POLYTEC WORLD working steps. Programme re-alisation also involves important capital goods investments, which are targeted on sustained improvements in working procedures. One example

POLYTEC WORLD 01/15 - JUNE 2015

INVESTMENTSPOLYTEC enlarges existing

capacity, page 5

ACOUSTIC SOLUTIONSIntegrated Acoustic Solutions for holistic concepts, page 12

NEW DIMENSIONSSuccessful launch of Europe‘s largest D-LFT press, page 30

ALL-ROUNDERSIN THE FRONT LINE POLYTEC’S HYBRID UNDERBODY SOLUTIONS DO MORE THAN JUST MAKE CARS SOUND GOOD page 22

03PASSION CREATES INNOVATION

POLYTEC WRITES HISTORY: THE LAUNCH OF EUROPE‘S LARGEST D-LFT PRESS

GLOSSARY WITH AN OVERVIEW OF ABBREVIATIONS AND TECHNICAL TERMS

HEARD THE NEWS? POLYTEC OFFERS CUSTOMISED ACOUSTIC SOLUTIONS

Introducing . . .

The expansion of existing capacity and the further development of production technologies constitute two major elements in POLYTEC strategy.

In fact POLYTEC’s SHIELDING solutions not only offer all-round acoustic advantages, but also weight reductions, improved aerodynamics and increased safety.

The latest innovation from the POLYTEC plant in Putte, Netherlands is the in-mould decoration process (IMD), which for example is used for DAF Truck logo panels.

The design of the Porsche Cayman GT4 involves more than perfect looks. Every aspect of its form follows a function.

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Dear Reader, Heard the news? A new Integrated Acoustic Solutions concept combines our development and production competence in this field and is a special focal point in this edition of our POLYTEC WORLD. The related articles extend from a portrait of our newly purchased Dutch plant in Roosendaal, where some 2.1 million acoustic components are produced annually using a one-shot process, to a concrete description of two hybrid underbody co-vers. We thus encompass every aspect from development to the finished part.

Our recent purchase of a plant in Putte, Netherlands, has also resulted in yet another increase in the technological diversity within the group through innovative application possibilities such as IMD. This plays a decisive role in the in-house value added chain related to the logo panels for DAF trucks described on pages 10 and 11. In the car exteriors segment, we are especially proud of our refe-rence projects involving a sporty roof spoiler for Suzuki and the initial use of our blow moulding technology for lightweight com-ponents in the brand new Porsche Cayman GT4. In addition, our new location for high-quality priming near Weiden in Germany has not been neglected in this connection. The POLYTECDAY events held at two Jaguar Land Rover locations and the successful trade fair presentations by our INDUSTRIAL business unit at the UTECH provide an insight into the event highlights of recent months.

Our motto PASSION CREATES INNOVATION also applies to the layout of the company magazine, which now appears in only one language in order to improve its legibility. The separation of the German and English issues also allows us to provide a more de-tailed account of every individual, exciting project. May I wish you fascinating reading on your trip through the world of POLYTEC!

“Technical know-how and the creative potential of our workforce forms the ignition key for shared success with our customers.”

FRIEDRICH HUEMER, CEO

Alice Godderidge, CSO

WE’RE STAYING AT THE TOP!

POLYTEC‘S UNDERBODY SOLUTIONS DO MORE THAN JUST MAKECARS SOUND GOOD

PRECISION AND AESTHETICS FOR TRUCK EXTERIOR PARTS

A DECISIVE PERFORMANCE PLUS

Highlights

A COMPETENCE CENTRE FOR ACOUSTIC SOLUTIONS

Cover Story . . .

Passion creates . . .

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WE’RE STAYING AT THE TOP! INVESTMENTS IN A SPARKLING FUTURE

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INCREASED PAINTING COMPETENCE AT THE POLYTEC PLANTS IN HÖRSCHING AND AKSARAYAfter a construction phase of only three months, new painting cabins became ope-rational at the location in Hörsching, Upper Austria. These systems facilitate the flexible painting of small series with great variety and quality. Moreover, in the case of full ca-pacity working, 100,000 parts can be provi-ded with Class A painted surfaces annually.

During the planning and installation of the cabins, the guidelines of the POLYTEC Per-formance System, our lean management programme, were taken into precise ac-count. This allowed the perfect integration of the cabins into existing production and the further improvement of working se-quences.

The construction programme at the POLYTEC location in Aksaray, Turkey is also proving to be a record-breaker. Less than twelve months are to elapse between the ground-breaking and the delivery of the first serial components. From the spring of 2016, parts for some 20,000 trucks belonging to the Mercedes-Benz Türk Strategic Future Truck

The expansion of existing capacity and the further development of production technologies constitute two major elements in POLYTEC strategy. To remain at the top of a market that is constantly on the move, POLYTEC sets itself new goals on a regular basis. For the realisation of trendsetting concepts, we require the know-how of our employees, the necessary techni-cal equipment and an up-to-date manufacturing environment. Accordingly, in the past few months investments have been made at several locations in Austria, Germany, Great Britain and Turkey.

Visualisation of the new works hall (marked in red) in Aksaray, Turkey

non-automotive areas. Consequently, apart from up to 4,000 primed plastic parts for cars and trucks, as many as 100,000 coa-ted small parts, which include products for leading cosmetic industry manufacturers, emerge from production. Among the big-gest customers of the plant, which is situa-ted very close to the Czech border are BMW, MAN, Daimler, VW and Siemens. On a covered plant area of 16,000 m2, the workforce of 60 generated sales revenues of around 4 million Euros in 2014 and free land is available, which offers a perfect oppor-tunity for location expansion.

The new POLYTEC industrial painting location in Alten-

stadt near Weiden, Germany

C. GRUBER, HÖRSCHING, AUSTRIA

A WIN-WIN ACQUISITIONHOW POLYTEC HAS SIGNIFICANTLY INCREASED ITS PAINTING CAPACITY THROUGH THE TAKEOVER OF WIN COATINGS

FROM LONG-TERM PARTNER TO A VALUABLE POLYTEC GROUP MEMBEREven before the takeover, our new loca-tion, POLYTEC INDUSTRIELACKIERUNG, which is located in the immediate vicini-ty of our plant in Weiden, Bavaria, already operated largely as an extended POLYTEC

The targeted acquisition of companies that represent an ideal supplement to our portfolio is just one of the means being used to attain the strategic objective of consolidating our market position in Europe. The accompanying aim is to offer our customers first class products from a technical, qualitative and logistical perspective. Accordingly, since February 2015, the former WIN Coatings has strengthened our painting competence in optimum fashion.

workbench. With this acquisition, we have achieved a significant increase in our ran-ge of competences in the priming field. Furthermore, this has also enhanced the

depth of value added within the POLYTEC GROUP.

Components with lengths of up to 2,300 mm and widths of 1,800 mm receive top quality

primed surfaces on either a fully automatic or manually operated painting line. At pre-sent, the new company obtains roughly se-venty per cent of its sales revenues in the automotive sector, but is also successful in

Cosmetic jar with a crackled paint coating

made by POLYTEC

BMW M4 Coupé trunk lid, primed at POLYTEC INDUSTRIELACKIERUNG in Weiden

The new paint shop in all its glory! Finished components are checked at the Hörsching plant in Austria

Programme will roll off the production line.

The paint shop will occupy 2,200 square me-tres of the hall’s total area of 7,000 squa-re metres, which will also accommodate downstream processes including a modern storage concept.

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AUTOMATION IS THE TREND OF TOMORROW AND WE’RE READY FOR ITS CHALLENGES Since 2014, the Wolmirstedt location in north-eastern Germany has been manufac-turing extremely complex intake systems for VW in a demanding process that first requi-red the installation of a new line on which injection moulding, welding, assembly and quality checks could be completed using ex-tensive automation.

Every component passes through a process, the sequence of which is controlled precisely by robots and a large number of pressure sensors, temperature sensors and gripper arms. One employee per line supervises the resultant smooth production. The high level of automation is a major factor in increased competitiveness.

The demand for POLYTEC’s intake systems is so large that a second, identical line was al-ready put into operation in the fourth quar-ter of 2014. Consequently, in future some 1.3 million intake systems will be manufactured yearly in Wolmirstedt.

