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MINERAL SOLUTIONS FOR A CHANGING WORLD IN BRIEF 2014

MINERAL SOLUTIONS FOR A CHANGING WORLDimerys-carbonates.com/wp-content/uploads/2015/09/imerys... · 2015-09-10 · SOLUTIONS FOR A CHANGING WORLD 4 Imerys serves a wide range of industries,

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MINERAL SOLUTIONS FOR A CHANGING

WORLD IN BRIEF 2014

THE WORLD LEADER IN MINERAL-BASED SPECIALTY SOLUTIONS FOR INDUSTRY

Imerys transforms a unique range of minerals to deliver functional specialty solutions (heat resistance, mechanical strength, conductivity, coverage, barrier effect, etc.) essential for its customers’ products and manufacturing processes.

Whether mineral components, functional additives, process enablers or finished products, Imerys’ solutions contribute to the quality of a great many applications in consumer goods, industrial equipment and construction.

Combining expertise, creativity and attentiveness to their customers, the Group’s teams constantly identify new applications and develop high value-added solutions, in line with a determined approach to responsible development.

04 Presence in a great number of markets

05 Our business: world leader of specialty minerals for industry

06 A leading position in its four business groups

08 OUR COMMITMENTS

10 Guaranteeing the group’s growth is preparing for the future

12 Developping know-how is preparing for the future

14 Acting with a responsible approach is preparing for the future

€3,688M revenue

€495M current operating income

234industrial sites

14,900 employees

50countries

CONTENTS

3

FILTRATION & PERFORMANCE ADDITIVES

Filtration &

Performance Additives

ENERGY SOLUTIONS & SPECIALTIES

Oilfield Solutions

Graphite & Carbon

Monolithic Refractories

Carbonates

CERAMIC MATERIALS

Clay Roof Tiles

Minerals for Ceramics

Kaolin

HIGH RESISTANCE MINERALS

Refractory Minerals

Fused Minerals

I N B R I E F 2 0 1 4

S O L U T I O N S F O R A C H A N G I N G W O R L D

4

Imerys serves a wide range of industries, guaranteeing

balanced exposure to different economic cycles.

The Group’s sales are spread across over 20 markets.

PRESENCE IN A GREAT NUMBER OF MARKETS

DECORATIVE MATERIALS AND FITTINGS

Sanitaryware, tableware, flooring, paint, floor tiles, etc.

STEELMAKING AND METALLURGY

Refractory linings for furnaces, etc.

AUTOMOTIVE, INDUSTRIAL EQUIPMENT

AND CONSUMER DURABLES

Plastics, batteries, paint bodywork,

tooling, etc.

HEALTH, BEAUTY AND CARE

Deodorant, skin creams, toothpaste,

hygiene products, etc.

AGRI-FOOD

Filtration of beer, wine, drinking water

and fruit juice, etc.

PAPER

Catalogues, advertising materials, brochures,

magazines, specialty papers, etc.

PACKAGING

Plastic film, specific packaging, etc.

CONSTRUCTION

Roof tiles, cement making, window profiles,

etc.

ENERGY

Batteries, photovoltaic cells and panels, oil and gas drilling, etc.

HORTICULTURE, PROTECTION OF FLORA

Hydroponics, UV production, repellents, etc.

ELECTRONICS

Device structure, processors,

semi-conductors, etc.

I N B R I E F 2 0 1 4

5

OUR BUSINESS: WORLD LEADER OF SPECIALTY MINERALS FOR INDUSTRY

Imerys dedicates 1.7% of its revenue to Research & Development.

This amount represents quite a significant share for the industrial

minerals industry and reflects the Group’s determination

to make innovation the driver of its internal growth.

By selecting relevant techniques for the characteristics of every deposit, Imerys can extract minerals with an economically efficient, yet environmentally-friendly approach.

Sites at the end of their industrial lives are restored in the best possible environmental conditions. The Group has established common responsible management processes, including for restoration plans that are studied from the outset of mine opening projects.

THE ART OF MINING

SPECIALTIES FOR WIDE-RANGING APPLICATIONS

Imerys’ mineral-based specialty solutions can be used in four different ways in the industrial chain:

- mineral components- functional additives- amanufacturing

process enablers- finished products

BENEFICIATION KNOW-HOW

To obtain the required properties and so add value, minerals are processed using various technologies, many of which are specific to Imerys, e.g. grinding, grading, drying, calcination, sintering, melting, bleaching, surface chemistry, magnetic purification and flotation, but also shaping processes such as pressing, extrusion, granulation and casting.

