FACET 2
1 Mixing technology 2–3 Rolic Technologies 4–5 Scale-up 6–7 Portrait 8 Interview
Custom manufacturing customer formulas Partnership is the key to success. Emerell operates as an independent production partner supporting different companies with the manufacture of chemical specialities. Emerell provides customer-specific mixing solutions meeting the most exacting industrial standards. They protect cars from the weather, keep timber structures together and ensure electronic displays deliver optimum image quality: chemical products such as dispersions, adhesives and liquid crystals transformed into applicable preparations using mixing technology are a key component of many everyday objects. And the formula specifications reflect the complexity and variety of the ways these products can be used. Complex manufacture Manufacturing quality products requires a lot of know-how, the right equipment, and flexible capacity. Swiss-based contract manufacturer
emerell
Emerell offers precisely these things, helping companies produce additives that subsequently play a key role in the quality of the finished product. It delivers mixing solutions covering everything from simple to complex mixtures and preparations. The rich experience of the company’s process technicians, chemists and mechanical engineers, coupled with Emerell’s state-of-the-art production facilities, ensures these complex systems retain their stability and high quality. Emerell concentrates on specialities, including production in smaller volumes, involving raw materials and
processes that require a great deal of skill and sensitivity. The company supports customers all the way from the first product test to large-scale production and ongoing development.
You can find out more about other key Emerell technologies on pages 4 and 5.
ROLIC TECHNOLOGIES
High-tech materials for optical effects Rolic Technologies, based in Allschwil near Basel, was established in 1994 when F. Hoffmann-La Roche spun off its liquid crystal research unit. Now the high-tech firm supplies major players in the electronics industry with unique, ready-to-use materials that set new benchmarks in light management. Chief of Supply Chain Dr Andreas Schuster has played a key role in setting up Rolic’s manufacturing and materials business. In this interview he talks about the com pany’s proprietary LCMO technology and explains why Emerell is such an important production partner for Rolic. Rolic has evolved from a small start-up to become an important partner for manufacturers of high-end displays and 3D applications. To what do you owe this success? We started out as a pure research and development company specialising in liquid crystal technology. Back in the early 1990s we discovered a process enabling the light controlled alignment of liquid crystal molecules – light controlled molecular orientation, or LCMO for short. This allows surfaces to be structured at the nano-level, which opens up huge potential for many companies in terms of optical effects. On the basis of LCMO technology we now develop and market ready-touse coating materials and functional films for displays and security documents and for protecting highly sensitive devices. So Rolic has evolved from an R&D firm into a manufacturer? It’s true that the company has seen massive changes over the years. Shortly after the spin-off, when we were only a small research lab, we sold Ciba an exclusive licence to manufacture our LCMO materials. Over the years we’ve developed more potential applications and have patented inventions, for example in high security, where we’ve developed non-copiable optical elements, and in LCMO materials that we’ve optimised for use in liquid crystal displays (LCDs). As a result we’ve been able to sell additional licences to select industry partners. In 2009 Sharp started using our technology in the manufacture of LCD televisions. Rolic subsequently decided to manufacture and market materials in its own right. These days we’re more heavily involved on the B2B side, supplying customised solutions enabling customers to manufacture their products with LCMO technology. Other LCD TV manufacturers have followed Sharp’s lead and are now using high-tech materials from Rolic. What makes your LCMO technology so attractive? LCMO has various advantages over other technologies in terms of manufacture and oper
“Emerell turned out to be a real lucky find.” 2
Dr Andreas Schuster, Chief of Supply Chain, Rolic Technologies AG
ation. Manufacturing an LCMO coating involves only a handful of steps compared with 20 or 30 for other technologies. The manufacturing process is very efficient. The reject rate is very low and the yield of input materials very high. You need around 1,500 kilos of active LCMO material for 35 million LCD TVs. Coating materials are applied to each substrate in an ultrathin layer, for example with an inkjet printer, which is then dried and exposed to light. LCMO is a contact-free technology, so you don’t have the problem of scratches or defects. In a nutshell, our technology makes building a television set a lot easier. Consumers also benefit from LCMO. Images are formed more rapidly and have higher contrast. LCMO technology also reduces a TV set’s energy consumption by around a third. When you consider that our technology is built into around 25 per cent of all LCD screens, that’s a lot of electricity saved. In Shanghai Rolic produces ready-to-use materials for the LCD industry. Otherwise you farm production out to contract manufacturers. What is Rolic looking for in a partner? We operate in a very dynamic market and need flexible partners that can cope with what in some cases are very short lead times. They have to be reliable enough to meet our high quality standards and deliver product to deadline. As a rule we look for partners that share our attitude to customers. Our aim is to give our customers a competitive edge in tomorrow’s marketplace with specially created solutions and materials. This means having the willingness and understanding to deal with spontaneous requests that are difficult to plan. And of course it requires the necessary manufacturing know-how. One of your contract manufacturers is Emerell in Central Switzerland. How did you find out about them? For many years we’ve been collaborating closely with a start-up developer that works with Emerell. That’s how Emerell was recommended to us. They met our expectations, and have turned out to be a real lucky find.