The robot-aided production of complex intake systems at the POLYTEC location in Wolmirstedt, Germany

One-shot production of the engine soft cover: a robot

system operates 8 foaming stations in Hörsching, Austria

EXPANSION AT THE LOHNE LOCATION SECURES OUR LEADING ROLE IN THE POWERTRAIN AREAOne of the fundamental aspects of our competitiveness is the provision of modern building and plants in order to possess the ability to maintain our position as a valuable technology partner to our customers. Accor-dingly, in 2014 we invested in the expansion of our POLYSWIRL® oil separation system production facilities at the group location in Lohne, Lower Saxony.

During last year, this POLYTEC-patented sys-tem was upgraded technically and is now

capable of removing oil droplets with a dia-meter of less than 0.001 millimetres.

Lohne is also one of the group’s tes-ting headquarters and its engineers have succeeded in bringing to production matu-rity an innovative filter system that offers improved filtration performance, reduced pressure losses and a longer useful life than standard systems. In order to fulfil the strin-gent technical demands made on the air fil-ter, POLYTEC invested in the installation of special filtration and fluidic testing equip-ment.

C. GRUBER, HÖRSCHING, AUSTRIA

More visual impressions of the engine soft cover production process can be accessed using this QR code

Pure racing culture:Jaguar‘s Project 7at full speed

This is the catchy motto of the POLYTEC Performance

System, our group-wide lean management programme

INFOThe aim of our group-wi-de PPS (POLYTEC Perfor-mance System) lean ma-nagement programme is to create value with every action through simple and efficient working steps. Programme re-alisation also involves important capital goods investments, which are targeted on sustained improvements in working procedures. One example is the opti-misation of the hot gas welding area, which is part of the production of inno-vative oil separation system production at our location in Lohne, Germany.

DO IT SIMPLYBUT SYSTEMATICALLY!

EUR 500,000 INVESTMENT IN INNOVATIVE ENGINE SOFT COVERPRODUCTIONIn future, greater process efficiency du-ring the production of engine soft covers is to be assured at the POLYTEC location in Hörsching, Austria, by means of a round table. This will facilitate clocked producti-on because it can accommodate as many as eight tools simultaneously.

Another advantage of this system is that tools can be pre-set off the table, thus redu-cing setting times, as work continues during the pre-setting process. Up to 280,000 en-gine soft covers are to be produced annually using this method.

WANT TO SEE SOME ANIMATION?MORE POLYTEC ON YOUTUBE.

FOR A PERFECT PROJECT START:BROMYARD FOCUSES ON PROTOTYPES AND PRE-PRODUCTIONAs a result of the high order volume at the Bromyard location in the UK and the gro-wing complexity of the components that it designs and produces, an investment has been made in new facilities for the develop-ment and industrialisation of small series in

the exterior area. These furnish the develop-ment team with an up-to-date working en-vironment that contains advanced technical equipment for the building of prototypes and their direct matching with vehicles. In the new, modern building the future will see the creation of prototypes and pre-production parts in close cooperation with customers, who will be able to gather an on-the-spot impression of components in combination with their vehicles.

The first project of this type to be success-fully realised involved the development of a bumper for the Jaguar Project 7. In team-work with Jaguar Land Rover, who provi-ded a pre-production car for the purpose, pre-series parts that matched the car to perfection were produced in just four weeks. Full production then commenced in May.

Further projects from Jaguar Land Rover, as well as Ford, Honda, Aston Martin and Lo-tus are already in the pipeline and demons-trate the probity and importance of the investment decision, which now allows the presentation of perfect prototype parts to customers within a very short time.

©Jaguar Land Rover


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A COMPETENCE CENTRE FOR ACOUSTIC SOLUTIONSTHE POLYTEC LOCATION IN ROOSENDAAL SPECIALISES IN HYBRID UNDERBODY COVERS

Since November 2014, the group product portfolio has been further upgraded by the Dutch location as a new POLYTEC GROUP company. Aerodynamic underbodies from Roosendaal offer automotive manufacturers clear advantages with regard to weight savings, safety and noise absorption at competitive production cost. The plant’s technical equipment represents the state-of-the-art and at the end of February 2015, the existing 17 presses were supplemented by Europe’s lar-gest D-LFT press, which was put into operation during a festive ceremony. More information regarding the press and its 4,300 tonnes compressive force can be discovered on page 31.

SHIELDING – A SYNONYM FOR HYBRID, LIGHTWEIGHT CONSTRUC-TION UNDERBODY SOLUTIONS In the industrial area of the Dutch district of Roosendaal, a POLYTEC GROUP complex with an area of more than 30,000 square metres, manufactures a range of lightweight components for the automotive world. Apart from core competences with regard to development and one-shot production, the plant portfolio also includes services such as prototyping, testing, assembly and the reali-sation of modern logistics concepts.

The focus is on high-tech components pro-duced from a combination of SMC, GMT, D-LFT and LWRT. In a single production process, these intelligent material blends are turned into hybrid underbody covers that combine reduced weight with exten-ded functionality. As SHIELDING solutions, these products represent a major addition to our Integrated Acoustic Solutions. Find out more about this innovative product seg-ment from the interview with Jeroen Dictus, an acoustics specialist from Roosendaal, on pages 12 and 13.

Underbody solution made of LWRT, GMT and GMTex

for the Audi A6

Plastics technology in the year of 1982: the Renault 5 with SMC bumpers from Roosendaal

Plastics technology today: the latest plant in combination with technological know-how for virtually unbeatably light and quiet underbodies

K. WEILCH, HÖRSCHING, AUSTRIA

POLYTEC COMPOSITES NL

Amsterdam

Paris

Brussels

50 YEARS OF EXPERIENCE – THE ROOSENDAAL PLANT CELEBRATES What started in 1964 with the foundation of a small mushroom farm is today a leading

location of the Dutch automotive subsupply industry with a total of 380 employees, 18 presses and yearly sales revenues of around 69 million Euros.

The first automotive component made from fibre reinforced plastic left the plant in 1968. In 1978, the first works hall was built on the current plant site and 1982 saw the installa-

POLYTEC COMPOSITES NL B.V.

Area 61,867 m2; thereof 32,218 m2 covered

Employees 380

Technologies Pressing of SMC, D-LFT, LWRT and GMT, VICS, PISA, laser cutting, milling, drilling, welding

Equipment 18 presses (100 t – 4,300 t), robots, CNC milling centres, ultrasound welding stations, laser cutting/BPU cells

Competences Development, prototyping, tool maintenance, one-shot process hybrid solutions, testing, assembly, JIT, FCL logistics

tion of a 2,400 tonnes press and hence the gathering of initial experience in pressing GMT. At this time, the works were already successfully manufacturing SMC bumpers

for the French Renault 5. The fruitful co-operation with Daimler Car, which is still the plant’s largest customer in terms of sales, commenced in 1986 and the steady expan-sion of the customer portfolio was particu-larly evident in 1992 with the completion of initial contracts for Scania and the British premium manufacturer Jaguar Land Rover. Today, both continue to number among the plant’s most important customers.

In 2002, the plant became part of voestalpi-ne Plastics Solutions and in December 2014 celebrated its golden jubilee as POLYTEC COMPOSITES NL B.V. with an event for em-ployees, business partners and representati-ves from the world of politics.

EXTREMELY STABLE ACOUSTIC INNOVATIONS ARE WELL WORTH A LISTENRoosendaal has added many advanced pro-ducts to the POLYTEC GROUP’s extensive range of competences. These include the further development of components made from materials such as LWRT and PISA, which have major acoustic effects. In 2014 alone, roughly 2.1 million differing acoustic components, from underbodies and bulk-heads to absorbers, were manufactured in Roosendaal.

In addition, on-the-spot technological know-how has led to the creation of VICS, an innovative combination of plastic and carbon or glass fibres, which is employed in lightweight underbody covers that offer enormously high mechanical performance capacity. More information is available on page 14.

London

Location of the POLYTEC plant in Roosendaal,

Netherlands


Passion creates. . .

PRECISION AND AESTHETICS FOR TRUCK EXTERIOR PARTSIN-MOULD-DECORATION: A ONE-SHOT-PROCESS FOR COMPONENTS WITH COLOURED SURFACES THAT MEET THE HIGHEST QUALITY REQUIREMENTS

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A major core competence of the POLYTEC plant in Putte, Netherlands, centres on injection moulded solutions for truck exterior applications. The latest innovation is the in-mould decoration process (IMD), which as shown on this page is used for DAF truck logo panels. During the production a thin foil carrying a special top coat finish is run through the open tool. During the subsequent injection moulding process, the top coat hardens and bonds with the injected polymer. The result is a component with a high-quality, extremely resistant colour coating that eliminates the need for a cost-intensive lacquering process. Read more on page 15.

