use their reserves to stay focused over In 2009 the rally relocated to South America. Last longer distances and at higher speeds. year’s contest took competitors 9,000 kilometres straight across Argentina, Bolivia and Chile in 13 “The physical principles of the rolling lobe air days. The annual test of endurance is usually inter- suspension are fundamental to the advantages it rupted by just a single day of rest, which tends to offers when it’s used in a vehicle with air springs. be scheduled somewhere around the middle of Its progressive spring characteristics allow us to the contest. The remainder of the time is spent on reconcile the high levels of comfort arising from the move, covering as much as 1,200 kilometres gentle responses with extreme sag-resistance – a day and reaching top speeds in excess of 180 because as a spring is compressed, it hardens kilometres an hour. consistently,” explains Marc Leinemann, project engineer with the Air Spring Systems OEM busi- Iginio Voorhorst – Developer and adventurer ness unit. Incredible as it may seem, it’s not only race-pros like top driver and eleven-times Dakar Rally winner Another advantage of the system is that it can Stéphane Peterhansel who subject themselves to be regulated. Air springs are height-adjustable, the rigours of the competition. Less experienced so ground clearance can be varied. This can be works pilots and even privateers dare to embark of benefit to the driver when a vehicle becomes on the adventure as well. that are used for commercial or private purposes – stuck, for example. “It saves a lot of time which ambulances and campervans, for instance. Air you would otherwise spend shovelling away the One of them is Iginio Voorhorst, founder and springs are vehicle components that perform sand,” says Voorhorst. “Even to me,” he adds, director of chassis specialist VB-Airsuspension invisibly. They work away on the underside of the “the dimensions of these strengths, which work and a long-standing ContiTech customer. When car, where they are normally totally unseen by to huge advantage, came as a complete surprise. the automotive engineer joined the Dakar for cars customers. But in a rally like Le Dakar their abili- I find them utterly convincing!” in 2009, his boyhood dream came true. Without ties really come to the fore. There’s visible evi- a doubt, the experience of his two-year round- dence of what they can do,” explains the 48-year- Trusting partnership the-world trip in a 4x4 in 1991 and 1992 was a old. Because air suspensions are not allowed in VB-Airsuspension has been a ContiTech customer great advantage to him. Ultimately, however, his the Dakar Rally for cars, Voorhorst’s teams fielded for seven years. The Air Spring Systems busi- >> 2014 saw the 35th Dakar Rally take place. Each year 2.2 million spectators show their support for the daredevil ­drivers – with cheers and action along the route 44_Technology and trends

The VB-Airsuspension team mastered the rally with confidence and was able to celebrate a very personal success

ness unit supplies the sleeve-type rolling lobe air “Good material combinations, optimised com- Many competitors in the Dakar Rally embark on springs Iginio Voorhorst needs to keep his daily pounds that suit the system’s final application and the adventure without a team of mechanics, mean- business ticking over. The components are primar- the highest quality are what makes ContiTech air ing they themselves are responsible for maintain- ily used in passenger and goods transportation. springs special,” comments Paul Neumüller, Key ing their vehicles. This puts them under additional Account Manager with Air Spring Systems OEM. pressure, as the lack of time often leaves them Even though air suspensions are traditionally unable to carry out repairs with any frequency found in the chassis constructions of heavy-duty Conical rolling lobe air springs for fast repairs or indeed at all. After a hard day’s racing, they commercial vehicles, other vehicle segments The truth of what he says is confirmed by those are likely reach their destination in the middle of also harbour growing potential for additional who use them, especially in tough conditions: the night, with just a few hours to prepare their applications. As a sponsor of the VB-Airsuspension teams in vehicle and themselves and catch up on some the Dakar Rally 2014, ContiTech Air Spring Sys- sleep. Faster repairs quite simply save them a lot “Demand for air suspensions in lighter com- tems provided rolling lobe air springs for their air of stress. Instead they can invest their strength mercial vehicles is growing all the time,” reports suspensions. in overcoming the unexpected challenges of the Meike Zettel-Sümnick, Sales Manager for Europe next day’s racing. with ContiTech Air Spring Systems. So far they Originally designed as standard for use in the have been the preserve of top-of-the-range cars chassis of heavy-duty commercial vehicles, With these innovative technologies and solutions, as they are still considered a high-tech product. the springs are “produced in such high quality ContiTech and its customer VB-Airsuspension are But air springs are, in fact, extremely versatile. that they can withstand even the most extreme making a major contribution to the safety and suc- They offer a smoother, more comfortable ride and stresses and strains of a desert rally,” Voorhorst cess of drivers in what’s probably the most excit- variable vehicle heights in trucks. Moreover, in explains. “That makes them ideal for Dakar.” ing rally in the world: Le Dakar. long-distance off-road racing like the Dakar Rally they have a distinct competitive advantage. Out on the rally their advantages are apparent not And one thing is for sure: Ultimately, victory will only en route but also during a breakdown – which come to those who are best-prepared and best- With this broad range of possible applications is why special conical rolling lobe air springs are equipped. The rest is down to luck. << in mind, ContiTech Air Spring Systems has spe- used in the Dakar competition. Compared with cialised in the development and production of conventional spring-based damping systems, air springs for an extensive spectrum of vehicle they are much quicker to replace and so save sig- classes. It produces them to customers’ specifica- nificant amounts of time. Given that chassis com- Contact: tions, always keeping in mind the specific require- ponents are regularly replaced as a precaution Marc Leinemann, [email protected] ments of the climate and road conditions they will during the race, speed of repairs is an important Paul Neumüller, [email protected] be used in. factor for success. Meike Zettel-Sümnick, [email protected]

