Polymer technology: the backbone of Irish manufacturing - Polymer Technology Ireland 2020 Strategy - Ibec
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Polymer Technology Ireland 2020 Strategy Polymer technology: the backbone of Irish manufacturing
Contents 1 Chair’s foreword 2 Director’s welcome 4 Polymer Technology Ireland strategic pillars 7 Polymer Technology Ireland organisational chart 8 Model of Substance 9 Business case studies 29 Categories of company in the polymer industry 30 Mapping Ireland’s polymer technology industry 32 Talent and skills 40 Gateway to growth 44 An eye on the EU
Chair’s foreword
In the late 1950s Ireland’s industrial take-off
was bolstered by manufacturing output growing
6% annually, 1958-1963. Manufacturing played
a major role in the development of the Irish
economy at a time when it was a predominantly
agrarian economy. And in these early years the
Federation of Irish Manufacturers, a precursor
of Ibec, played an important role leading the
business agenda and driving growth.
T
he manufacturing as agri-food, automotive, vision for the future in this
industry in Ireland medtech, ICT and biopharma. special publication.
has expanded The polymer technology While the sector continues
significantly since industry is the backbone of to be ambitious with 4.2%
then. The sector now Irish manufacturing with world- growth forecast for the Irish
comprises 4,000 enterprises class processors, suppliers economy in 2018, we must
employing 230,000 people, and service providers continue to work with our
making it the second largest employing nearly 7,000 people members to ensure they
employer in Ireland and across 230 businesses with are adequately equipped to
accounting for nearly a quarter exports of €1.62 billion. face challenges and seize
of economic output. Polymer technology opportunities in the years
Irish manufacturing has businesses are manufacturing ahead.
evolved from traditional autoinjector devices for Polymer Technology Ireland,
industries such as textiles and diabetes treatment, plastics as part of Ibec, will continue
steel to a higher technology, components for Jaguar to provide industry foresight
higher value businesses, such and Land Rover cars, and business services to
as ICT, biopharma, medech, engineering materials for use our members to help them
agri-food and automotive. in cardiovascular stents, and compete and thrive.
Polymer Technology designing packaging to extend Thank you to our member
companies, represented by the shelf-life of food products, organisations and expert
Polymer Technology Ireland, as well as leading the way in colleagues who helped us
have played a major role using recycled materials for develop our 2020 strategy.
in the growth of these high use in the automotive industry.
technology manufacturing We’ve brought together
industries. These companies some of these leading John Wallace
are driving growth and companies in a series of Chair, Polymer
creating jobs across Ireland interviews to outline their Technology Ireland
and across key sectors such strategies for success and
2020 Strategy 1
Director’s
welcome
The Irish polymer sector continues to evolve
as one of Ireland’s premier manufacturing and
technology industries. It has been very rewarding
for Polymer Technology Ireland to be part of this
success story and to watch companies from
across Ireland mature, win new customers and
invest in their technology and people. Many of the
member companies of Polymer Technology Ireland
have developed beyond recognition over the last
ten years to become world class providers of the
most advanced polymer solutions.
2 Polymer Technology Ireland
“ Polymer Technology Ireland will
continue to be the voice of the sector
in Ireland. We will work with our
colleagues in Ibec to deliver a
high-quality environment where
businesses can grow and prosper.”
P
olymer Technology of the Polymer Processing to tackle challenges arising
Ireland is developing Technologist Apprenticeship from the evolving policy and
alongside its that is delivered in conjunction regulatory environment. With
membership. We with Athlone Institute of the support of our colleagues
have changed our Technology and IT Sligo. The across Ibec, PTI promotes
name from Plastics Ireland Apprenticeship is geared industry best practice through
and we continue to develop towards providing the polymer working groups on Operational
our services. Our focus industry with an attractive Excellence, Advanced
has traditionally been on long-term career path for Manufacturing, EHS/OHS,
developing skills and on new employees who can Skills, Employer Relations
promoting the industry. The become apprentices in the and Gender Leadership
First Polymer Training Skillnet knowledge that they will work Development.
centre in Athlone continues to towards a level 7 qualification The European Union plays
go from strength to strength and a rewarding career in a vital role in the evolution
and is consistently adding to polymers. With a growing of the industry particularly
its offering of training courses industry and extremely strong through its regulation of the
for the sector. In this fast- demand for skilled people, industry, the EU Plastics
moving world, it is essential the apprenticeship will play Strategy and its work in the
that our training centre adapts an important role in attracting area of the circular economy.
to the needs of industry the highest calibre of young PTI’s memberships of EuPC
and stays up to speed with people into the polymer and Plastics Europe enable
the latest technologies and sector – this is fundamental us to effectively represent
techniques. First Polymer to the future development the industry’s interests in
Training Skillnet is highly of our industry. these areas.
regarded by the industry Polymer Technology Ireland Polymer Technology
because of the quality of will continue to be the voice Ireland will continue to deliver
training that it provides, its of the sector in Ireland. We a strong, industry-specific
cost effectiveness and its will work with our colleagues offering to the polymer
ability to meet the industry’s in Ibec to deliver a high- industry and we look forward
requirements. There is no quality environment where to growing our organisation
doubt that First Polymer businesses can grow and further and to supporting the
Training Skillnet has made an prosper. Skills and training will continuing evolution of the
enormous contribution to the remain core elements of what polymer sector in Ireland.
skills profile of the polymer we do whilst we continue to
industry in Ireland and Polymer bring companies together to
Technology Ireland is proud to make connections, develop Mark McAuley
continue to support this. business links and identify Director, Polymer
Polymer Technology opportunities. PTI enables our Technology Ireland
Ireland is also the backer members to work together
2020 Strategy 3
Polymer
Technology
Ireland
Polymer Technology Ireland is part of Ibec,
Ireland’s leading business organisation.
|t represents the polymer industry including
suppliers of raw materials and technologies,
polymer processors and support services.