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©DAF

POLYTEC employees carry out tool design and perform a

mould flow analysis to simulate the production process

A robot removes the high-gloss component with finished surface from open tool fully automatically

The finished logo panel for DAF with an abrasion-

resistant, coloured surface that rules out an expensive

lacquering process

Precise measurement of the component with 3D coordinate measuring equipment ensures the flawless production of the

logo panel

Logo panels being wrapped in transport packaging by a POLYTEC employee prior to just-in-time delivery to DAF

The logo panel is part of the front lid of DAF trucksA. PEIKSMA, PUTTE, NETHERLANDS

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HEARD THE NEWS?POLYTEC OFFERS CUSTOMISED CONCEPTS FROM THE FOUR PRODUCT AREAS OF ITS INTEGRATED ACOUSTIC SOLUTIONS

What began in 2013 with the start of production of engine soft covers for Volvo’s petrol driven cars and was then supplemented by flexible foam components lying directly on the noise source, has by no means reached its conclusion with our hyb-rid underbody covers. The editorial team asked Jeroen Dictus, POLYTEC’s acoustics specialist, what else customers can expect from these intelligent solutions.


The acquisition of two plants in the Netherlands has brought the POLYTEC GROUP important compe-tences with regard to the develop-ment and production of hybrid un-derbody covers. Moreover, this has considerably strengthened the Inte-grated Acoustic Solutions segment. But what advantages have resulted for POLYTEC GROUP customers?

Jeroen Dictus: Whether for engine or en-gine compartment encapsulation, with our Integrated Acoustic Solutions the group can provide acoustic concepts using a diver-sity of materials and technologies that are tailor-made to customer requirements.

In our SHIELDING solutions competence cen-tre in Roosendaal for example, a multi-ex-pert development team has been working on the optimisation of material combination and production processes for a number of years. As a consequence, we are now able to compress up to five different materials in various heights in a single working pro-cess. The resultant underbody covers offer a precise combination of strength, noise ab-sorption and temperature control, and thus secure both maximum functionality and cost efficiency. The latter is possible as the one-shot production process provides size-able cost advantages.

Injection Moulding Compounding is also a new technology within the POLYTEC GROUP. What possibilities does this process offer?

Jeroen Dictus: Injection Moulding Com-pounding allows us to create customised

material mixes, for example through the addition of reinforcement fibres, directly upstream of the actual injection moulding process. This cuts spending on materials and creates a sustainable reduction in customer production costs. Here, too, we are able to demonstrate exceptional flexibility and em-ploy the material combination best suited to customer needs.

What are the main products manu-factured using Injection Moulding Compounding?

Jeroen Dictus: At present, we are using this production technology for HOUSING solu-tions. The resultant heavy-layer component is installed between the engine compart-ment and the passenger cell and provides perfect acoustic encapsulation, which ensu-res a far quieter vehicle interior.

Can one measure these acoustic advantages objectively?

Jeroen Dictus: Yes, at the moment we are using two recognised acoustic test proces-ses. On the one hand, there is impedance tube measurement and on the other, alpha cabin testing.

What is the difference between these two measurement procedures?

Jeroen Dictus: Acoustic measurement with an impedance tube facilitates the quick de-termination of the noise absorption level and the reflection factor. A result can be obtained simply and directly after measu-rement using only a small material sample. However, we have seen that these measure-

ment results are often difficult to transfer to customer requirements. Accordingly, by and large we undertake acoustic measurements in an echo chamber, the so-called alpha ca-bin. A component measuring 1.2 square me-tres is laid out in this highly noise-insulated cabin and then subjected to evenly distribu-ted sound from several loudspeakers.

Using a mobile microphone, the frequen-cy-dependent absorption level is then calcu-lated as a mean value from various points in the room. The measurement results from the alpha cabin can be clarified in the form of absorption curves and the minimisation of the decibels is thus clearly recognisable.

What benefits derive from this in-house testing in the acoustics field?

Jeroen Dictus: The possibilities for in-house testing enable us to adhere to the strict qua-lity stipulations of our customers and also generate additional impetus for our develop-ment work. We are especially proud of the acoustic advantages provided by our PUR integral flexible foam COVERING solutions, which leave conventional engine covers standing. In fact with our engine soft co-vers we achieve a 35 per cent improvement in acoustic performance irrespective of the material used in the comparative product.

In closing, a look into the future. What developments are being wor-ked on at the moment and where do you see the greatest potential for In-tegrated Acoustic Solutions in years to come?

Jeroen Dictus: At present, the focus of our development work is on a further increase in the possibilities for functional integra-tion. In our opinion, the PUR flexible foam employed in our COVERING and ENCLOSING solutions possesses especially large poten-tial in this regard. Equally, we are pushing ahead with additional improvements to the acoustic characteristics of our products and are also seeking targeted and innovative combinations of the four areas contained in our Integrated Acoustic Solutions.

However, irrespective of what happens next, I can say one thing with absolute certain-ty: Using the mix created by our wealth of experience and the technological diver-sity within the group, working with our customers on the creation and realisation of individual acoustic concepts is a highly pleasurable activity.

LIGHT AND QUIET AS A FEATHER: POLYTEC AT BMWIn February, POLYTEC gave a successful presentation of its Integ-rated Acoustic Solutions at the BMW Research and Development Centre in Munich, Germany. While BMW top management and de-velopment engineers informed themselves on our fair stand, our specialist lectures were followed by interesting discussions with the expert audience.

1 COVERINGPURe sound absorbers

covering the engine

2 ENCLOSINGProducts tightly

enclosing the noise source

3 HOUSINGEngine compartment

encapsulations

4 SHIELDINGHybrid underbody solutions

Application possibilities with product examples using

POLYTECs Integrated Acoustic Solutions

Jeroen Dictus


OUR INNOVATIONS ARE POWERED BY PASSION SIGNIFICANT CUSTOMER ADVANTAGES “MADE BY POLYTEC”

LIGHTER, STRONGER AND TOUGHER – A JACK-OF-ALL-TRADES CALLED VICSThe abbreviation VICS stands for Variable In-moulded Composite Sandwich, an inno-vative combination of a thermoplastic mat-rix core with carbon or glass fibre reinforce-ment in the form of so-called organosheets, which is employed for the production of structural parts and intelligent underbody solutions. The components manufactured using VICS demonstrate a considerable in-crease in mechanical capacity in tandem with lightness. Indeed, as compared to steel, weight reductions of up to 50 per cent are possible.

As a proactive partner for our customers, we work continually on the development of new materials, technologies and pro-ducts for both the automotive and non-automotive areas. These include intelligent material combinations for our Integrated Acoustic Solutions such as VICS and PISA, as well as advanced technologies such as injection moulding compounding and in-mould decoration.

“Innovative products result from innovative thinking.”

FRIEDRICH HUEMER, CEO

The particularly high-strength and tenacity of the material provides underbodies with excellent damage resistance characteristics and robustness, which is most important as they are subject to the impact of stones and in the case of poor road conditions, even surface contacts. Furthermore, stiffness can be matched selectively to individual compo-nent requirements.

This technology also facilitates the optimum use of the space available. Glass fibre-rein-forced, mixed fibre fleeces (LWRT), which owing to their excellent noise absorption capacity have proven highly effective in un-

derbody applications, can be strengthened considerably with VICS. Moreover, the one-shot processing of these components offers marked cost advantages.

MORE THAN 5 MILLION QUIETER VEHICLES THANKS TO PISAThe underbody covers produced in a com-pression moulding process in combination with PISA (POLYTEC In-moulded Sound Ab-sorber) are currently to be found in five mil-lion vehicles around the globe. PISA offers optimum noise absorption even in very limi-ted material thicknesses. Furthermore, the sealed sound absorber is impregnated and

protects the engine compartment against moisture, dirt and mould.

PISA can be pressed with a range of light-weight construction materials in an efficient one-shot process and with its outstanding acoustic capabilities ensures noise reductions on both the in- and outsides of vehicles. More information about the successful use of PISA in a product example is contained in our cover story on pages 22 to 24.

FULLY AUTOMATED PROGRESS: INJECTION MOULDING COMPOUN-DINGInjection moulding compounding (IMC) is a single-phase process in which thermoplastics can be combined efficiently with any type of reinforcement fibres, fillers or softeners. The material components are first melted to form a homogenous mass, before being subjected to actual injection moulding. The main aim of the process is a sustained reduction in pro-duction costs.