HIGH-QUALITY MINERALS

The Group develops specialty solutions by transforming and formulating a range of around 30 minerals. Thanks to its mining sites, where it holds on average 20 years’ high-quality mineral reserves and with teams dedicated to exploring additional resources, Imerys guarantees its customers a lasting supply.

• Graphite to meet the specifications of mobile energy and precision engineering industries (lithium-ion batteries, etc.)

• Monolithic refractories for high-temperature industries (steelmaking, foundry, etc.)

• Diatomite and perlite to filter edible beverages

• Electrofused magnesia for domestic appliances (dishwashers, etc.)

A WIDE VARIETY OF USES

The Group calls substantial resources into play to innovate in line with its customers’ needs: 300 scientists based in market-focused Research & Development centers across the world, and collaboration with renowned institutes.

The Group has developed many exclusive processes, technologies and products that it strives to protect.

INDUSTRIAL AND TECHNOLOGICAL SKILLS

S O L U T I O N S F O R A C H A N G I N G W O R L D

6

WORLD #1 in talc for plastics, paints, paper,

ceramics, health & beauty

WORLD #1 in mica

WORLD #1 in mica for engineered plastics and high-performance coatings

WORLD #1 in diatomite-based and

perlite-based products for filtration

WORLD #1 in minerals for breathable

polymer films

WORLD #2 in carbonates for paper

WORLD #1 in alumino-silicate monolithic refractories

WORLD #1 in graphite for alkaline batteries

WORLD #1 in conductive additives for Li-ion batteries

The Filtration & Performance Additives business group is a supplier to a great number of industries

(agri-food, plastics, paint, rubber, catalysts, paper, pharma, personal care & beauty, etc.).

Its activity is driven by trends in consumer goods (beverages, food, packaging, etc.), capital goods

(particularly automotive) and construction (new buildings and renovation).

The Energy Solutions & Specialties business group manufactures and sells

high-performance mineral solutions for various demanding industries: the consumer goods and paper sectors with Carbonates, high-temperature industries served by Monolithic Refractories, Graphite & Carbon

applications linked to mobile energy, and oil and gas exploration served by the

Oilfield Solutions activity.

A LEADING POSITION IN ITS FOUR BUSINESS GROUPS

ENERGY SOLUTIONS

& SPECIALTIES

Carbonates

€ 1,279 million revenue (35% of Group total)

28 countries

76 industrial sites

4,958 employees

Monolithic Refractories

Graphite & CarbonOilfield Solutions

FILTRATION & PERFORMANCE

ADDITIVES

Filtration & Performance Additives

€ 658 million revenue (18% of Group total)

16 countries

45 industrial sites

2,518 employees

9%

7% 43%

41%

100%

I N B R I E F 2 0 1 4

7

WORLD #1 in raw materials & ceramic bodies

for sanitaryware

WORLD #1 in kiln furniture for roof tiles

WORLD #1 in kaolin for paper

EUROPEAN #1 in raw materials and ceramic bodies

for porcelain tableware

FRENCH #1 for clay roof tiles and accessories

WORLD #1 in alumino-silicate minerals

for refractories

WORLD #1 in fused minerals

for abrasives

WORLD #1 in fused zirconia

The Ceramic Materials business group is organized around Clay Roof Tiles (France’s largest producer of clay

roof tiles and roof accessories), Minerals for Ceramics and Kaolin activities. The Minerals for Ceramics activity

mainly addresses the ceramic industries (tableware, tiles, technical ceramics), but also other markets such as

fiberglass. Imerys kaolins are a key component of many products including consumer goods (paper, packaging,

paints, plastics and polymers).

The High Resistance Minerals business group is positioned upstream of the industrial equipment chain

(steel production, industrial and automotive sectors). The business group leverages on sophisticated manufacturing processes for high-temperature operations, to offer mineral-based specialties

with key functionalities: refractoriness, abrasiveness, mechanical resistance, purity and conductivity.