Vision for the industry
The polymer industry in Ireland
is a dynamic, innovative and
competitive industry where
technology-led firms provide
high quality products and
services and give employees
excellent careers in a sector
where firms are growing
and prospering.
4 Polymer Technology Ireland
Strategic pillars:
1. Represent the polymer sector
n Represent the Irish polymer industry sector to key stakeholders including the Government, state agencies,
the EU and partner manufacturing sectors.
n Advocate for policies and conditions that support a competitive business environment where polymer
companies can prosper and grow.
n Support an ambitious national planning strategy which invests in infrastructure to address the needs of all
regions of the country.
2. Build awareness of the value of the polymer
industry to key stakeholders
n Build awareness of the scale, diversity and value of the polymer industry to the Irish economy by showcasing
end market application across manufacturing sectors.
n Promote the polymer sector as an innovative high-tech industry.
n Publicise the environmental credentials and initiatives of the polymer industry and ensure that the correct
information about plastics is fed into the environmental debate.
n Provide information about the positive contribution of plastics to the health sector and the environment.
3. Deliver high quality information to Polymer
Technology Ireland members
n Improve awareness of policy and market developments affecting members. Identify key areas for specific focus
such as skills, the circular economy, health and safety and trade.
n Establish appropriate forums to enable industry leaders to share knowledge, discuss the impact of changing
business models and prepare for the future.
n Collaborate with the Technology Gateways which provide close-to-market technology solutions and work
closely with centres, such as APT in Athlone IT and PEM in Sligo IT.
n Encourage businesses across the polymer sector to become early adopters of new technologies in areas such
as additive manufacturing.
4. Support the development of a world class talent pool
for the polymer sector
n Promote policies and conditions that will make Ireland a leader in talent development for the polymer industry.
n Continue to develop Ibec’s First Polymer Training Skillnet Centre in Athlone which upskills and reskills talent
for the sector.
n Grow the Polymer Processing Technologist Apprenticeship in line with global best practice and evolving
industry needs.
n Publicise job opportunities and raise awareness of the exciting career development in the sector.
n Support the development of skills required for new business models and emerging technologies.
5. Provide opportunities to maximise B2B engagement
and support business development
n Facilitate interactions with relevant sectors which offer business-to-business opportunities.
n Help members to identify opportunities and new markets in the light of changing market and economic trends.
n Host events and collaborate with strategic partners to provide opportunities for networking.
2020 Strategy 5
Polymer Technology Ireland will:
+ Be the voice of the polymer industry in Ireland.
+ Further the objectives of the polymer industry
through Ibec.
+ Promote skills supply and development in the
sector, grow and develop the First Polymer
Training Skillnet Centre and the Polymer
Processing Technologist Apprenticeship.
+ Connect member companies to exchange
views, develop business links, address
industry concerns and identify opportunities.
+ Provide members with industry relevant
information, expertise, knowledge and insight.
+ Support industry best practice through
working groups in the areas of Operational
Excellence, Advanced Manufacturing, EHS/
OHS, Skills, Employer Relations, Gender
Leadership Development.
+ Support the industry across Europe through
EuPC and Plastics Europe.
6 Polymer Technology Ireland
Organisational structure
Polymer Technology Ireland Chair
Polymer Technology Ireland Council
Innovation Skills Business
Excellence
Advanced First Polymer Operational
Manufacturing Steering Group Excellence
Working Group Working Group
Polymer
Apprenticeship Gender Leadership
Consortium Development
Taskforce
The Council and working groups
allow Polymer Technology Manufacturing
Ireland members to work on
strategic issues for the industry
Apprenticeship OHS/EHS Forum
and share best practice. Consortium
IR/HR Forum
To find out more about business trends, Ibec member
supports, and how to get involved in initiatives like this
special publication, contact Polymer Technology Ireland
Executive Ciara Finlay by emailing ciara.finlay@ibec.ie.
2020 Strategy 7
Model of
substance
The business environment in Ireland is
characterised by substantial activity in key
areas, which means opportunities and a
bright future for the polymer industry.
T
he Irish economy is favourable to the polymer the problems of too much markets are becoming more
now in a very new industry – is the fact that of a good thing. In order and more sophisticated.
phase. While it may Ireland is bang in the centre of to deal with the emerging They are moving away from
feel similar, nothing the latest industrial revolution, challenges, we need to mass manufacturing and
that went before known as Industry 4.0, McCoy move quickly to ensure we commoditisation. The capacity
can be compared to what notes. This is concerned with have the right infrastructure of their workforces to deliver
we are experiencing now, automation, the interoperability to sustain prosperity,” he sophisticated solutions has
according to Ibec CEO Danny of machines and devices says. “This includes modern increased,” he says. “In order
McCoy. “I don’t believe we and the ability of information housing solutions, maximising to stay competitive with these
have ever had a better set of systems to virtually represent interconnectivity and countries we need to keep
circumstances in terms of the physical world. broadband and modernising going further and further up
the business environment,” “Historically, Ireland missed the education curriculum to the value chain and continue
he says. previous industrial revolutions. be geared towards artificial to embrace new technologies
A report released by Ibec What is driving innovation in intelligence and robotics.” in manufacturing.”
recently shows how the Irish manufacturing now are not Seen by many in the Looking to the future,
business environment is built natural resources such as business world as one of McCoy believes it is very
on what the OECD terms iron ore, but rather computer- Ireland’s biggest challenges in bright for the polymer industry
“substance”. In McCoy’s view, aided design, technology the coming years, Brexit may because of globalisation
the polymer industry is well and intellectual property. A well be more of an opportunity as well as Ireland’s access
placed to take advantage of lot of substance in terms of for manufacturing and the to European markets and
the immense opportunities for these intangible assets has polymer industry, according talented, skilled workers.