The blending of the components during pro-duction eliminates the purchase of so-called

interim products and provides the shortest possible drying times, rapid processing cycles and improved moulded part quality. An ad-ditional advantage derives from the flexible adjustment of the material mix to customer requirements, which means it can always be made to precisely match the respective ap-plication.

At POLYTEC this innovative process techno-logy for HOUSING applications is employed for the group’s Integrated Acoustic Solu-tions, which furnish the engine compartment with optimum acoustic encapsulation using tailor-made, heavy layer material.

The injection moulding compounding process is carried out at our location at Putte in the Netherlands by two fully automatic robot systems. As a result, no manual intervention is required right up to component packing.

SURFACES WITH IN-MOULD DECORATION ARE BOTH ATTRACTIVE AND TOUGHThe in-mould decoration process puts com-ponents with surfaces subject to stringent

SHIELDING: underbody solu-tions using a VICS and PISA material combination

PISA: POLYTEC In-moulded Sound Absorber with animpregnated surface against water, fuel and oil


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VICS for lightweight underbody covers that offer enormously high mechanical performance capacity

quality demands into top shape. A thin carri-er film with a special coating is placed in the open tool and in the course of subsequent injection moulding this coating is bonded with the plastic material. The result is a high-quality, abrasion-resistant, coloured component.

This technology rules out the need for a cost-intensive lacquering process and is employed for the production of decorative exterior components in lengths of up to 1.6 metres. The diversity of colour variations and decorative effects available is virtually limitless.

POLYTEC utilises this technology with great success for the high-quality logo panels on DAF trucks. The related production process can be seen on pages 10 and 11.

Injection moulding compounding: component

being removed from the mould by a robotic arm

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IN EUR MILLION Q1 2015 Q1 2014 CHANGE

Turnover 155.8 117.9 32.1 %

EBITDA 14.2 8.2 73.1 %

EBIT 8.8 4.3 103.2 %

Earnings after tax 5.9 3.2 85.9 %

EBITDA margin 9.1 % 7.0 %EBIT margin 5.6 % 3.6 %Earnings per share 0.26 0.13 100.0 %

INTERIM REPORTQ1 2015

DESIGN MEETS TECHNOLOGYTHE SUZUKI VITARA CREATES A LASTING IMPRESSION WITH A SPORTY ROOF SPOILER FROM POLYTEC

GROUP RESULTS

Since the market launch in March 2015, with its fresh SUV design and extra helping of functionality, the new Suzuki Vitara is the talk of the town.

POLYTEC’S PASSION FOR DETAIL ENABLES US TO FULFIL CUSTOMER DEMANDS PRECISELYIn future, roughly 6,000 attractive roof spoilers for the Vitara will be produced at the POLYTEC location in Hörsching, Aust-ria, annually. Our Upper Austrian plant not only provided the CAD data for the B-side and the anchorage of the component, but also manufactured the necessary aluminium tools.

The roof spoiler is made from PUR rigid, which is ideal for the realisation of the

Group sales of POLYTEC GROUP increased by 32.1% to EUR 155.8 million in the first quar-ter of 2015. This includes the earnings con-tribution of approx. EUR 29.2 million by the two Dutch plants in Roosendaal and Putte acquired at the end of November 2014. Ex-cluding this acquisitive effect would result in an organic sales growth of EUR 8.6 million

The Suzuki Vitara with its POLYTEC roof spoiler has been designed with

sportiness in mind

The new Suzuki Vitara offers numerous individualisation possibilities

©Suzuki

W. BUNDSCHUH, HÖRSCHING, AUSTRIA

desired design and lends the powerful SUV a sporty aspect. POLYTEC has also assumed responsibility for the painting of the compo-nent in six different colours.

Like many other leading automotive ma-nufacturers, Suzuki has spotted the trend towards vehicle individualisation and there-fore the spoiler is both part of its “Urban” design package and available as a separate accessory.

A POLYTEC employee painting a roof spoiler at the POLYTEC location in Hörsching, Austria

Comparison of the group sales revenues and EBIT margin in the four quarters of 2014 with Q1 2015

or 7.3%. This was driven in particular by the sharp rise in sales of passenger cars in small series sector.

Group EBIT more than doubled in the first three months of 2015 to EUR 8.8 million. In addition to the earnings contribution by the sites in the Netherlands, the improved prof-

itability of individual business divisions con-tributed to the increase in operating profits. In addition, the acquisition of the property portfolio of approximately EUR 1.5 million, previously held by Huemer Holding GmbH, had a positive impact on operating profits.

The EBIT margin amounted to 5.6% in the first quarter of 2015 (Q1 2014: 3.6%). Both the material and personnel cost ratio im-proved compared to the values from the pre-vious year. The financial result amounted to EUR -0.9 million (Q1 2014: EUR -0.3 million). The change is primarily due to the interest expense from the promissory notes issued at end of September 2014. The tax rate of the POLYTEC GROUP for the first quarter of 2015 amounted to 25.3%. For the whole of 2014, the tax rate of the Group amounted to 24.9%. The Group generated a net profit of EUR 5.9 million. (Q1 2014: EUR 3.2 million). The earnings per share amounted to EUR 0.26 (Q1 2014: EUR 0.13).

Q1 2014 Q2 2014 Q3 2014 Q4 2014 Q1 2015

3.6 %3.9 %

3.8 %

5.3 %5.6 %

SALES REVENUES (IN EUR MILLION) EBIT MARGIN

117.9 120.6 118.1

134.7

155.8

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IN EUR MILLION Q1 2015 SHARE Q1 2014

Passenger cars 107.2 68.8 % 76.5

Commercial vehicles 34.0 21.8 % 29.1

Non-automotive 14.6 9.4 % 12.3

POLYTEC GROUP 155.8 100.0 % 117.9


Part sales and other sales 141.2 90.3 % 104.6

Tooling and engineering sales 14.6 9.7 % 13.3

POLYTEC GROUP 155.8 100.0 % 117.9


Austria 5.5 3.5 % 3.2

Germany 83.5 53.6 % 70.4

Other EU countries 57.0 36.6 % 36.6

Other countries 9.8 6.3 % 7.7

POLYTEC GROUP 155.8 100.0 % 117.9

CROSS-SEGMENT DATA

CAPITAL EXPENDITURE AND KEY FINANCIAL FIGURES

SALES REVENUES BY MARKET SEGMENT

CAPITAL EXPENDITURE

FINANCIAL FIGURES

SALES REVENUES BY CATEGORY

SALES REVENUES BY REGION

In the POLYTEC GROUP market segment with the highest sales, i.e. passenger cars, sales rose by 40.1% to EUR 107.2 million com-pared to the same quarter in the previous year. This significant increase was primarily due to the two newly acquired Dutch plants. Growth in customer Daimler Car, Jaguar/Land Rover and Volvo Car exhibited the greatest positive change. Even the passenger car customer with the largest share of Group sales, VW Car, developed very positively in

The increase in tooling and development sales resulted from the corresponding activ-ities in the Dutch plants. In addition, tooling and development sales moved at a stable level.

The additions to fixed assets amounted to EUR 100.5 million are mainly a result of the acquisition of the property portfolio previ-ously held by Huemer Holding GmbH. The acquisition of WIN Coatings GmbH and the increased investments in production plants,

The Group’s balance-sheet total increased at the end of the first quarter of 2015 by EUR 45.2 million to EUR 469.2 million. This was mainly due to the increase in fixed assets by around EUR 95.2 million. Most of this (EUR 87.3 million) is attributable to the acquisi-tion of the real estate portfolio previously held by Huemer Holding GmbH. This is offset by a decrease in liquid funds by EUR 59.0 million which were used primarily to pay the purchase price for the real estate portfolio

the first quarter of 2015.

Sales in the commercial vehicles market seg-ment increased by 16.8% to EUR 34.0 million in the first quarter of 2015 compared to the same period last year. This increase was also due to the customer DAF Truck - an effect of the Company acquisition.

Sales in the Non-automotive market seg-ment increased compared to the same quar-

ter of 2014 by 18.7% to EUR 14.6 million. This includes a revenue contribution of the customer Miele. The production of switching panels for washing machines and dryers was launched in the third quarter of 2013. The project still is in start-up phase. The sales of transport boxes likewise increased signifi-cantly in the first quarter of 2015.