CERAMIC MATERIALS

Kaolin

€ 1,157 million revenue (31% of Group total)

21 countries

84  industrial sites

4,269 employees

Minerals for Ceramics

Clay Roof Tiles

HIGH RESISTANCE MINERALS

€ 642 million revenue (16% of Group total)

14 countries

29 industrial sites

2,841 employees

Fused Minerals

Refractory Minerals

33%

27% 40% 41% 59%

The composition of Imerys’ business groups was changed in 2014 as a result

of the acquisition project of S&B. The Kaolin activity was integrated into the Ceramic Materials

business group and S&B’s activities were integrated into the Filtration & Performance Additives

business group on March 1st, 2015. All 2014 financial data are therefore presented

under the new organization.

8

OUR COMMITMENTS

GROW

TH

RESPONSIBILITY

KNOW-HOW

IMERYS

I N B R I E F 2 0 1 4

9

For Imerys, preparing for the future consists of three

commitments: to ensure the Group’s growth, develop

its know-how and be a responsible actor. To ensure

its growth, the Group is implementing a strategy based

simultaneously on innovation, geographic expansion, entry

into new growing markets and carefully targeted acquisitions.

Regarding know-how development, Imerys leads

a Human Resources policy promoting the evolution of

its employees and the recruitment of new talents. The Group

also seeks to develop and share, within the company, good

practices in operational excellence to improve and sustain

its industrial success.

To meet its growth targets while ensuring its social and

environmental responsibility, the Group is engaged

in performance improvement plans that encourages each

of its entities to implement concrete local initiatives whose

progress is assessed using performance indicators.

PREPARING FOR THE FUTURE TODAY

S O L U T I O N S F O R A C H A N G I N G W O R L D

1 0

 Imerys has developed rapidly since the early 2000s thanks to a strategy based on innovation, expanding its geographic footprint and

activity portfolio, and stepping up its presence on profitable markets.

STAYING ONE INNOVATION AHEADImerys innovates with and for its customers. Three hundred researchers and technicians are mobilized at all times worldwide to meet customers’ expectations while the marketing teams try and anticipate their needs. In 2014 Imerys launched 75 new products: innovations stemming from improvements to existing ranges, or disruptive innovations based on

the development of new concepts. For 2014 alone, the new products introduced over the last five years have generated €449 million, i.e. 12% sales revenue. The vast range of applications offers many possibilities for our teams’ creativity.

FOCUS ON GROWING MARKETSImerys focuses its research efforts in the areas with the strongest growth potential. The projects launched in 2014 notably reflect the dynamism of the plastics markets, recycling, lithium-ion batteries and organic agriculture.

PRODUCTION CAPACITY DEVELOPMENTImerys has developed new production capacities to continue

its development on growing markets identified as having the highest potential. In Brazil, the Group unveiled a new blending

S&B ACQUISITION

With the integration of S&B’s activities into the

Filtration & Performance Additives (F&PA) business

group, Imerys counts on a number of synergies: business’ exposure on existing and growing

markets, increased geographic presence

and innovation potential development.

GROW

TH

RESPONSIBILITY

KNOW-HOW GUARANTEEING

THE GROUP’S GROWTH IS PREPARING FOR

THE FUTURE

IMERYS

S O L U T I O N S F O R A C H A N G I N G W O R L D

1 1

€242 million

industrial investments in 2014

Imerys’ innovative solutions are appreciated on every continent. In Europe, the C-NERGYTM materials for electrodes have become a benchmark for high-performance battery manufacturing; Steagreen™ talcs are used to restore mechanical properties to plastics compounds; the ImerCare™ Scrub range, based on engineered perlite, was developed in response to growing demand in the cosmetics industry for natural ingredients. In North America, the JetWhite® references, functional additives for polymer compounds, are used in color-sensitive automotive and appliance end uses. In Asia customers benefit from CerafluxTM, a new range of fluxes for glazes developed to lower sintering temperatures, thus reducing tile production costs and subsequent environmental impacts.

75new products

marketed in 2014

INNOVATIONAnticipating our customers’ needs

_

platform for the Minerals for Ceramics activity. The High Resistance Minerals business group launched a new production line in Austria for ultrafine alumina. The Energy Solutions & Specialties business group opened a new natural graphite quarry in Canada and commissioned a third production line for monolithic refractories in India. The new production line in Willebroek (Belgium) enabled Imerys Graphite & Carbon to double its capacity for carbon black.