Ireland that this represents. been moving to Ireland,” says to McCoy. “We have no idea
Entitled ‘Ireland: A Model McCoy. of the impact of Brexit or
of Substance’, the report “I believe the polymer the form it will take. It could
points out that economies industry has a unique be disastrous but equally
of substance have depth, advantage in this regard as manufacturing could actually
diversity, and years of it is in the vanguard in terms benefit from it. This is because
tactical policy planning and of manufacturing. It doesn’t it is involved in global value
implementation behind them. have to deal with the legacy of chains and is not affected in
In contrast, insubstantial post industrialisation and the the same way as agri-food, for
economies don’t encourage baggage of Brownfield sites.” example, which is dependent
a diversity of industries; While Ireland’s economy on the British consumer
they don’t do research and of substance presents huge market,” he says.
development (R&D) or high- opportunities, it brings with it Low cost, but highly
value manufacturing and don’t certain challenges. However, productive, jurisdictions such
generate indigenous firms of in McCoy’s view these as China, Indonesia, Malaysia
scale or outward investment. challenges are a function of and South Korea present
One of the reasons that success not failure and should much greater challenges to
the economy is in a new be viewed as largely positive. Irish manufacturing than Brexit
phase – which is particularly “We are grappling with does, McCoy adds. “These
8 Polymer Technology IrelandBusiness
case studies
From plastics processors, suppliers
and service providers, the industry
in Ireland is leading the way. Get to
know some of these businesses here.
2020 Strategy 9Business case studies Over 30 years ago, JL Goor
started out as a supplier of of
machinery and later moved into
supplying polymer raw materials.
Going
a step
further
Recognising that there was
T
he polymer industry
in Ireland started
in a modest way in
an opportunity to add to the the 1980s. It was
made up of injection
knowledge of polymer materials moulding companies, sheet
manufacturers, film and
rotomoulders and, until about
in the growing medtech sector ten years ago, there was a
predominance of relatively
in particular in Ireland, Dublin- basic products,” says JL
Goor’s sales director Joe Wall.
based JL Goor decided to make
Injection moulding is the most
widely used plastic process,
producing high volumes from
this a point of difference for it all polymers in every shape and
size while rotomoulding is used
as a distributor and become
for products with larger hollow
sections, such as oil tanks.
“The medtech sector really
more proactive in this area. began to grow and more
research and development
was happening in Ireland. Our
approach on this was to meet
market demand but go a step
further,” says Wall.
10 Polymer Technology IrelandImage
supplied
“We decided to be a Administration approval,” Based in Co Waterford, such films are made before
resource for customers or notes Wall. Mima Films, one of the they decide to make major
potential customers in the Over 30 years ago, JL Goor country’s leading suppliers capital investments,” explains
medtech sector and guide started out as a supplier of of stretch film for the Wall. “Cheese packaging
them on the most appropriate machinery and later moved containment of pallets, is also needs to protect the cheese
materials to use to begin initial into supplying polymer raw a client of JL Goor, as well and extend its shelf life for as
product approvals.” materials. In addition to the as Boran Plastic Packaging long as possible. Many cheese
Currently employing a team medtech sector, it serves in Co Kildare – a company packs may have up to seven
of nine people, in recent years clients in the automotive, which invested heavily in layers to control the barrier
JL Goor hired two polymer aerospace, pharmaceutical, innovation through the properties. This design it is
scientists and also invested in general packaging and food economic downturn to ensure driven by a mix of commercial
logistics expertise to ensure and beverage markets. No its packaging keeps food reasons and the desire to
it is offering added value. It one sector accounts for more fresher longer. reduce food waste.”
has two strategic warehouses than 30% of turnover. Food JL Goor’s partnership JL Goor has also worked
in Dublin, one in Cork; one and beverage is the largest approach in sharing polymer with Irish Custom Extruders
in Belgium and another in followed by pharmaceuticals expertise extends beyond in finding the right materials
Singapore. and automotive. the medtech sector. In food for its unique comfort slat
“The logistics process In Northern Ireland, JL Goor packaging, it has worked mats for cows and Oral-B
for medtech products can works closely with Denroy with a number of customers in coming up with a material
be complicated and time Plastics in supplying injection which were looking to do for toothbrushes that was
consuming. It is very important moulded components to a things differently, for example, resistant to biting and
to ensure the right amount of wide range of customers in modifying cheese packaging could withstand being in a
materials is held in stock at the aerospace industry and using layering of different dishwasher.
the right time so companies with coachbuilder and pioneer materials.
can quickly ramp up once of the low-floor bus Wrightbus “We work with these clients
they get US Food and Drug International. to help them to indentify how
2020 Strategy 11Business case studies
Proactive
partners
As the demand for more cutting-edge plastic
products has increased, distributors of polymer
materials based in Ireland have become
more focused on engaging with clients at the
research and development phase.