VW CAR

DAIMLER CAR

JAGUAR LAND ROVER

VW TRUCK

VOLVO CAR

BMW GROUP

DAIMLER TRUCK

VOLVO TRUCK

JOHN DEERE

FORD GROUP

DAF TRUCK

OTHER AUTOMOTIVE

NON-AUTOMOTIVE

28.7 %

10.9 %

8.4 %

7.8 %

6.2 %

5.7 %

4.3 %

3.8 %

3.6 %

2.9 %

2.6 %

5.7 %

9.4 %

Group sales revenues split showing the largest

customers in Q1 2015

IN EUR MILLION Q1 2015 Q1 2014 CHANGE

Capital expenditure 100.5 4.8 N/A

EINHEIT 31.03.2015 31.12.2014

Equity EUR million 150.4 144.3

Equity ratio % 32.1 34.0

Net working capital EUR million 61.0 56.2

Net working capital of turnover % 11.5 11.4

Net debt (+) /- cash (-) EUR million 105.9 11.8

Net debt (+) /- cash (-) to EBITDA % 2.49 0.32

Gearing % 0.70 0.08

Capital employed EUR million 266.2 164.7

compared to the previous year, contributed to the significant increase in additions to fixed assets.

In the first quarter 2015, capital expendi-tures amounted to EUR 36.6 million. The dif-

as well as for refinancing. The equity ratio decreased at the end of the first quarter by 1.9% percentage points to 32.1% against the balance sheet date of 31 December 2014. This was primarily due to the initial consoli-dation of POLYTEC real estate group.

Net financial liabilities rose compared with the balance sheet date of 31 December 2014 by EUR 94.1 million to EUR 105.9 million. The main driver was the financing of the pur-

ference between capital expenditures and additions to fixed assets amounted to EUR 63.9 million and is due to partly non-cash purchase price. Thereof EUR 57,7 million amounted to the purchase price of the ac-quisition of the property portfolio.

chase of real estate portfolios. In addition, the acquisition of WIN Coatings GmbH as well as ongoing investments in fixed assets of the POLYTEC GROUP contributed to the significant increase in net financial liabilities.

Net current assets increased by EUR 4.8 mil-lion to EUR 61.0 million at the end of the first quarter 2015 compared to 31 December 2014 due to the increase in business volume.

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DESIGN CONCEPTS FOR GREATER SAFETYTAILOR-MADE TRANSPORT SYSTEMS FROM POLYTEC COMBINE DESIGN, FUNCTIONALITY AND COST-EFFICIENCY

POLYTEC FURNISHES THE NEW VOLVO XC90 WITH SUPERIOR SAFETY AND FLEXIBILITY POLYTEC CAR STYLING is not only supplying the underride guard, a side component and the side sills for the new Volvo XC90, but also accessories made of tubular steel. A modular boot divider system has been de-signed at the location in Schoten, Belgium, where it is also being produced. It offers end customers considerable increases in both safety and flexibility.

The standard component consists of a stable mesh, which is located directly behind the back seats. It reliably secures and separates both the boot with its contents and the pas-senger compartment. Moreover, a second

optional divider splits the boot area into two sections.

Should the vehicle owner wish to transport a dog, additional kennel gates can be installed with the help of the extendable system. The-se ensure that the dog remains in a defined area and prevents it from jumping out too quickly as soon as the tailgate is raised.

TRANSPORT SYSTEMS FOR SPECIAL DEMANDSPOLYTEC CAR STYLING in Schoten has also designed a tailor-made boot divider for Au-di’s special vehicle segment, which in future will be employed in police cars.

Prototype of the Volvo XC90 with integrated POLYTEC

transport system

©Volvo Car; use of the photographic material takes

place with the friendly permission of Volvo Car

W. CREMERS, SCHOTEN, BELGIUM

P. RETTENBACHER, HÖRSCHING, AUSTRIA

INFOPOLYTEC CAR STYLING in Schoten, Belgium is the only company in the POLYTEC GROUP that processes metals. It is located roughly 10 kilometres away from Antwerp and produces top quality door sill panels, motorcycle accessories and transport systems for numerous leading automotive manufacturers.

EMPLOYEES

POLYTEC SHARE

OUTLOOK

FULL-TIME EQUIVALENTS (FTE)END OF PERIOD PERIOD AVERAGE

31.03.2015 31.03.2014 CHANGE Q1 2015 Q1 2014 CHANGE

Austria 570 545 25 572 537 35

Germany 2,366 2,275 91 2,326 2,272 54

Other EU countries 1,186 522 664 1,182 527 655

Other countries 165 161 4 164 164 0

POLYTEC GROUP 4,287 3,503 784 4,244 3,500 744

The number of Group employees (incl. tem-porary staff) increased by 784 employees at the end of the first quarter of 2015 com-pared to previous year. The integration of the two Dutch plants at the beginning of

Assuming a stable business cycle, the man-agement of the POLYTEC GROUP forecasts a consolidated sales of more than EUR 600 million for the complete fiscal year 2015. As the substantial sales growth underlying these expectations is backed by the full-year consolidation of the acquired two Dutch plants and the noticeable organic growth

December 2014 increased the number of Group employees by 651 persons. Further-more, the number of employees increased through the acquisition of WIN Coatings GmbH (Germany) in February 2015 by an

based on the launch of series production for new products. The earnings figures should improve significantly, despite the restructur-ing costs in the COMPOSITE business unit.

additional 56 persons. The staff ratio de-creased by 0.5 percentage points to 32.6% compared to the previous year.

January 2015 April 2015

Share price development of the POLYTEC share in

red; Source: Wiener Börse AG, data indexed as at

January 2nd 2015

22 PASSION CREATES INNOVATION 23

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NCover Story

POLYTEC’S HYBRID UNDERBODY SOLUTIONS DO MORE THAN JUST MAKE CARS SOUND GOOD!IN FACT POLYTEC’S SHIELDING SOLUTIONS NOT ONLY OFFER ALL-ROUND ACOUSTIC ADVANTAGES, BUT ALSO WEIGHT REDUCTIONS, IMPROVED AERODYNAMICS AND INCR EASED SAFETY

The Mercedes-Benz C-Class and the Audi A7 Sportback are

both fitted with underbody solutions from POLYTEC

Our SHIELDING solutions use the space available to optimum effect and absorb both engine and traffic noise. They combine outstanding aerodynamic characteristics with functions such as heat ab-sorption and sound attenuation in the form of lightweight components. In addition, they effectively safeguard the engine against damage caused by stones and kerbs. POLYTEC develops individual un-derbodies and manufactures them using a variety of material combinations in highly cost-efficient, one-shot production processes. They can be employed for both the encapsulation of the engine com-partment, or the whole of the underside of the vehicle and with their aerodynamic design contribute to reduced fuel consumption and a pleasant driving sensation.

©Mercedes-Benz ©Audi

PISA UNDERBODIES CIRCLE THE WORLD IN THE NEW MERCEDES-BENZ C-CLASS With just a single, clever product, POLYTEC has succeeded in answering all of Merce-des-Benz’s demands for outstanding noise insulation, heat protection and rigidity as a safeguard for the powerful diesel engine against damage caused by flying stones and kerb contacts.

The basic material comprised of GMT with a glass fibre content of 30 per cent ensures an especially high level of stability, while alumi-nium lamination acts as a heat shield. In ad-dition, PISA, the POLYTEC-developed sound absorber, guarantees the optimum acoustic

POLYTEC COMPONENTS LEND THE PORSCHE CAYMAN GT4 MORE THAN JUST A STREAMLINED APPEARANCEThe design of the Porsche Cayman GT4 in-volves far more than mere perfect looks, for every aspect of its form follows a function. POLYTEC CAR STYLING responded to the challenges of this credo with creative ener-gy and innovative thinking, and was able to initially convince Porsche of the merits of blow moulding technology for the producti-on of the elegant rear spoiler, which with its integrated separating edge ensures the best possible aerodynamics.

The technical and design competence of the responsible team then also inspired Porsche with regard to another component. The la-teral air intake covers, or sideblades, with the embossed “GT4” logo now provide ad-ditional air pressure behind the doors, thus

25PASSION CREATES INNOVATION24

performance of the underbody of the elegant C-Class diesel. Using a one-shot process, the location at Roosendaal in the Netherlands turns out up to 400,000 PISA absorbers an-nually for employment around the world.

INDIVIDUAL UNDERBODY COVERS FOR THE NEW AUDI A6 AND A7 MODELSIn the new Audi models, it is not only the engines that contribute to a reduction in emissions, as POLYTEC’s hybrid underbody solutions also play a major role in this connection.

