Interview
New technology provides a competitive edge
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f.l.t.r |
During a visit at Gutex in Waldshut-Tiengen in October 2006, we had the opportunity to speak with Managing Director Mr. Claudio Thoma. We were especially interested in finding out more about the new production method, the machines, the products, and of course the market situation.
The new plant for the production of wood-fiber insulation boards is utilizing a dry-manufacturing process. The method developed by Siempelkamp was first implemented at this location. What experiences have you had with it so far?
C. Thoma:
Until now, wood-fiber insulation boards were produced using the traditional wet-manufacturing process. We have been successfully operating such a line for many years. However, the wet-manufacturing procedure only allows the production of boards up to a certain thickness.
The dry-manufacturing process, put on the market by Siempelkamp, was highly interesting to us because it combines several advantages: The entire water management and the costly drying of the insulation boards, parts of the wet-manufacturing process, no longer apply. Boards with a thickness of up to 240 mm can be produced.
Shortly after our plant manufactured the first board on the dry-manufacturing line in February of 2006, we achieved the maximum level of performance after a start-up phase of three months. Today, the plant has reached its full capacity; board thickness and density are adjustable, and our customers compliment us on the high board quality.
In summary, it can be said that Siempelkamp’s newly developed method has kept its promise.
The process operates with a number of innovative machine concepts, for example, the new blending system for dry fibers or the new calibration and curing device based on the pre-heating unit ContiTherm. Is everything working smoothly?
C. Thoma:
You are correct; a number of new machines were developed especially for the procedure. First of all, resin is applied to dry fibers in a tower. That process is a dream for the entire MDF industry because the application of resin to dry fibers has many advantages over the application of resin to wet fibers followed by a drying process.
Siempelkamp gained experience during numerous test runs. A full size resin tower had been set up at the research and development center in Krefeld to test its efficiency. That same tower is now used here. The entire air management system in connection with the geometry of the tower was also tested until perfection. The results collected during these tests led to finding a solution for avoiding resin built-up inside the tower. The calibration and curing device based on the pre-heating unit ContiTherm is also new and was used here for the first time. Since operations started, the learning curve that our teams had to deal with has flattened. This means we have already gained a lot of experience and will continue to do so. In many cases we have broken new ground. For example, when adjusting the fiber moisture content, the dew point in the pre-heater, or the pressure. However, our people have a good understanding of the product and the cooperation with Siempelkamp continues to be excellent.
You were aware of the fact that you were going to buy a prototype. Did that make you feel like a guinea pig?
C. Thoma:
A guinea pig has only little influence on the course of action. We did not feel as such at all!
To be the first one to apply a new process and new machines usually means to take some risk, but at the same time, it provides an opportunity. We mainly saw our chance to be the first ones on the market with a new product. Additionally, we trusted Siempelkamp and were certain that any technical problems were solvable. Today, I can say it was the right move. The product quality is excellent and we were able to more than double our sales.
The new method and the produced wood-fiber boards are environment-friendly. Is this a good selling factor?
C. Thoma:
Yes, the wood-fiber insulation board is an ecologically friendly product because it is made of an easy to obtain resource: Wood.
The dry-manufacturing process conserves water and energy. Yet, compared to the wet-manufacturing process, it also requires the use of a special PMDI resin. However, since the resin is applied to dry fibers, we need only about 4% resin per ton of fiber. Therefore, the actual chemical contents in our board product only play a minor role.
How would you define quality for the wood-fiber insulation board and how would you evaluate the quality of the boards produced on your equipment?
C. Thoma:
The quality of our wood-fiber insulation boards is monitored and approved by a supervision and certification authority. The quality and eco-management system according to DIN EN ISO 9001 and ISO 14001, as well as according to EMAS II (EU Eco-Management and Audit Scheme), provides the highest safety possible to acquire ecological insulation materials with a continuous high quality. Our new plant allows us to produce a product with consistent quality using constant application parameters. With the help of an up to date monitoring system, we are able to quickly recognize quality discrepancies and counteract them. We are happy about the excellent quality of our boards, which is also confirmed by our customers.
Where are your products used and what are the advantages compared to alternative insulation materials?
C. Thoma:
Our products are used in the building industry to insulate against heat and cold, but also for flooring to insulate against impact sound. The benefit of the wood-fiber insulation board is, next to a protection against cold, an optimal heat protection. To protect living spaces from overheating, especially those spaces directly below the roofs of houses, the insulation material has to absorb and delay the heat flow from the outside to the inside of a room as much as possible. Wood has these characteristics by nature. Therefore, Gutex wood-fiber insulation boards are an excellent protection against summer heat. Furthermore, these boards stabilize the room moisture content and thus contribute to a better room climate. Because of their open-pored fiber structure they can absorb different sound waves. Last, but not least, these boards can be easily disposed of.
You produce many different product types. Does the product changeover always operate smoothly?
C. Thoma:
For each application we offer a special product. Now, of course, we are able to produce on two different lines. The wet-manufacturing line mainly produces boards up to 20 mm. Our new line is used for the production of thicker boards. A product changeover on this line can be carried out in half the time it takes on the old line.
Is the product mainly sold to environmentalists? Who are your customers?
C. Thoma:
Our end customers are people who want to use environment-friendly insulation materials with the above described characteristics. Furthermore, house construction based on wood materials is becoming more popular. In Bavaria, every fifth home has been built with wood. Builders of these houses would also rather insulate with wood, which, in turn, results in a growing market for us. However, in Germany we face a North-South divide. Therefore, our products have a higher distribution in the South.
Is that a niche market with a potential for further growth?
C. Thoma:
Yes, this is a niche market. Wood-fiber insulation boards are twice to three times more expensive than, for example, glass fiber insulation materials. At the same time, a use in multi-story houses is not possible because of the fire protection requirements. Nevertheless, we are anticipating a growing target group which is willing to spend a little more money for the sake of the environment and will use our insulation boards in their one and two-family homes.
Is the high demand for insulation material in general (high energy costs) the reason for the growth, or are wood-fiber insulation boards replacing other products on the market?
C. Thoma:
Today, there is a tendency towards better insulation materials, which is also enforced by law. Thicker boards are in demand; a reason why we invested in the new line. Furthermore, we were able to accommodate our 150 % increase in market share without problems and still have delivery times for our products. Also, we have to acknowledge that the construction business is doing very well at the time. We do not yet know if that will be the case next year.
Your company is located close to Switzerland. Is your product a desired export?
C. Thoma:
Switzerland’s demand for insulation material is covered by a national manufacturer. However, we have other existing export activities, especially to Austria and Northern Italy. The bottom line is that wood-fiber insulation boards have won market shares.
Mr. Thoma, thank you very much for the interview.
The interview was conducted by Mr. Ralf Griesche.