W
ith offices in 27 “Where we are trying to Jeff Hobbins, Ultrapolymers
countries and step in is by getting involved
50 warehouses at the start of a research
across Europe, and development process
polymer by proposing new and/or
distributor Ultrapolymers alternative materials produced
Group brands itself as locally in Europe that are
“a partner from design to fully medically accredited
production”. with a notification of change
In Ireland, the healthcare process which is critical
sector has become a for that industry,” says Jeff
particularly strong focus Hobbins, managing director of
recently as local medical Ultrapolymers Ireland.
device manufacturers “By utilising tools such
engage in the material as Moldflow we can offer
selection process for new guidance on topics such
product designs and/or seek as common issues in
alternatives for materials which component design, design
can often be specified on other features to avoid when
continents and converted at using certain materials as
plants here. Ultrapolymers well as trade-offs between
hired a business development aesthetics and mechanical
manager dedicated exclusively performance.” Moldflow
for medical applications two simulates the injection
years ago. moulding process in order to
Ultrapolymers’ philosophy improve plastic part designs,
is to work in partnership injection mould designs and
with designers, converters manufacturing processes.
and original equipment “Moldflow allows us to make
manufacturers, providing material recommendations,
a significant competitive pre-empt problems and
advantage through effective suggest doing something
material selection, improved different,” Hobbins adds.
part performance and process Headquartered in Belgium,
optimisation. Ultrapolymers employs
12 Polymer Technology Ireland250 people. In 2002, it was curve and Ultrapolymers now consumer packaging and becoming a one-stop shop
acquired from BASF by the has offices all over Europe, also rotomoulding. It works for our customers,” says
Ravago Group, a service including South Africa and with around 15 major polymer Hobbins. “We have chosen
provider to the plastics Turkey,” notes Hobbins. “We manufacturers, including global to be exclusive with each of
industry founded by Raf have always maintained a leaders such as LyondellBasell our suppliers and not to offer
Van Gorp in 1961. Ravago strong presence in the Irish – which Ultrapolymers works the same resin type from
Group was one of the first market because we firmly exclusively with in supplying competing manufacturers.
companies in the world to believe that a local supplier Polyolefins to clients – and This allows us to work
get involved in the recycling has a better understanding of the world’s largest Styrenics closely with suppliers whilst
of plastics. Since becoming customer expectations so we manufacturer INEOS simultaneously providing
part of Ravago in 2002, can adapt and continuously Styrolution. support to and being
Ultrapolymers’ footprint has improve our service level to all “We work very closely more innovative with our
grown beyond Ireland and customers.” with our suppliers. That customers.”
UK to now having a pan- In terms of market allows for penetration into Ultrapolymers also acts
European presence. segments for Ultrapolymers, multiple markets around as the Irish agent for Romi
“Ever since then we have these include healthcare, Europe through our large Moulding Machines (formerly
been on a steep growth automotive, construction, customer network whilst also Sandretto).
The polymer industry has
an annual turnover of
€2.1bn
Each year the
Irish polymer
77%
of sales in
industry pays out the industry
€314m
are exported
in wages
2020 Strategy 13Business case studies
Global grasp
Spotting a gap
I
nnovative Polymer drying, dosing and dispersing
Compounds (IPC) was technologies. It is currently
set up in Kilbeggan, evaluating putting its current
for the supply of county Westmeath
in 2008 as a joint
product range of around 2,000
different polymer compounds
polymer compounds venture between polymer
compounding company
Associated Plastics of Ireland
into 3D filament format.
In each instance, a special
formulation is made for
to the medtech and polymer and chemicals
distributor National Chemical
medtech clients in volumes
ranging from as small as 5kg
sector in Ireland Company (NCC) – each of
which has over 30 years’ track
for engineering trials up to 5
tonnes for mass production.
in 2008, Innovative
record in the polymer industry. The compounds processed
The joint venture partners by IPC end up in products
saw an opportunity to supply in a number of key areas:
Polymer Compounds compounded materials
to original equipment
cardiovascular tubing/stents;
neurovascular treatment;
has gone on to
manufacturers (OEMs) intrauterine devices;
and first- and second-tier orthopaedics; gastric balloons
suppliers serving the and surgical tools.
successfully grow medtech sector in Ireland.
“NCC had been supplying
“We take the basic
engineering polymer and then
its export business
polymer raw materials to put additives into it to improve
the medtech sector as far its performance. These
back as 1996 so it knew the include radiopaque materials
around the world. customer base well. Instead
of just selling raw materials,
the aim with IPC was to work
– which allow clinicians to
see devices inside the body
on x-rays – specialist colours
with clients such as Boston or antimicrobial materials,”
Scientific, VistaMed and explains Howard.
Teleflex by adding capability “From the outset we
and value,” explains sales recognised that it was
and marketing director of IPC imperative that IPC is involved
David Howard. at the very beginning of a
“Until IPC was established client’s product life cycle so
not a single granule of we can recommend materials
compounded materials was and ensure they are suitable
supplied from within Ireland – for application. Once a
historically it all came from the specification is written by
US. We wanted to compete engineers and materials are
with the American companies validated on a product, this
on the basis of local service, cannot be changed without
faster lead times and research huge cost and revalidation.”
and development [R&D] IPC is unusual in Europe for
support.” its medtech specialisation and
IPC’s state-of-the-art white in 2010 decided to leverage
room facility in Kilbeggan this to extend its footprint
features the latest in material outside Ireland.
14 Polymer Technology Ireland“Historically in Europe its European agent IPC won Stuttgart and Compamed in Avenues is an initiative
industrial materials contracts with a number of Dusseldorf. “We are also very funded by the EU aimed at
compounders have been large clients in Germany, well supported by Enterprise helping European companies
focused on electrical or France and Italy. It has since Ireland across Europe as well to establish long-lasting
automotive applications. We built up a customer base as in the US. We recently business collaborations in
are a small unit employing nine of over 100 clients in 23 won a client in South Korea Asia. Selected companies get
people, purpose-built to only different countries. having visited the country to participate in a one-week
serve the medical technologies A key driver of IPC’s there as part of the EU business mission focused
sector,” notes Howard. business has been attendance Gateway/Business Avenues on a specific sector in South
Further to taking on at major medical tradeshows programme,” says Howard. Korea, South East Asia,
German distributor Velox as such as MedTech Europe in EU Gateway/Business China or Japan.