Whereas a blend of LWRT, GMT and GMTex has been in use for vehicles with standard petrol engines since 2010, louder TDI engines required an adjustment to the material mix and since the SOP in November 2013, this

has been seting new acoustic benchmarks. With a wall thickness of up to 25 millimetres, the high-loft LWRT (Low Weight Reinforced Thermoplastic) absorbs noise in optimum fashion owing to its excellent acoustic cha-racteristics and high core. In this SHIELDING solution, the high-performance fibre com-pound materials, GMT glass mat reinforced plastic and special further developed GMTex, provide extremely high impact resistance and stiffness in the wheel suspension area, and thus replace conventional metallic ma-terials in an intelligent manner.

The annual production of roughly 60,000 underbodies for diesel vehicles using these three different plastic materials employs a cost-efficient, one-shot process.

An innovative underbody solution for the Audi A6 and

A7 using LWRT, GMT and GMTex materials

PASSION CREATES INNOVATION: Porsche puts its faith in POLYTEC’s attractive blow moulding solutions for the first time

© Porsche

A DECISIVE PERFORMANCE PLUS POLYTEC LIGHTWEIGHT TECHNOLOGY PROVIDES A 385HP POWER PACK WITH PERFORMANCE-ORIENTED SIDEBLADES AND A REAR SPOILER

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creating improved suction and more effi-cient engine cooling.

BLOW MOULDING TECHNOLOGY OFFERS A WEALTH OF ADVANTAGES This was the first time that Porsche decided to employ the highly promising blow moul-ding technology for component manufac-ture. The process involves the initial creation of a hollow body using heated thermopla-stic. In the closed mould the material is then blown into the required form by means of compressed air and subsequently retains its shape following cooling.

This type of production, which POLYTEC CAR STYLING has already been using for some time for other leading automotive manu-facturers, provides numerous advantages. The hollow body offers considerable weight reductions as compared to injection moul-

ding solutions and moreover, production in a single piece. This furnishes optimum pro-cessing quality, as the bonding of several parts is not required, and at the same time ensures the overall, cost-efficiency of small series output.

FLEXIBILITY ALONG THE ENTIRE VALUE ADDED CHAINIn a very brief development period lasting just 10 months from the order allocation to SOP, the multi-member POLYTEC project team accompanied Porsche along the enti-re value added chain from the development phase and in-house tool making, to produc-tion, painting and logistics. The exclusive sports car has been available in twelve diffe-rent colours since February 2015.



Cover Story

Brand AudiModel A6, A7Material High-loft LWRT, GMT and GMTexSOP November 2013Pieces 60,000 p.a.

Brand Mercedes-BenzModel C-ClassMaterials GMT, PISA and aluminiumSOP December 2013Pieces 400,000 p.a.

The Mercedes-Benz C-Class underbody, which is produced in a one-shot process


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TWO IS BETTER THAN ONESUCCESSFUL POLYTECDAY EVENTS AT JAGUAR LAND ROVER

THE POLYTECDAY - AN EVENT BECOMES A SERIESFollowing the successful launch of the new POLYTECDAY concept at Volvo Car in Go-thenburg during last spring, November 2014 saw another event in this series and this time in twin-pack form. Six-strong teams of sales and engineering experts presented POLYTEC GROUP innovations at two locations of the British Jaguar Land Rover premium automo-tive manufacturing group.

A GUEST APPEARANCE AT JAGUAR LAND ROVERThe first of the two POLYTECDAY events took place on November 25th at the high-tech location in Gaydon (GDEC, Gaydon Development & Engineering Centre), which is a key Jaguar Land Rover technology cen-tre. With a total of 6,000 employees, Jaguar Land Rover in Gaydon combines the group’s R&D competences in the exterior and body areas with its testing capacity for the Ja-

guar and Land Rover cult brands. Gaydon is also the design cradle for the individual and unique Land Rover models.

POLYTEC’S INNER AND OUTER LIGHTNESS VALUESIt was therefore only logical that POLYTEC’s visit focused on lightweight construction so-lutions for the exterior and structural areas such as the ultra-light trunk lid for the BMW M4 Coupé, which is made from low-density and carbon SMC. With a total weight of just 7.6 kilogrammes, as compared to steel, this two-layer design provides a weight reducti-on of 40 per cent, not to mention tempera-ture resistance of up to 200°C, which facili-tates online painting at BMW.

Of special interest was also the fact that apart from exteriors, carbon SMC can be used elsewhere. This means that in future si-milar weight savings will be attained in the case of structural body components. Indeed,

POLYTEC’s development engineers are alrea-dy working at full speed on concrete projects.

Another highlight of the day was formed by POLYTEC’s underbody solutions. Using light-weight construction materials such as LWRT, these combine outstanding aerodynamic characteristics with functions such as heat and noise absorption, and the protection of the engine against stones and impacts with kerbs.

PASSION FOR INNOVATION IS AT ITS BEST WHEN SHARED Richard Hale, a Key Account Manager from Bromyard: “The diversity of the POLYTEC GROUP’s solutions was demonstrated im-pressively with our show car, which contains over 50 components from various technolo-gical areas. For me, the POLYTECDAY provi-ded an ideal platform for becoming better mutually acquainted and exchanges with contacts both old and new.”

“For me, the POLYTECDAY provided an ideal platform for becoming better mutually acquainted and exchanges with contacts both old and new.”

“It was evident how fruitful the acquisition of voestalpine Plastic Solutions by the POLYTEC GROUP has proven, as through the numerous, resultant synergy effects we can increase the advantages for our customers!”

RICHARD HALE, KEY ACCOUNT MANAGER

EDWIN ALFERINK, KEY ACCOUNT MANAGER

An impressive display of solution diversity: the

POLYTEC show car with more than 50 components using

various technologies

POLYTEC experts in a Q&A session at the Jaguar Land Rover location in Gaydon, UK

Following the successful event in Gaydon, the second POLYTECDAY event was on the programme for the next day. This took pla-ce at the Jaguar Land Rover headquarters in Whitley, where over 4,000 employees focus on Jaguar design and state-of-the-art de-velopments, especially in the engine com-partment.

POLYTEC SHOWS ITS STRENGTHS IN THE POWERTRAIN SECTOROn this occasion it was POLYTEC’s extensi-ve portfolio in the powertrain sector that caught the eye, as the use of plastic as a substitution material not only creates light-ness and a high degree of design freedom, but also the possibility for the integration of an increasing number of functions.

Moreover, these advantages are achieved largely within the scope of highly automa-ted production processes, as is the case with complex intake systems and rocker covers equipped with our integrated POLYSWIRL® fine oil separation system.

In addition, the group not only delivers pro-ducts and systems, but also acts as an active technology partner during the development of new engine compartment solutions. In this connection, POLYTEC’s development experts recently brought a new air filter system to industrial maturity that offers im-proved filtration performance, lower pressu-re losses in combination with longer useful life, and a reduced space requirement in the engine compartment. This product was also the object of great interest in Whitley.

Edwin Alferink, a Key Account Manager from the new POLYTEC location in Roosendaal: “We drew Jaguar Land Rover’s attention to a range of lightweight and highly functio-nal innovations in the engine compartment area. As a new member of the POLYTEC GROUP, I also learned a great deal of exciting information from my colleagues. During the POLYTECDAY, we were able to present our-selves as a company with over 4,200 emplo-


yees for the first time. I think it was clear to all the participants how fruitful the acquisi-tion of voestalpine Plastic Solutions by the POLYTEC GROUP has proven, as through the numerous, resultant synergy effects we can increase the advantages for our customers!”


“As a highly competent partner in the development and production of customised multi-component dosing systems, we fulfill customer wishes with PURe PASSION.””

PURe PASSIONPOLYTEC INDUSTRIAL KICKS OFF THE 2015 TRADE FAIR SEASON AT THE UTECH AND ALSO CONTINUES ITS SUCCESSFUL WORKSHOP SERIES

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The doors to this year’s UTECH opened during April in Maastricht and as was anticipated, the polyurethane industry’s leading trade fair attracted a record number of visitors to the Netherlands. The fair serves as both a congress for branch decision-makers and an international showcase for the latest technological innovations. It therefore provided the perfect platform for POLYTEC INDUSTRIAL to present itself to an international audience from over 90 countries.

DOSING SYSTEMS IN A CLASS OF THEIR OWN – POLYTEC EMC EN-GINEERING SHOWS ITS PACESThe UTECH, which took place in Maastricht in the Netherlands from April 14-16th 2015, is by far the largest polyurethane processing industry trade fair in Europe. On the attrac-tive POLYTEC EMC ENGINEERING stand, the

INDUSTRIAL business unit presented visitors with three types of casting systems, which in order to cover the widest possible range of applications, could not have been more varied.