Et cetera_45

A more comfortable ride with bushes by ContiTech Imprint Bushes by ContiTech Vibration Control will offer Each Jetflyer axle is fitted with four zero-mainte- a safe and comfortable ride in innovative electric nance, noise-free MEGI® bushes. Subjected to Published by: vehicles of the future. One such vehicle is the Jet- radial loads, these can withstand tremendous ContiTech­ AG flyer. Neither quad-bike nor scooter, the Jetflyer is forces. But they can also be used under axial loads Vahrenwalder Str. 9 30165 Hannover smaller than a car but safer and more comfortable and with angular rotations of between -15° and [email protected]­ than a scooter. It travels at speeds of up to 45 kilo- +15°, making “Jetflying” safe, comfortable and fun! www.contitech.de­­ metres an hour. Produced by the Austrian innova- www.contitech-online.com­­ tor e-volution Elektromobilitätskonzepte GmbH, Responsible for the content these little runarounds could one day become all and Editor in chief: the rage. In fact, they are already in use in some Jens Fechner, countries around the world, Dubai being one, Head of Market Communications ContiTech­ AG where they are used by the police. Editorial team: As well as being fun to ride, Jetflyers are Peter Abbes Meral Adenli very comfortable – thanks to MEGI® Erik Braunreuther bushes by ContiTech Vibration Con- Sibylle Engel trol. These form an elastic joint Silke Haas between the axle and wheels of the Elvira Kluth Dirk Kroll mini e-mobile to ensure smooth Andreas Mänz and stable progress. Dr. Elke Neujahr Kerstin Porsiel-Voges Julia Schmitz Dr. Edith Wienand

Concept and coordination: ­ContiTech AG und Acquisition to strengthen industry business comm:up Kommunikation & Management GmbH, Düsseldorf

Continental is planning to develop its industry ­ContiTech would achieve some 60 percent of its Layout and production: business through an acquisition. In February sales outside the automotive OE sector. bubedamekönig designbüro GbR, Köln 2014 it reached an agreement with the Carlyle Photos: Group, based in Washington DC, USA, to buy “Veyance Technologies will complement our ­ContiTech AG, Dakarpress.com (pp. 40-41), Fo- tolia (p. 24), Thomas Böllinghaus, Paulo Fridman Veyance Technologies Inc, Fairlawn, Ohio, USA. ContiTech division in key markets where our (pp. 2, 37-39), Laif (pp. 4, 26, 31), Tom Peschel Veyance is globally active in natural rubber and presence is limited, particularly in the US and (pp. 5, 6, 8-13), plainpicture (p. 14), Mick Ryan plastics technologies and employs 9,000 people. South America. Plants in Mexico, Canada, (pp. 5, 32-33), Uli Steinmetz (pp. 22-23), And- The acquisition is subject to the approval of the China, Australia and also South Africa will pro- reas Teichmann (pp. 5, 16-21), Rally Maniacs/ responsible anti-trust authorities. vide additional opportunities,” explained Heinz- Marcel Vermeij (pp. 5, 43-44), 123RF (p. 28) Gerhard Wente, CEO of the ContiTech division. Printed by: According to plans Veyance will be integrated “­ContiTech’s ­Conveyor Belt Group and Fluid BenatzkyMünstermann Druck GmbH, Hanover into the ContiTech Group, which would come Technology business units in particular will bene- Printed with ContiTech offset printing blankets a step closer to its strategic goal of increas- fit from an enhanced global presence. The Power ing further the proportion of sales to industrial Transmission Group and Air Spring Systems will carbon neutral natureOffice.com | DE-191-001025 customers and private end users. In future also achieve positive results from the merger.” print production Industrial Supply 2014

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