“ IPC won contracts
with a number of large
clients in Germany,
France and Italy. It has
since built up a
customer base of
over 100 clients in 23
different countries.”
David Howard, Marketing
Director, Innovative Polymer
Compounds (IPC)
2020 Strategy 15Business case studies
Achieving
process
perfection Andrea Cawley, Director
of Sales and Marketing,
Automatic Plastics
The pace of process innovation is
accelerating in manufacturing and Irish-owned
companies are making sure to adapt to compete.
B
ased in Tinahely, improve pricing or quality,” incorporated a mentoring strength to play to,” she says.
county Wicklow Cawley explains. “This requires partnership with Waters “It has been transformational
since 1972, expertise not only on the Technologies in county for us in terms of reducing
Automatic Plastics design side, but also on the Wexford involving reciprocal waste as well as staff
differentiates itself technical side – as frequently site visits and the sharing of engagement and up-skilling.”
from other injection moulding visits on-site to see the client templates for lean tools. Automatic Plastics recently
companies through its lines identifies root-cause “The mentoring partnership launched its APL2020 vision
focus on improving product problems that design tweaks fast-tracked our lean which includes, for example,
design for manufacture for its can eliminate.” implementation. The further up-skilling of its 90 staff
clients in the pharmaceutical, Once the design is agreed, whole area of lean is really and aiming to have all staff
medtech and food packaging Automatic Plastics builds the collaborative in Ireland. trained to lean manufacturing
sectors. custom-made tool or mould Other companies such as white belt in 2018, with a
“Clients come to us with for its injection moulding Rottapharm and Depuy core team of 12 accredited to
a design for food packaging machines to make the client’s Synthes have been happy green belt.
with specific requirements, for product or parts. Having to open their doors to us The company has served
example. We give feedback started out as heavily focused and show us what they have the UK market for many
on a better way to go about on the automotive sector, the achieved,” notes Cawley. decades, mainly focused on
the design to avoid quality company gained certifications Automatic Plastics has also the medical technologies and
issues – this could be the such as the 13485 (ISO) worked closely with Enterprise food packaging sectors. It
use of different materials or quality management standard Ireland on lean manufacturing represents a significant part of
slightly different processes for medical technologies, programmes. Richard Keegan, its portfolio.
to reach the finishing line,” which allowed it to diversify in head of the competitiveness Since the Brexit vote, the
explains director of sales and the past five years. department at Enterprise family-run company has
marketing Andrea Cawley. An increased emphasis Ireland – who has led over realigned its strategy with the
In food packaging or on operational excellence 1,500 best practice lean aim of targeting the French
pharma, Automatic Plastics’ has been a major driver of missions to Toyota’s Deeside and Benelux markets. “We
clients might be making Automatic Plastics’ success. plant in the UK – visited believe that the larger injection
millions of units to run down During the past 12 months it Automatic Plastics and said moulding companies in
fast filling lines. This can has used the Mór Benchmark it was “like a little piece of Europe are not as agile and
require precision down to +/- Model devised by members Japan” in county Wicklow, flexible as we are. Our aim is
0.10 of a millimetre. of Ibec’s Irish Medtech Cawley points out. to always come up with new
“Our clients come with a Association to measure “We recognise that if we ideas,” says Cawley.
product design, but small the company in areas of can be lean and efficient in
changes can drastically lean manufacturing. This our processes, this is a major
16 Polymer Technology Ireland2020 Strategy 17
Business case studies
Embracing
automation
Over the past year family-owned business
Gem Plastics Ltd has undertaken a number of
key measures as part of its continuous pursuit
of general process innovation at its 10,000
square metre plant in Regaskin, county Cavan.
18 Polymer Technology Ireland“ With turnover now in excess of €21 million and
employing 90 people, Gem Plastics supplies a full
range of industrial containers that are used across
a spectrum of industries in the UK and Ireland.”
T
his general process “We supply the largest has given Gem Plastics the Over the past 12 months
innovation is focused chemical distributors in ability to monitor the dosing Gem Plastics undertook
on implementing the UK and Ireland. We of polymer materials into the a Sedex Members Ethical
improved production also supply the Irish and machines to an accurate level. Trade Audit (SMETA), which
methods through the UK manufacturing sites of “With blow moulding there involved a deep investigation
use of different techniques, top global pharmaceutical are so many variables and and holistic review of its
equipment and technologies companies as well as serving variability impacts cost and plant focusing on labour
such as new ways of global brands in beverages,” quality. Every shot is unique. standards, health and safety,
measuring data and an says Burke. This smart piece of kit allows environment and business
upgraded material handling Investment in automation us to monitor dosing in terms ethics. A global not-for-
system. and achieving the quality of the weight and volume profit organisation, Sedex is
Alec Milligan established management system standard of the materials going in, home to the world’s largest
Gem Plastics in 1988 as a (ISO 9001) and the food safety which will then be converted collaborative platform for
sister company to his lubricant system certificate (FSSC to produce the containers,” sharing responsible sourcing
distribution company Gem 22000) in recent years led explains Burke. data on supply chains.
Oils, which was founded in to the company’s focus on Gem Plastics’ process “The SMETA audit
1962. He started out with high-end food, chemical and involves three materials being started as a key customer
one blow moulding machine beverage packaging. mixed at all times: virgin requirement but since then
making plastic drums to “The nature of our work resin, colour masterbatch we have used it as a positive
supply the oil industry. Blow has changed largely because and regrind (material that selling angle. More and more
moulding mainly produces of investment in high-tech has undergone at least companies have requirements
hollow products, such as equipment and automation,” one processing method). for their suppliers in this area,”
bottles, drums and ducts. says Burke. “There used The company has adopted says Burke.
