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Bayer Showcases Innovative Applications at Composites & Polycon 2006 Conference

  • Monday, 23rd October 2006
  • Reading time: about 5 minutes

For bringing Wausaukee Composites to target profitability and increasing average monthly production by 95 percent, Will Ingold has won a Composites Manufacturing magazine Excellence & Innovation (E&I) Award for Plant/Project Management.

The award was announced along with six other E&Is at Composites & Polycon 2006 in St. Louis, Mo.

“”The awards are designed to recognize outstanding achievement by people in the composites industry,”” said CM Editor Andy Rusnak. “”They were created by the ACMA and CM magazine to highlight excellence and innovation such as Ingold’s. Not only did he increase monthly production sales by 95 percent, he grew the labour force by 25 percent, increased labour efficiency by 13 percent, reduced scrap 50 percent, and held a year-to-date on time delivery record of 99.3 percent. Those are some pretty impressive numbers for a company with a diverse product line.””

Triad Technologies of Syracuse, N.Y., who has spent the last six years developing a new concept in biofiltration for the capture and control of styrene on the production floor, took the E&I for Health & Safety Practices. With funding assistance from the New York State Energy Research and Development Authority (NYSERDA) coordinated by Barry Liebowitz, Senior Project Manager of the R&D Program at NYSERDA, and with assistance from Dr. Anthony G. Hay, Associate Professor of Microbiology at Cornell University, a line of engineered bio-furniture has been developed and is currently under test for future commercialization.

Pat McGown of the Idaho-based Fiberglass Systems, took the E&I for Excellence as a Production Supervisor. “”Most recently, Pat demonstrated his highly specialized skills by finishing the seam of a Safas granicoat spray-able solid surface walk in bathtub door,”” company President Eugene Thurston said. “”Our manufacturing team has contemplated building a walk in bathtub with this surface but has been hesitant to do so because they did not believe we could finish the seam in the door. Pat and his team accepted the challenge.””

This year’s E&I for Community Stewardship went to two divisions of Strongwell. The Bristol Division participates, makes donations, and supports the United Way, Boys and Girls Clubs of Tennessee and Virginia, Red Cross blood drives, The American Cancer Society and the Susan G. Komen Breast Cancer Foundation’s annual Race for the Cure. The company’s Chatfield Division supports and makes donations to the community chest, the Chatfield Commercial Club and ambulance service, local school fundraising activities, the Chosen Valley Care Center, Juvenile Arthritis Foundation, Muscular Dystrophy Association, Lions Club, VFW, and the Marine Corps’ annual Toys for Tots drive.

The Wichita, Kansas-based Fiber Dynamics took the E&I for Innovation in Manufacturing Process for its fabrication of hollow composite structural motorcycle components using a proprietary Lost Core Resin Transfer Moulding (LCRTM) process. The Confederate Motorcycle Company teamed with Fiber Dynamics to produce fuel tanks and seats for the company’s radical Hellcat bike. Confederate’s all-composite Wraith was featured on the cover of CM’s 2005 November/December issue.

For Excellence as a Manufacturing Employee, the E&I went to Appalachian Plastic’s David Louthian, for “”strong leadership and unwavering dependability,”” says company President Allen DeBusk. “”David leads by example at Appalachian Plastics, having earned the respect of his fellow employees as well as upper management for both his initiative and company pride.”” Bayer MaterialScience’s gave attendees a first hand look at a variety of materials, applications and technologies at Composites & Polycon 2006 in St. Louis.

“This conference is a tremendous opportunity for everyone to see for themselves the inherent benefits of working with polyurethane RIM technologies,” said Harry George, business manager, Specialty RIM Group, Bayer MaterialScience. “The broad range of products on display in our booth reflects the design flexibility, excellent appearance and durability of products molded using RIM technologies in general, and Bayer polyurethanes, in particular.” Applications on show included:

Clearwater Spas 2007 Spa Line. The outer cabinets for the company’s entire 2007 spa line are formed from Bayer MaterialScience’s Baydur STR RIM System.

Triple-E Luxe Tafels from Tinga Research & Development – Lightweight, stackable tables that are easier to handle than “”conventional”” wooden furniture, thanks to a sandwich composite made of the polyurethane system Baypreg from Bayer MaterialScience.

Mack Granite Axle Back Fender Extensions from Romeo RIM – The Granite Axle Back vehicle from Mack Trucks is the most recent addition to the company’s lineup of vocational trucks. The fender extensions, or eyebrows, of the trucks are molded from the Bayflex 110-50 polyurethane RIM system.

“F1” bathroom line from Keramag and F.A. Porsche Design – Two modern polyurethane products from Bayer MaterialScience are used to make the F1 bathtub: the Multitec Short Fiber Spraying system and Baydur 60 foam-molded, microcellular, rigid integral skin foam.

Karl Niedersüss Rescue Spineboard – The strong, lightweight spineboard, produced by the Austrian company Karl Niedersüss, is manufactured using the HexFlow system from Hexcel Composites GmbH & Co. KG based on Baypreg polyurethane raw material from Bayer MaterialScience.

Premium Fiberglass Doors with PÜR-Fiber Technology from JELD-WEN – To achieve increased dimensional stability, better impact resistance and strength, as well as the aesthetics consumers demand, JELD-WEN, the world’s largest manufacturer of windows and doors, worked closely with Bayer to develop a Baytec polyurethane and Baydur STR polyurethane formulation especially for its new line of exterior doors.

USF-7636 Lightweight Valve Box from U.S. Foundry & Manufacturing Corp. – The new valve boxes from U.S. Foundry are formed from the Bayflex 110-50 polyurethane RIM system. Bayer’s system offered the physical properties required in addition to extraordinary light weight. The boxes weigh just 16 pounds, compared to the hefty 166 pounds of traditional cast iron valve boxes.

John Deere Soy-based Polyurethane RIM System – John Deere combines, which have been used by generations of farmers to harvest corn, soybeans, small grains and specialty crops, are constructed with strong, flexible and durable composite panels that are made with corn and soybeans. A soy-based polyurethane RIM system developed by Bayer Corporation for John Deere helped to make this composite possible.

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