You say lucky find. What did you like about Emerell? They’ve proved to be a reliable and flexible partner that’s able to respond to our requests very quickly indeed and work with a lot of passion and dedication. Whereas many partners will simply say an order isn’t feasible, Emerell shows a lot of spirit when it comes to taking on challenges and delivering complex orders. It doesn’t always come off, but Emerell is very flexible and produces high-quality product. They also work very quickly. For example we were able to bring a product to the market rapidly despite a change of plan practically in the last 24 hours before launch. Emerell makes up our recipes quickly and reliably, and can make a big difference when it comes to helping a Rolic product out of the niche and into the mass market. We’re happy to have found a production partner of this calibre.
LCMO layer Photo mask Linear polariser
Light source
Image: Rolic
LCMO: Rolic’s core technology LCMO technology makes it possible to induce a specific spatial alignment in functional materials by using polarised light. Light is shone through a polarising film, which absorbs a specific direction of oscillation. The light that is not absorbed (polarised light) then passes through a mask that defines the area of photoalignment in the adjacent LCMO layer. By choosing suitable combinations of LCMO materials and selecting the direction of incidence and polarisation of the light, it’s possible for liquid crystal molecules to be aligned in any direction of the three-dimensional space.
LCMO material is applied to a substrate. Because the products are lightsensitive, the work is done in a cleanroom with no UV light.
Rolic Technologies in Eindhoven (NL) is your centre of competence for developing the products of your own research for market. They work with partners to optimise industrial manufacturing processes. What’s Emerell’s role in ensuring successful mass production? Emerell is at the end of this value chain, formulating raw materials according to our specifications to make ready-to-use products for optical applications. They’re in close contact with our developers, especially at the introductory phase. The master batch record for a formula generally has to be adapted to the production facility in question. Here Emerell delivers valuable input that is used in future formulations. In most cases no major changes are necessary. The most important thing is for there to be the right chemistry and trust between the partners. Our partnership with Emerell works very well and we hope that we’ll be able to extend the partnership in the future.
Rolic manufactures unique optical components that only become visible under a polarising filter.
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Another Rolic speciality: non-copi able, easily recognisable effects used for banknotes and other security documents.
Successful projects through collaboration
SCALE-UP
The path from formula to finished product is a long one. Emerell provides customers with expert process technology support from initial tests in the lab and on the pilot line all the way to scaling up for industrial-scale production. Emerell’s product engineering process (PEP) is a key planning tool from the first customer enquiry all the way to the finished product. It clearly maps all the relevant work steps and responsibilities and ensures the whole process runs smoothly. The customer is involved in the development process at all times and can track each step on the market, technology, production and quality management level. Emerell offers a comprehensive
range of services running from technical and economic feasibility studies to producing representative samples, product mainten ance and ongoing development. Thanks to Emerell’s process and production know-how, customers have the assurance that their product will be brought to market on schedule to the desired standards of quality.
PROJECT DEVELOPMENT Customer
Define project requirements
Key account
Check project requirements
Define project proposal
Technology
Check project proposal
Project release
Check project feasibility
Production
Cost estimate
Price level
Produce lab sample, check formula
Go/no-go kick-off meeting
Plan production process
Check formula
Produce definitive lab sample
Safety screening
QM/QC
Pilot trials, lab extrusion trials 1
Project phase When a request is received from a customer the first step is to thoroughly check the project proposal, the materials and the formula and then calculate the production costs.
The customer can keep constant track of the status of the project.
