Pushtrusion TM. New Direct Compounding Technology. New. Integrating new technology with state-of. of-the-art production systems

Transcription

1 Pushtrusion TM New Direct Compounding Technology New Integrating new technology with state-of of-the-art production systems Eric V. Lee, product manager

2 Presentation Content Review market dynamics contributing to the rise of LFRT s. The disruptive nature of Direct Compounding. New technology review. Direct Compounding platforms. Cost analysis.

3 The Growth of LFRT s The origins of fiber reinforced thermoplastic composites is LFRT 1950 s: Short glass compounding developed s: Pultrusion initiated to achieve longer fiber in pellets. Increasing Stiffness Fiber Reinforced Thermoplastics Long Fiber Short Fiber Unfilled (LFRT) Increasing Fracture Toughness 2008 global LFRT Forecast 480MM pounds CAGR >15% Validates D-LFRT D-LFT, 214 MM pounds Global LFT Market BRG Townsend Report, 2004 Pellets, 265 MM pounds

4 Brief History of LFRT s The rise of long fiber reinforced thermoplastics (LFRT) The addition of long fibers boosted performance and created new opportunities for first generation plastic applications. Price vs. performance ratio gained favor with market leading companies and early adopters to displace welding and die casting. Market acceptance invited competition and forced producers to increase scale and efficiency. Automotive LFRT applications increase and large structural parts are commonly being made using LFRT-PP. New Direct In-Line Compounding (D-LFRT) process further reduces cost and enables higher volume, lower cost LFRT-PP. Increased competition among LFRT-PP pellet suppliers as new entrants emerge; concentrate strategy renewed to lower costs. Scale and efficiencies continue to make modest improvements in conversion costs of LFT-PP pellets.

5 Injection Molding Snapshot Greater than 250 North American Compounders. Predominant polymers are PP, PE, ABS, PA, and other ETP s. Nearly 3.5 BN pounds of fiber-reinforced plastics processed. More than 600 injection molders. 30,000 installed injection molding machines & growing.

6 The Perfect Storm Fiber reinforced thermoplastics is an established, huge market! LFRT's expand the opportunity to displace incumbent materials and technologies (e.g. metals, stampings, assemblies). D-LFRT processes are viable and validated in key markets. Material suppliers focused on providing incremental improvements to existing customers and markets while increasing efficiency and profitability of core offerings. Negligible integration of the supply chain. Material costs dominate the processors cost structure. Converters are increasingly more sophisticated and willing to assume greater risks to compete differently. Enter Pushtrusion a very, very Disruptive Innovation

7 Direct Compounding A Disruptive Innovation What makes this Direct Compounding technology disruptive? It s not reserved for a select few! It s simple and affordable. Those who would normally be excluded due to high capital expense or complexity may participate. It s not dedicated to a particular process or material. Demystifies the art of combining fibers with polymers. Leverages technology to enter an established market not reliant on efficiency gains or supply chain manipulations.

8 Simple and Adaptable New compounding technology for converters invented by the LFRT pioneers Compounding unit atop press Most thermoplastics; PP, PA, TPU, PPS, PC, PVC (short or long fiber) Most continuous rovings; Glass - Carbon - Stainless Aramid - Natural fibers Injection molding machine

9 2 Platforms: 1. OEM Option 2. Portable retrofit, aside press

10 Simple and Elegant New compounding technology for converters Simple elegant mechanical process with few moving parts. Adaptable easily mounts to other converting processes. Portable able to be moved among various machines. Capable accommodates various reinforcing fiber and polymer. Versatile creates long or short fiber reinforced thermoplastics. Affordable quick payback on investment.

11 Maintaining Performance at Lower Costs LFT Pellets Pushtrusion D-LFT material cost savings per part, US $ Kayak Rudder part volume: 221 cc <$0.10> <$0.65> GF30-PP 248g GF30-PA6 300g

12 Reducing Price Di$parity Formula PP 40 wt% glass UV, CC, Black PA 6 40 wt% glass UV, CC, Black PA 6,6 40 wt% glass UV, CC, Black PBT 40 wt% glass UV, CC, Black TPU 40 wt% glass UV, CC, Black Short glass pellets $ 1.00 $ 1.40 $ 1.50 $ 1.40 $ 2.15 Long fiber pellets LFT $ 1.20 $ 2.30 $ 2.40 $ 1.80 $ 3.20 Direct Compounding $ 0.90 $ 1.25 $ 1.40 $ 1.15 $ 2.35 Savings per pound vs. LFT pellets $ 0.30 $ 1.05 $ 1.00 $ 0.65 $ 0.85 Approximate market pricing, 6/2006 increasing USD $ per pound PPS, TPU, & other ETP s pre-compounded LFRT pellets Direct Compounding PA 6,6 polyamides pre-compounded LFRT pellets >20% >20% Direct Compounding PP Olefins pre-compounded LFRT pellets Direct Compounding decreasing performance and relative cost

13 Thank you!