The product portfolio extended from a small DG 10 type, a two-component laboratory

unit, and a DG 108 mobile mixing and do-sing system for the processing of adhesives, to the DG 120, a three-component casting system for small product series. In the case of the latter, all the machine components can be heated up to 130°C and in addition the mixing head offers the possibility for the dosing of additives or colours.

Discussions with business partners at

the UTECH 2015

The POLYTEC INDUSTRIAL stand at the UTECH in Maastricht, Netherlands

P. STINSHOFF, BOCHUM, GERMANY

The POLYTEC stand also provided space for our cooperation partners from Scandinavia, Southern and Eastern Europe. This arrange-ment created an opportunity for the discus-sion of new projects and during the three days of the fair several offers were end- negotiated.

INTERNATIONALISM PLAYS AN IMPORTANT ROLE IN PLANT BUILDINGMoreover, these successes were not all, as the trade fair season for POLYTEC INDUSTRIAL had actually only just begun. And this year, the globally active POLYTEC EMC ENGINEERING, which obtains 90 per cent of its sales from export business, made its debut at the branch gathering of the North Ameri-can polyurethane processors.

The meeting of the PMA (Polyurethane Ma-nufacturers Association) took place in Char-lotte, the largest city in the state of North Carolina, from April 26 to 28th. Within the framework of a model project, POLYTEC EMC ENGINEERING presented its innovative de-velopments and the possible applications of its equipment to the North American audi-ence.

The aim was to boost our recognition levels in the USA and to further increase the sha-re in the national dosing system market. In addition to participation in technical presen-tations, the event also provided a forum for discussions with all the attendees.

POLYTEC AND DOW – A FRUITFUL COOPERATION IS EXTENDEDIn May, POLYTEC EMC ENGINEERING cont-inued its successful “PURe COMPETENCE” workshop series at the Zlin University of

Technology in the Czech Republic. From May 6-7th, the new DG 123 dosing system made its pubic debut in a joint presentati-on with the DOW chemicals group. Further-more, during a practice-oriented workshop, customers and partners from Eastern Europe had an opportunity to test this advanced four-component casting system under rea-listic production conditions.

The attendees were even offered a chance to bring and fill their own moulds, which natu-rally demonstrated the simple, user-friendly operation and advantages of the POLYTEC system. In addition, the chemicals experts from DOW provided information regarding their raw material systems.

DOW Germany numbers among the ten largest US companies in the country and among other activities is concerned with the development of high-performance plastics.

PETER STINSHOFF, MANAGING DIRECTOR

The DG 120 series is ideally suited to small series

production in a range of industrial branches


POLYTEC WRITES HISTORY

THE LAUNCH OF EUROPE’S LARGEST D-LFT PRESSTURNS INTO A SINGULAR EVENT

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POLYTEC OFFERS AN INVITATION TO A VERY SPECIAL OCCASIONNo less than 200 guests, including many bu-siness partners and representatives of both local government and employer associa-tions, responded enthusiastically to the invi-tation to visit our Dutch location. CEO Kees Bruinsma and Plant Manager Eric van der Horst welcomed the guests and then shared the remarkable story behind this mammoth project with the highly attentive audience.

HOW EVERYTHING BEGAN...In 2013, the Roosendaal workforce was already working on a five-shift, 24-7 basis and was confronted by a continuous, stea-dy rise in the demand for its innovative un-derbody solutions. As a result, a point was reached at which even this level of commit-ment was no longer sufficient. Moreover, it was precisely at this juncture that Daimler Car held out the prospect of another major project. Therefore, the time for action had

clearly arrived. The question was what could be done in a situation in which the delivery time for new plant was longer than that between order receipt and the start of serial production?

It was then that employees heard a sto-ry about a brand-new D-LFT press, which

allegedly had been ordered by a Russian company, but never collected, and was now in storage at the port of Antwerp. The fa-mous Dutch civil engineer and statesman

Roughly a year ago, work started at the new POLYTEC location in Roosendaal on the construction of an 18m-high hall for a press that is unique in Europe and packs an impressive 4,300 tonnes compressive force. On February 25th 2015, this project reached a fitting climax with the public unveiling of the D-LFT press during a stunning celebratory presentation. And at the latest, anyone who had not already been enthralled by the impressive dimensions of the press was certainly captivated by the event following the appearance of a humanoid robot.

1. The dosing system mixes the thermoplastic components in the extruder, where they are processed to form a 210°C mass

2. The material mix is conveyed to the first robot using a heated transport belt.

3. The robot transfers the mass to the tool, which closes immedia- tely and generates pressure of up to 4,300 tonnes.

4. A second robot removes the formed and somewhat cooled component from the tool using vacuum grippers and places it in a punching press.

5. The required punching is carried out, prior to a third robot laying the component on a transport belt, which carries it to a quality check.

“A project result to be proud of, is only achievable by working as a team.”RALPH STASSEN, MANAGER MANUFACTURING & ENGINEERING

More visual impressions of the

event can be accessed using this QR code

The process phases of the D-LFT press in

Roosendaal, Netherlands

Cornelis Lely once pithily stated that: “In order to make marvellous things possible, three things must come together: a cata-strophe, a person with a plan and someo-ne who is ready to finance it.” This was the case in July 2013 at the Roosendaal location when there was a lack of production capa-city. At this moment, the abandoned D-LFT

press in Antwerp offered the ideal solution to the problem and as soon as the financing had been organised, work started on the hall needed to house the impressive machine.

In order to erect the 680 tonnes press, 250 concrete piles had to be driven into the ground to a depth of up to 18 metres. The reinforced foundations were then further strengthened with a 300mm-thick layer of ferroconcrete and 600 cubic metres of con-crete and over 180 tonnes of steel went into the hall construction. The hall floor in Roo-sendaal was then able to withstand pressure loads of as much as 12 tonnes per square metre and not only support the D-LFT press, but also a crane with a transport capacity of twice 50 tonnes.

EXCEPTIONAL ACHIEVEMENT DESERVES AN EXCEPTIONAL CELEBRATION The opening event on February 25th 2015 began in absolute darkness. A pair of flas-

hing lights then appeared and suddenly a humanoid robot was standing in the hall entrance. This was steered from the stage via a joystick by our honorary guests together with CEO Kees Bruinsma.

The guests watched the robot’s mechanical movements in fascination as it headed for its destination. Upon arrival, it pressed a red button to the thunderous applause of the audience and the D-LFT press became ope-rational.

ONE-SHOT-PRODUCTION IN A LEAGUE OF ITS OWNWith a height of almost 15 metres and a pressing force of 4,300 tonnes, the new D-LFT press in Roosendaal is the largest of its type in Europe. Using its 4 x 2.8m tool table, the giant can easily shape even the

A. VAN GELDEREN, ROOSENDAAL, NETHERLANDS

Messrs Pauli, Struik and Bruinsma on stage with the

humanoid robot

largest components within cycle times of less than 30 seconds. It is employed for the one-shot-production of hybrid underbody solutions, during which as many as five com-ponents are compressed together in varying thicknesses in a single operation.

The production process corresponds with the guidelines contained in the POLYTEC Performance System with a central focus on TPM (Total Productive Maintenance) and 5S. The machine’s tool changes are also highly efficient with less than an hour elapsing between two different types of production.


What motivates you? A desire for the new

What is your passion? Music, cars and the good things in life

What is important in cooperation with other departments?

A good mood in the team

The world needs… fewer stressed people.Future means… life.

Time is… short.The most important thing in life is… my family.

Contentment… is the real name of good fortune.Change… means not standing still and always seizing

new opportunities.Friends describe me as… warm-hearted and honest.

What motivates you? Taking pleasure from obtaining fresh knowledgeWhat is your passion? My familyWhat is important in cooperation with other departments? The professional handling of assignments and their punctual completion

The world needs… more visionaries, who through honesty and fairness contribute to the common good.Future means… the opportunity to correct mistakes made in the past.Time is… generally in short supply.The most important thing in life is… to live.Contentment… is sadly often forgotten, or pushed aside by greed.Change… is the only constant in life.Friends describe me as… a person possessing common sense, empathy and stamina.

My Motto:What motivates you? Solving interesting assignments with nice peopleWhat is your passion? Chilling out on the North Sea island of JuistWhat is important in cooperation with other departments? The same information level and a shared objective

The world needs… more tolerance.Future means… perspectives, visions and ideas in combination with coincidence.Time is… a luxury that becomes more precious with age!The most important thing in life is… my family and our cat Drops.Contentment… anyone who is dissatisfied with what they have, will also be dissatisfied with what they would like to have.Change… means leaving the comfort zone. The prerequisite for a fresh orientation and further development.Friends describe me as… friendly, frank, reliable and a tough opponent in any sport.