“The company grew rapidly to be one person to every blending and control systems Gem Plastics recently
from there to have a life of its blow moulding machine and from TSM to ensure a hired a full-time HR manager
own,” says managing director a lot of heavy lifting. Now, consistent mix. It is piloting a focused on skills development
Maura Burke. With turnover there is one person running system which measures the and team building. “We have
now in excess of €21 million multiple machines and the skill trend of weight of containers a rigorous training system
and employing 90 people, needed to do an entry-level and alerts engineers if there in place. Presently we are
Gem Plastics supplies a full job has moved on quite a lot. is a variation outside of the rolling out a new food safety
range of industrial containers Traditionally, we had general specification. In addition, it has programme to all operations
from 1-litre to 220-litres in maintenance people to fix invested in a vision system unit staff building on good
size that are used across things when they broke down; used for measuring containers manufacturing practices
a spectrum of industries now we have skilled electrical, as they are produced and (GMP) training which they had
in the UK and Ireland. electronic, design, quality and spotting any malformations. previously completed.”
Containers include anything project engineers. We are “All of our own data
from wholesale washing-up recruiting further for 2018.” combined with TSM systems
liquid bottles to rigid packs Re-investment in a gives us an advanced picture
to contain highly dangerous sophisticated material handling of the true performance of a
chemicals. system in the past 12 months machine,” says Burke.
Gem Plastics was established in 1988
2020 Strategy 19Business case studies
From its base in
county Cavan, fibre
specialist Wellman
International
has addressed
commoditisation
and competition by
carefully targeting
four key market
segments and
focusing on R&D.
Staying
well ahead
20 Polymer Technology IrelandDonal Breen, CEO,
Wellman International
I
n October, Wellman fibre with a capacity of 88,000 then cooled and spun into Recent product
International announced tonnes, it mainly exports to a continuous fibre. At the developments for the
a new research mainland Europe. Ireland Wellman International plant, automotive market from
collaboration with the accounts for about 3% of the fibres are then collected Wellman International have
Royal College of Surgeons sales. in special containers and put included bespoke hollow
in Ireland (RCSI). It is the latest At its plant in Mullagh, through a second process. and coloured solid fibres for
step in the county Cavan- county Cavan, it started out “We elongate the fibres aesthetically critical parts such
based company’s strategic making fibres for domestic under tension to improve as carpets, door panels and
R&D programme to deliver bedding and home furnishings the tensile properties. This parcel shelves and black and
higher value added fibre- – which have become allows us to do things to white fibres for acoustic and
based products to the market. increasingly commoditised the fibre to engineer it to a thermal insulation in cars and
Together with RCSI clinical in recent years due to specific application, such as light trucks.
researchers, Wellman competition from the Far East. specialised crimping or adding “We supply tier 1 and tier
International will develop To address this challenge, attributes such as inherent 2 suppliers to the original
a novel bedding material it diversified into specialist antimicrobial properties,” equipment manufacturers of
with the aim of preventing solutions for the hygiene and Breen explains. Ford, BMW, Mercedes, Audi,
pressure ulcers by controlling healthcare and automotive Wellman International Volkswagen, Volvo, Hyundai,
moisture levels on the skin’s markets in the past ten years. has several unique fibres Nissan and General Motors
surface and evenly distributing It has also evolved from being undergoing trials with key and work as a development
pressure while a person is a mainly a polyester fibre customers at the moment partner with them,” says Breen.
seated or lying in bed. provider to providing multiple in areas such as moisture Back in its early days,
“Otherwise known as bed polymer and fibre types. management, microbe Wellman International was one
sores, pressure ulcers cost the It is continuously learning inhibition, skin health of the first companies in Ireland
NHS in the UK £4-6 billion a how to further enhance and promotion, blood flow to use recycled materials
year. As people get older and improve the performance and enhancement and optimum to produce polyester staple
living standards continue to efficiencies its fibres can offer, comfort. The type of products fibres and this ethos has been
rise, healthcare systems and according to Breen. which may result from these maintained ever since.
care homes could potentially “We are focused on using unique fibres include special “At least 75% of our
face more problems like engineered fibre design to bandages for people with polymer base now comes
this,” says CEO of Wellman solve specific problems in conditions like diabetes. from recycled materials.
International Donal Breen. our four key segment areas: Drinking bottles are turned
“We are looking at designing hygiene and healthcare; into flakes at Wellman
fibres that can facilitate the technical fibres; automotive; Automotive advances manufacturing units in
absorption of much larger and home and apparel,” says France and the Netherlands
volumes of fluid compared to Breen. “This has required The automotive market is and shipped to our plant in
those used in baby diapers capital expenditure every going through quite a change Mullagh, where we convert
and other care products.” year in order to upgrade our at present as it moves more them into fibres,” says Breen.
Founded in 1973, Wellman plant to meet the needs of the towards hybrid and electric “For our home and apparel
International is owned by products of the future.” vehicles, notes Breen. “Weight segment, we have recently
global chemicals company In order to be turned into becomes even more critical produced fibre from plastic
Indorama Ventures and fibres, polymers go through a with these new types of reclaimed from the sea which
employs around 270 people process where they are heated vehicles and we have focused will eventually be transformed
directly. The largest European into a liquid and extruded on designing lightweight fibres into fabrics for T-shirts and
producer of polyester staple through small capillaries, for that purpose.” other types of clothing.”
“ At least 75% of our polymer base now comes from
recycled materials. Drinking bottles are turned into
flakes at Wellman manufacturing units in France and
the Netherlands and shipped to our plant in Mullagh,
where we convert them into fibres.”