TARGETED EXPANSION In the regions identified as high potential development sources, the Group is expanding

extensively through organic growth projects, acquisitions or partnerships. The Group has completed the acquisition of Termorak, a Finnish refractory material producer, and Kinta Powdertec Sdn Bhd, a Malaysian producer of ground calcium carbonates. Imerys also set up its first industrial facility in the Middle East with a fused alumina plant in Bahrain, built under a joint venture with the Al Zayani Investments group, extending its geographic footprint in a strategic area for the Group. With the S&B acquisition, I m e r y s a c c e l e ra t e s i t s development and increases its offer in mineral-based specialty solutions for industry.

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S O L U T I O N S F O R A C H A N G I N G W O R L D

1 21 2

GROW

TH

RESPONSIBILITY

KNOW-HOW

 Driven by entrepreneurship and focused on sound values, the Group imple-ments a Human Resources policy that is consistent

with the changes in today’s world.

TRAINING TO ENHANCE EXPERTISE To accompany its strategy implementation, the Group has designed training programs through Imerys Learning Center (the Group’s training center), and its business groups, on security, industrial performance, etc. Imerys Learning Center provides training on all continents to allow employees to develop their skills, broaden their internal network and share the Group’s culture. In total,

over 10,200 employees, e.g. 66% of the average annual workforce, were trained during 2014.

ALL ONLINEIn 2014, the Group decided to extend the scope of its training through IM-Pulse, a new e-learning solution. The aims of this online training platform are to reach as many employees as possible, especially in the most remote regions, and to offer personalized training. More than 4,000 employees will eventually benefit from this new ongoing training offering from 2017.

A SHARED CORPORATE CULTURE All over the world, the Group’s

men and women add to its value, build its success and forge its reputation. Many in-house initiatives are taken to strengthen this company spirit. Cross-division seminars are organized by function to share best practices. External and internal communication support information sharing (electronic newsletters, social networks and videos published online via YouTube on Imerys Replay channel).

WELCOMING NEW EMPLOYEESTo facilitate new employees integration, a welcome program cal led “Onboarding” was launched in 2014. This program, based in part on the best

S O L U T I O N S F O R A C H A N G I N G W O R L D

DEVELOPING KNOW-HOW

IS PREPARING FOR THE FUTURE

IMERYS

1 3

221, 000 training hours

were allocated to 10,200 employees

75%of employees

are covered by a collective agreement

A Group-wide analysis of industrial assets showed performance levels that varied from site to site. To reach a common standard of operating excellence, Imerys implemented in 2014 a program to improve its industrial processes called Imerys Industrial Improvement (I-Cube). The implementation of the program follows a three-phase roadmap expected to conclude in 2018. The program is a new guarantee from Imerys on its commitment to supply increasingly high-performance products that meet strict quality criteria.

OPERATIONAL EXCELLENCEDeveloping and sharing

best practices_

practices of the Group’s entities, includes a practical presentation kit on Imerys, its businesses and its sustainable development policy, as well as essential i n fo rmat ion fo r smooth integration. “Welcome Sessions” for new employees are organized several times a year in Europe, North America and Asia. In 2014, a session was organized in Brazil for the first time.

SOCIAL MODEL, ETHICS AND BUSINESS CONDUCTWi t h b a s e s i n a l m o s t 50 countries, Imerys also has to take account of specific social legislation and practices that can vary widely. Considering that its

employee benefits had to be harmonized if not identical, the Group set down the principle of gradually aligning its subsidiaries’ compensation and benefits. In 2014, Imerys updated its Code of Ethics and Business Conduct to st rengthen po l ic ies and procedures against fraud and corruption.

I N B R I E F 2 0 1 4

1 41 4

 To reconcile its growth ambitions with its social and env i ronme nta l responsibilities over the long term, the Group has

centered its Sustainable Development strategy on three main areas: social, environment and governance.