Customer-specific offering From high-end Primacor dispersions, manufacturing individual products with low residual monomer content to flexible, air-permeable blown films, Emerell offers a full range of custom manufacturing services, and over the years has amassed a wealth of production know-how in extrusion, polymerisation and mixing technology. Technologies
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Services
Chemicals
Film extrusion
Emulsion polymerisation Mixing technology Special technologies
Blown film extrusion Cast film extrusion Extrusion coating
You’ll find details of the individual technologies on the Emerell website.
Emerell offers services ranging from filling, packing and labelling to safety management.
Emerell works with modern pilot lines (the photo shows a pilot line for blown film extrusion) to produce representative samples close to the final product that the customer can test.
PRODUCT DEVELOPMENT
PRODUCT MANAGEMENT
Release sample
OOS release
Investigate production costs (post calculation)
Perform pilot run or first production run
Define production process
Scale-up procedure released
Quality planning (PPAP/FMEA/ ISTR if necessary)
Perform QC and release
Delivery phase I Then trials are run on a pilot line and the results compared with the specifications. The manufacturing process and technical feasibility are evaluated.
Delivery phase II: scale-up/operating trials Once the pilot trial is completed the process is scaled up to the final production line. The formula is adjusted or optimised as required and a provisional production process is set down. Process capability is assured.
Emerell’s extrusion lines can be used to feed two substrates at the same time to manufacture complex composite materials.
Process and product reliability released
Perform QC and release
Maximum duration: 10 lots or 1 year 3
Perform QC and release
Maximum duration: double shelf life 4
Market launch The provisional production process is at the implementation phase. The final product specifications are known. The costs of manufacture have been reviewed.
Legend
5
Definitive production procedure
Perform QC and release
Maximum duration: 5 scale-up runs or 2 years 2
Project appreciation
Provisional production procedure
Staff qualification
Define QC and release criteria
1
Process and product reliability reached
Process reliability reached
Production procedure
Plant qualification
Technical feasibility evaluated
OOS release
Project dossier
Process feasibility reached
Evaluate production process
OOS release
5
Trial phase The final production process is confirmed and storage stability is assured. By the end of the trial phase the process and the product are secure.
Responsible
Co-decision
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7
Product maintenance After the trial phase, Emerell works with the customer to ensure that the formula can be manufactured in the long term. The procedure in the event of any adjustments (colouring, matting, etc.) and changes to the process or formula are described in a change management document.
Information
Emerell has a wealth of production know-how in aqueous emulsion polymerisations and dispersions.
Milestone
The whole world from the heart of Europe
PORTRAIT
Emerell has three facilities in Switzerland and Germany, each focusing on specific technologies.
In Buxtehude near Hamburg, Emerell custom manufactures high-end films for industrial applications. The facility’s specialities are cast film extrusion and extrusion coating.
Emerell’s state-of-the-art facility in Schmitten in the Swiss canton of Freiburg manufactures multilayer adhesive films and multilayer films with functional layers.
Sempach Station near the Swiss city of Lucerne houses Emerell’s head office and its facility specialising in emulsion polymerisation, mixing and special technologies.
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Close partnership with customers Emerell is a Swiss-based flexible custom manufacturer dedicated to producing speciality polymers and high-end adhesives. Its business model is designed to help customers absorb fluctuations in demand and bring products to the market on time. Rapidly accelerating product cycles and poorly matched production capacity pose a huge challenge for many companies. Emerell is an ambitious production partner serving companies manufacturing high-tech products. Thanks to Emerell’s wealth of know-how and comprehensive range of services, customers can start out by producing smaller batches on a job order basis, enabling them to reduce investment risks, launch new products more rapidly, extend their portfolio beyond their core competencies, or outsource their manufacturing processes. A partner you can rely on When you outsource production and entrust formulas to another company you have to have absolute trust in your partner. Emerell earns this trust. Our customers can take security and assurance from the fact that we’re the first provider of adhesives and speciality polymers to focus exclusively on process engineering and the manufacturing process rather than developing and marketing our own products.
Low-volume production Emerell concentrates on producing small to medium volumes to cover an area of the market that’s too big for small companies and too small for big ones. Manufacturers, processors, suppliers, contract developers and start-ups can depend on Emerell’s great flexibility to help them deliver innovative product solutions, from the initial test to industrial production.
Close partnership There are many different options when it comes to working with Emerell, from a one-off order to long-term service agreements and strategic partnerships or joint ventures. This reflects Emerell’s firm belief that custom manufacturing always involves close partnership with the customer.