2020 Strategy 21Business case studies
Bang on trend
Trend Technologies’
C
urrently employing Technologies became one of
175 people, Trend its major suppliers and, by the
Technologies’ state- early 2000s, the computer
plant in county of-the-art facility in
Mullingar, county
giant accounted for 40% of
its business. Nowadays, the
Westmeath has Westmeath is the centre
of excellence for injection
moulding for the whole group.
medical technologies and
automotive sectors make
up the lion’s share of Trend
constantly adjusted Since it was set up in 1981,
the facility has come through
Technologies’ output, although
it does still supply inkjet
to changes in a number of phases of
reinvention to enable it
cartridge mouldings to HP.
Most of its clients are in Ireland
the marketplace,
to adapt to the needs of and the UK.
different industries. “In order to be able to serve
The most widely used the medical technologies and
ensuring it has plastic process, injection
moulding produces high
automotive industries, we had
to develop a lot of expertise
the expertise and
volumes from all polymers and achieve certifications,
in every shape and size; this including, the standard to
was Trend Technologies’ core supply the automotive industry
capability to stay technology from the outset.
“We started out
(ISO16949) and the standard
to supply the medical
competitive.
manufacturing and supplying technologies industry (ISO
products to the young 3485),” says Murtagh.
computer industry at the Trend Technologies built its
time, such as tape reels and first clean room in Mullingar in
floppy disk boxes,” explains 1997, mainly geared towards
Brendan Murtagh, business HP. It now has three Class
development manager at 7 clean rooms, with one
Trend Technologies. “Within dedicated to post-moulding
a few years, this business operations.
was declining so we decided “In order to work with
to become a sub-contract medical technologies
manufacturer of plastic companies, we had to have
components for the an area like an operating
computer industry.” theatre – the products have
From the mid 1980s to be produced in a very
to the late 1990s Trend clean environment and are
Technologies’ Mullingar packaged and sealed before
operation supplied global they leave the clean room,”
companies such as IBM, says Murtagh. “The next time
Apple, 3Com and Dell with the package is opened is in
outer housings for desktop a similar clean room at the
computers, keyboards and client’s manufacturing site.”
mice. “By 1999 there was Trend Technologies invested
none of that type of computer €3 million in upgrading the
manufacturing left in Ireland site and adding clean-room
– one by one the companies capacity in 2017. “We want
moved it to the East,” to be able to add as much
says Murtagh. value as possible to the raw
When Hewlett Packard plastic component and have
(HP) arrived in Leixlip, Co introduced new technologies
Kildare 20 years ago, Trend such as digital printing and
22 Polymer Technology Irelandlaser welding specifically for of plastic components every ensure that a good product is
that purpose,” notes Murtagh. day to Draexlmaier in the UK, consistently made, regardless
Medtronic, Cook Medical, which then converts them of any kind of variation in
Olympus Medical and KCI are into complete car interiors for the environment (such as
among Trend Technologies’ Jaguar and Land Rover. “The a change in temperature
medical technologies components we supply are or moisture in the air) or in
customers. It supplies used for everything you see in material supply,” Murtagh
the sector with wound the front of a car, including the explains.
care products, diagnostic dashboard, heater controls, Typically, when a client
laboratory consumables, glove box and Sat Nav,” notes comes to Trend Technologies
ventilator housings, surgical Murtagh. they have the general concept
handles and stent delivery Trend Technologies uses of a product developed and
systems. moldflow analysis to develop know how it is going to work.
From 2000 to 2007, tooling before it is built. This What they don’t know is how
Trend Technologies built simulation technology allows to move the design on so
up capability in serving the engineers to assess how that it can be manufactured in
automotive industry and by the polymer material will volume at the lowest possible
2007 Donnelly Mirrors in flow through the tool and to cost.
Naas accounted for 50% of predict and eliminate potential “We provide a huge amount
its business. When Donnelly problems. It has also built up of advice and support in this
Mirrors closed its Irish particular expertise in product area,” notes Murtagh. “We
operation and moved much and process validation after a would usually be involved
of the business to Slovakia, tool is built and in advance of six months to two years with
Trend Technologies replaced production start. a client during the product
that business with other “Customers expect development stage onwards
automotive clients. production processes to be to manufacture.”
It now ships two containers validated to the highest level to
“ Trend Technologies now ships two
containers of plastic components every
day to Dräexlmaier in the UK, which
then converts them into complete car
interiors for Jaguar and Land Rover.”
Brendan Murtagh, Business
Development Manager,
Trend Technologies
2020 Strategy 23Business case studies
The path to
industrial 3D
manufacturing
3D printing is now viable for
large scale manufacturing
24 Polymer Technology IrelandHP is investing heavily in industrialising
nylon based 3D technology to transform
manufacturing industry. The HP Multi Jet Fusion
Technology allows for final part production
economically in volumes of up to 110,000 small
parts when compared to traditional injection
moulding techniques. This along with design
improvements and single process production
for complex parts means that many industries
can make better parts whilst reducing
inventory and total cost of production.
3
D printing is one of and the ability handle larger Today, HP also announced strength, versatility, and
the most disruptive quantities of 3D printing the further expansion of its flexibility, but only one of them
technologies of our materials, while significantly industry-first Open Materials is going to space (for now).
time, spearheading lowering production costs with Platform, a collaborative The new HP 3D High
a new 4th Industrial reduced pricing on HP’s 3D development and distribution Reusability PA 12 Glass
Revolution that will radically materials and shared service model where HP and its Beads, an innovative new
change the way we conceive, contracts. growing ecosystem of 3D nylon material filled with tiny
design, produce, distribute, When put together with partners work together to glass beads, was used to
and consume pretty much HP’s industry-leading Multi drive materials innovation, make one of the most complex
everything. Jet Fusion technology, reduce costs, and create new parts in a specially-designed
But until now, 3D printing those enhancements double applications and markets for HP ENVY Zero-Gravity printer
hasn’t been a viable means the existing “break-even Multi Jet Fusion technology. developed with NASA that’s
of large-scale industrial point” at which 3D printing There are already over 50 being sent to the International
manufacturing (think big remains cost-effective to an leading companies actively Space Station this February.