CONSERVING THE ENVIRONMENTAll of Imerys’ facilities worldwide have set up an Environmental Management System (EMS) and 81 of them are ISO 14001 or Eco Management and Audit Scheme (EMAS) certified. An EMS enables each operation to manage and control the risks and issues relating to the protection of the

environment. The systems are fully integrated into the Group’s environment, health & safety (EHS) audit program. Every site has to measure its water, ensure waste water is recycled and check the quality of discharged water. These actions have achieved tangible results as the Group’s total water withdrawals have been cut by 13.2% since 2013 and by almost a third over the past five years. As far as biodiversity is concerned, Imerys pledges to respect the ecosystems around its facilities and conserve their value. In-depth studies are conducted on fauna and flora before any operations start on a

site. In addition, a restoration program is systematically set up for the site’s entire lifespan. On a Group scale, the measures taken since 2009 in favor of

TAKE 5

In 2014, Imerys rolled out “Take 5” in all its

operations worldwide. Each employee without

exception is asked to acquire the habit of taking

five safety steps before starting any task. This initiative was the focus of a broad awareness

campaign.

GROW

TH

RESPONSIBILITY

KNOW-HOW ACTING WITH

A RESPONSIBLE APPROACH

IS PREPARING FOR THE FUTURE

IMERYS

S O L U T I O N S F O R A C H A N G I N G W O R L D

1 5

-61% in five years

for the frequency rate of lost-time accidents

(including subcontractors).

ENVIRONMENTEnvironmentally-friendly

cement _

With Andalusite quarries close to the Pretoria Portland Cement (PPC), Imerys was able to offer a more efficient and environmentally-friendly product than fly ash from thermal power plants transported over long distances before going into cement production.

COMMUNITYFine perlite for local population activity

_

Used as a clay replacement to manufacture bricks, fine perlite, transformed in our factories, is a sustainable and economical solution, which helps to develop local activity but also to stop degradation and protect flora and fauna.

renewable or low-carbon energies have already led to a decrease in atmospheric CO2

emissions.

SPREADING SAFETY AWARENESS The Imerys Safety System is a program based on compliance, continuous improvement, and communication/training. The purpose of this integrated approach is to communicate the Group’s safety culture and ensure compliance with the same safety standards and rules at all of its activities worldwide. It presents t h e m a i n c o n t i n u o u s improvement levers for safety. The disciplined rollout of the Imerys Safety System has helped

to cut the lost-time accident rate (including subcontractors) by 61% in five years. Prevention efforts have been stepped up since 2013, leading to a 27% reduction in frequency.

BEING AN INTEGRATED PARTNERBuilding and sustaining the best possible relations with the communities near its sites is an essential condition for Imerys’ successful growth. The Group integrates social responsibilities into its sustainable development policy based on respect for its neighbors, leading to tangible actions on education, culture or health. A specific protocol on community relations has been

published, translated into seven languages and has been implemented at all Imerys sites.

75new products

launched in 2014 are of benefit to the environment.

More than one-third of the

I N B R I E F 2 0 1 4

S O L U T I O N S F O R A C H A N G I N G W O R L D

154, rue de l’Université – 75007 ParisTelephone: + 33 (0) 1 49 55 63 00Fax: + 33 (0) 1 49 55 63 01

TRANSFORM TO PERFORM

To find out more?

To find out more,visit the websites of the Group www.imerys.com and its activities

ENERGY SOLUTIONS & SPECIALTIES

Carbonates:www.imerys-carbonates.com

Monolithic Refractories:www.calderys.fr

Graphite & Carbon:www.imerys-graphite-and-carbon.com

Oilfield Solutions:www.imerys-oilfieldsolutions.com

FILTRATION & PERFORMANCE ADDITIVES

Filtration & Performance Additiveswww.imerys-perfmins.com www.imerystalc.com www.imerys-filtration.com www.celitecynergy.com www.advancedminerals.com www.insulation.imerys.com www.imerplast.com www.imerys-specialitiesjapan.com www.imerysvermiculite.com

CERAMIC MATERIALS

Clay Roof Tiles:www.imerys-toiture.com www.imerys-solaire.com

Minerals for Ceramics:www.imerys-ceramics.com www.imerys-aurora.com www.thequartzcorp.com www.ikf-solutions.com

Kaolin:www.imerys-kaolin.com www.imerys-perfmins.com www.imerysnopara.com.br

HIGH RESISTANCE MINERALS

Refractory Minerals:www.imerys-refractoryminerals.com

Fused Minerals:www.imerys-fusedminerals.com www.ifme.eu

Design and production:

Photo credits: G. Carillo • Fotolia • Imerys • Kwestion • N. de La Falaise • D. Lecuivre • Thinkstock • P. Wiangnont

Print: TI Médian impressions. This report is printed on paper produced from sustainably managed forests. The paper is FSC certified and contains Imerys pigments.