Services In addition to managing the chemical and technical aspects of production, Emerell can take charge of storing raw materials for ongoing production or to strategically safeguard the customer’s supply of raw materials. Emerell can also fill, package and label products according to particular needs and specifications. It also assists customers with customs declarations and other formalities such as clarifying the relevance in terms of REACH or classification and labelling of chemicals under the Globally Harmonized System (GHS).
Your personal point of contact The Markets team looks after Emerell’s national and international customers. It’s headed by Norbert Bazelli.
Norbert Bazelli Executive Manager Global Markets
Marco Montagner Market Development & Key Account Manager
norbert.bazelli@emerell.com T +41 41 469 93 13
marco.montagner@emerell.com T +41 41 469 93 24 Areas: Emulsion polymerisation Mixing technology Special technologies
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Frank Hübel Market Development & Key Account Manager
Günther Spaeth Market Development & Key Account Manager
frank.huebel@emerell.com T +49 160 368 85 76
guenther.spaeth@emerell.com T +49 2335 847 49 03
Areas: Blown film extrusion Cast film extrusion Extrusion coating
Areas: Cast film extrusion Blown film extrusion Extrusion coating Emulsion polymerisation Mixing technology
“Our customers can use outsourcing to save costs and mitigate risks.”
INTERVIEW
Norbert Bazelli, Executive Manager Global Markets, Emerell AG
water-vapour-permeable fabrics for breathable clothing. Another major area is the automotive industry. We’re also actively involved in the paint and varnish business.
Custom manufacturing: a win-win strategy Norbert Bazelli is a member of the management committee, and as Executive Manager Global Markets is responsible for expanding Emerell’s sales market. In this interview he talks about the benefits of custom manufacturing, the diversity of Emerell’s customers, and the company’s future potential. What makes Emerell’s offering so attractive in the marketplace? The practice of outsourcing services is still uncommon in the industrial chemistry business. Old structures tend to dominate, with a product developed, produced and marketed at the same site by the same company. But there’s a rethink going on, and gradually these structures are dissolving. We’re finding that our services as an independent production partner are meeting a rapidly growing need. In Europe we’re in a special position, with few competitors able to offer customers such close collaboration as we do, all the way from the initial contact to launching a mature product.
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Who are Emerell’s typical customers? Customers ranging from start-ups and adhesives manufacturers to product and system providers are all discovering the benefits of an external production partner they can trust to take care of their formulas. One customer may have an
idea but lack the necessary production capacity. Another may have the capacity but want to remain flexible and have a partner to help even out varying production needs. We also work with companies that already have a special formula but don’t have the right equipment or manufacturing know-how to produce it. These are just a few examples illustrating how Emerell has the speed and flexibility to respond to and address a wide range of needs. What all our customers have in common is that outsourcing enables them to massively reduce their costs and also substantially mitigate the investment risk. It seems that Emerell manufactures products for very different customers. It’s true, especially if you consider the enduse of the products. Products manufactured by Emerell on behalf of its customers include products used in display technology (see the article on Rolic on pages 2 and 3) and textiles − for example bulletproof vests or windproof, waterproof and
Where do you see potential for development? We see great potential in chemicals companies in Asia and the United States who need a production partner in Europe. Of course many companies choose to shift production to low-wage countries because of the high costs. But different rules apply to a niche market like ours, where the benefits of a location in the heart of Europe more than make up for the costs. Another development creating opportunities for us is the trend away from welding, screwing and riveting to high-end adhesives. Adhesives can be used to join virtually any two materials, and have many other benefits besides quick processing times and weight advantages. Since we’re also increasingly operating in mixing and speciality technology, we see major market opportunities opening up there as well. There’s also potential in emulsion polymer isation, where we already produce binders and dispersions for the varnish industry. How does Emerell keep up to speed? The trust that our customers place in Emerell and the partnerships we’ve built up in recent years make us proud. Different companies benefit from collaboration in terms of greater effectiveness, capacity and speed. By the same token we also benefit from this close collaboration. It gives us more in-depth know-how which enables us to respond optimally when needs arise. We’re constantly endeavouring to optimise our product development process and hone our process engineering. We’re also investing in new technologies at all our sites to be able to keep up with rapid developments. The most recent example is our coextrusion coating line for multilayer films at our Buxtehude facility. The pilot line will be up and running by the end of 2016, followed by the large-scale line at the end of 2017. We also stay current by taking part in conferences and trade fairs.
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Facet – the magazine for
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Michael Suter and
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Issue 2, September 2016
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