My Motto:

In troducing .. .

Paul Rettenbacher – a competent contact for stockholders, analysts and the financial media

In recent months, POLYTEC has strengthened its central units with three new and highly competent recruits. Paul Rettenbacher became the Head of Investor Relations in January 2015, since when he has been cultivating the contacts with our stockholders and investors. He also publishes news regarding the business status of the group and looks after the financial section of the annual report. Concentrated female power is now the order of the day in the Legal Department. Dr. Gisela Edelbauer is responsible for all legal matters within the POLYTEC GROUP and receives strong support from Anja Pietrzykowski from Lohne.

My Motto:

PAUL RETTENBACHER

Head of Investor Relations

Date of birth 22.04.1965

Personality Communicative, committed and creative

Date of entry 01.01.2015

Location Hörsching, AT

ANJA PIETRZYKOWSKI

Specialist Legal Department


Personality Friendly, communicative and determined


Location Lohne, DEDR. GISELA EDELBAUER

Head of Legal Department


Personality Dynamic, reliable, and empathic


Location Hörsching, AT

PEO

PLEThis strong team always

has the law on its side: Anja Pietrzykowski and

Dr. Gisela Edelbauer (FLTR)

34

Now+Then

During the 1980s, the concept of using do-sing systems to support manual polyuretha-ne casting systems became increasingly po-pular and POLYTEC EMC ENGINEERING also responded to this trend.

Today, the key component in every dosing system is the mixing head. However, where relays were once used for the setting of the mixing ratios, this task is now assumed by modern, programmable logic controls with touch panels and plant visualisation. Apart from far more precise and above all faster cycles, these controls facilitate the linkage of automated systems and data recording for integration into customer production

DOSING WITH PRECISIONMADE IN AUSTRIA: MIXING AND DOSING SYSTEMS FROM POLYTEC EMC ENGINEERING IN THE COURSE OF TIME

GLOSSARY

Employee using the touch panel of a

POLYTEC dosing machine

POLYTEC plant engineering in the 1980s P. STINSHOFF, BOCHUM, GERMANY

INFOAs a part of the POLYTEC GROUP, the Upper Aus-trian company POLYTEC EMC ENGINEERING specialises in the de-velopment and production of advanced mixing and dosing systems that are trim-med precisely to customer requirements.

data acquisition systems. Plant control sys-tems such as throughflow quantity measu-rement are also now included directly in the control technology.

In past decades, we also matched our do-sing systems to the advances in raw material systems. Apart from colour injection, these developments relate to the direct injection of tiny quantities of additives or catalysts in the mixing chamber.

The global export of our equipment, inclu-ding sales to countries with temperatures of over 40°C in the production area neces-sitates the offer of both plant heating and cooling systems. These guarantee the preci-se temperature control of the raw materials throughout the year and hence the provision of a reproducible and controlled process.

More information regarding POLYTEC‘s mixing and dosing systems is available at www.polytec-industrial.com

ABS Acrylonitrile-butadiene-styrene: a thermoplastic

Additive Substance that is added to plastics in order to achieve or improve certain characteristics

Blow moulding Process for the production of thermoplastic hollow bodies (lightweight construction technology)

BPU Flaming and primer unit

B-side (Class B) Component surfaces that are normally not seen by the user

CAD Computer-aided design: product engineering using EDP

CEO Chief Executive Officer: management board chairperson

Class A (A-side) Visible, exterior and interior component surfaces

CSO Chief Sales Officer: member of the board with responsibility for sales, marketing and development

D-LFT Method for the processing of long-fibre, reinforced thermoplastics, in which the matrix is plastified prior to pressing in an extruder and then blended with shortened continuous filaments in a mixer

Extruder Production device that presses hot, solid to viscous material uniformly through a moulding nozzle under high pressure

FCL-Logistik Full container load: door-to-door transport of a complete container

GMT Glass mat reinforced thermoplastic

Heavy layer see injection moulding compounding

High-Loft-LWRT LWRT with improved noise absorption due to a wall thickness of up to 25 mm

IMD see in-mould decoration

Injection moulding compounding Process for the injection moulding of long-fibre thermoplastics; high level of design freedom and output for HOUSING solutions

In-mould coating Process for integrated surface upgrading; complex surface pre-treatment and subsequent lacquering are not required

In-mould decoration Process for the upgrading of plastic parts with a coloured and abrasion-resistant coating in a one-shot injection mould process

JIT Just-in-time: workpiece is delivered punctually to the assembly line

Low-density SMC SMC with hollow glass spheres for reduced material density and hence lower weight

LWRT Low-weight reinforced thermoplastics: light, glass fibre reinforced, thermoplastic blended fibre nonwovens with high acoustic efficiency

Matrix Compound materials embedded in other components

One-shot process/production Single step manufacture

PISA POLYTEC In-moulded Sound Absorber: patented POLYTEC product that protects the engine bay against moisture, dirt and mould

Polyurethane Plastic or plastic resin with an exceptionally large range of application

PPS POLYTEC Performance System: the POLYTEC GROUP’s lean management programme

PUR see polyurethane

SMC Sheet moulding compound: pressed mass consisting of duroplastic, reaction resins and glass fibres for the production of fibre-plastic composites

SOP see start of production

Start of production Launch of serial manufacture

SUV Sport Utility Vehicle: car with limousine-style comfort, but increased off-road capabilities and a body that resembles an all-terrain vehicle

TDI engine Diesel engine with direct fuel injection from the VW Group

Thermoplastics Plastics that can be moulded within a certain temperature range

TPM Total productive maintenance: programme for continual improvements throughout every area of a company with a main focus on the production area

VICS Variable In-moulded Composite Sandwich: combination of a thermoplastic matrix with carbon or glass fibres

Imprint and disclosure according to § 25 Austrian Media Act:POLYTEC HOLDING AG; Managerial functions as well as engineering and production of plastic parts. UID no.: ATU 49796207; Company reg. No. 197646 g, Regional court Linz; Polytec–Straße 1, 4063 Hörsching, Austria; Tel. +43 7221 701-0, Fax +43 7221 701-35, [email protected]; Executive Board: Friedrich Huemer, Markus Huemer, Alice Godderidge, Peter Hai-denek; Chairman of the Supervisory Board: Fred Duswald; Half-yearly magazine for information of customers and employees of the POLYTEC GROUP with regard to tasks, targets and operations of the company. Responsible for contents: Alice Godde-ridge; Chief editor: Karin Weilch; Concept and graphic design: Carina Gruber; Editorial team: C. Gruber, K. Weilch, A. Peiksma, W. Bundschuh, P. Rettenbacher, W. Cremers, P. Stinshoff, A. van Gelderen, A. Pietrzykowski, G. Edelbauer; Images: POLYTEC GROUP, istockphoto, Fotolia, Jaguar Land Rover, DAF, Suzuki, Volvo Car, Mercedes-Benz, Audi, Porsche, Seehotel Wassermann. Errors and printing errors excepted.

You want to unsubscribe from receiving the POLYTEC WORLD or update your contact data? Please send an e-mail to [email protected].

PEFC certified: Printed on paper from sus-tainably managed forests and controlled sources. More info at www.pefc.at.

PASSIONCREATES

INNOVATION

READ & WIN1. How many materials can be pressed in a single process for our SHIELDING solutions?2. Within what timeframe did the POLYTEC project team realise the SOP of the components for the Porsche Cayman GT4?3. How many vehicles worldwide are already fitted with PISA, the POLYTEC In-moulded Sound Absorber?

Send the answers to the questions above to [email protected] by July 31st 2015 and win a vou-cher for three nights for two persons including breakfast and a 5-course menu at the Seehotel Wassermann in Seebruck am Chiemsee, Germany. The voucher is valid from October 19th to December 22nd 2015. The editorial team is excluded from the competition.

WINNER FROM THE LAST EDITION: AXEL WALZ, POLYTEC COMPOSITES GERMANY, GOCHSHEIM, GERMANY

Seehot el Wassermann

Chiemsee, Germany

Win a luxury break for two !

Visit us at the IAA in Frankfurt/Main in Hall 4.1, Stand F05. We are looking forward to seeing you!

17.-18.09.2015

www.polytec-group.com

Documents

POLYTEC WORLD working steps. Programme re-alisation also involves important capital goods investments, which are targeted on sustained improvements in working procedures. One example