factories) because of unprecedented 110,000 parts, engaged on the platform. The printer’s output tray
prohibitively expensive and drastically reduces the Materials companies can use needed to be particularly
production costs and limited cost-per-part, up to 65% less HP’s Materials Development lightweight, watertight, and
technology. In order to than other methods. Kit to quickly test compatibility durable for its journey to
realize HP’s vision of digitally “The new 3D 4210 with Jet Fusion printers. space, and 3D printing with PA
transforming the $12 trillion Printing Solution enables Materials companies 12 Glass Beads provided the
global manufacturing industry, our customers to mass- can use HP’s Materials perfect solution.
the economics of 3D printing produce parts using HP’s Development Kit to quickly HP continues to unlock the
needed to be completely Multi Jet Fusion technology test compatibility with Jet economics and technology
rewritten. for significantly less than Fusion printers. of 3D manufacturing, with
At the end of 2017, HP other processes, and fully It was announced that a deeply-engaged network
announced that it has benefit from the economies leading chemical companies of partners committed to
smashed that economic of scale,” said Ramon Dressler Group and Lubrizol accelerating the digital
barrier and paved the way Pastor, General Manager of have joined the growing HP industrial revolution.
for cost-effective, industrial- Multi Jet Fusion for HP’s 3D 3D partner ecosystem, and Says Corey Weber, co-
scale 3D manufacturing with printing business. “HP’s Jet also that three new three founder of leading printing
the new Jet Fusion 3D 4210 Fusion 3D systems have now new engineering-grade 3D service bureau Forecast 3D,
Printing Solution. reached a technological and printing materials are coming “It has never been more
The new solution increases economic inflection point that to the open platform: PA clear to us that HP’s Multi Jet
production volume for HP Jet combines the speed, quality, 11, PA 12 Glass Beads, and Fusion represents the future
Fusion 3D printers by enabling and scalability needed to Polypropylene. of digital manufacturing.”
continuous operation, greater accelerate manufacturing’s The new materials raise
overall system efficiency, digital industrial revolution.” the bar on production quality,
2020 Strategy 25Business case studies
Expanding
operations
through
manufacturing
excellence
With contract
A
global manufacturer a new 60,000 sq ft building
of packaging facilitating the manufacture
components and of medical devices with
manufacturing delivery systems
for injectable drugs
electronic component
integration to meet the
operations in and health products, West
Pharmaceutical Services
has built up its presence in
increasing global needs of
customers and patients for
connected devices. Today,
Dublin since 1998 Ireland significantly since
acquiring the Tech Group,
around 500 people are
employed at West’s Dublin
and following its which included a contract
manufacturing operation in
facility.
The Dublin site is to produce
acquisition of ‘The Tech
Mulhuddart in Dublin 13 around 35 million devices
years ago. and 2 billion components
Now West’s largest this year to support its
Group’ in 2005, West contract manufacturing site
globally, the Dublin facility
medical technology and
pharmaceutical customer
recently expanded its
started out in 1998 with 17 base, according to senior
employees in a 40,000 sq director Tom Clarke. These
ft facility, initially serving the devices will be shipped all over
operations in Ireland, consumer electronics sector.
By 2004, when a further
the world.
“We have 95 injection
both in Dublin and
40,000 sq ft was added, it moulding machines in Dublin
was 100% focused on serving supporting 14 high-volume
medical technology and assembly lines,” says Tom
with a new site in pharmaceutical customers.
Demand for autoinjector
Clarke, senior director, at
West. “Currently processing
Waterford.
devices for the treatment almost 6,000 tonnes of
of diabetes drove further polymer resin per year, we
expansion in 2014 and in expect this will grow even
2016, the ribbon was cut on more in 2018.”
26 Polymer Technology IrelandIn recent years, West has specific to Dublin, is going for multiple product lines and has 28 sites around the
invested in the digitisation to enhance our efficiencies in the future. It was built in world employing a total of
of its Dublin contract and make us an even leaner a campus layout to ensure 7,300 people. The Waterford
manufacturing facility to operation.” flexibility to grow in all facility currently employs
allow real-time process and West recently expanded directions. 80 people, with plans to
product monitoring across its global manufacturing “Waterford will be a continue hiring in 2018.
the machines and automation operations to include a new centre of excellence for Commercial production is
systems that produce the site in Waterford on the our proprietary elastomeric planned to begin there by
devices. back of increased demand sheeting, which is used the end of the year.
“This has significantly from pharmaceutical and to package insulin for use West won the inaugural
enhanced our biotech customers. The in pen injectors,” explains Partner/Supplier of the
competitiveness and new facility will produce Clarke. “It will also offer high- Year 2016 at the Medtech
business growth. 2018 will packaging components for value finishing for West’s Rising: The Irish Medtech
see us embark on another insulin injector cartridges and elastomer products, such CEO Conference and
enhancement of the facility, other high-value packaging as stoppers and plungers. Awards hosted by Ibec’s
as we are going to look at components. These capabilities include Irish Medtech Association,
automation from the receipt Situated at a 44-acre site, washing, vision inspection Enterprise Ireland and
of orders right through to the the facility is around 20,500 and sterilization.” IDA Ireland.
shipping of products,” notes sq m in size and is designed Founded in 1923, West
Clarke. “This pilot project, to accommodate expansion is headquartered in the US
“ [West’s] Dublin site is to produce around 35
million devices and 2 billion components
this year to support its medical technology
and pharmaceutical customer base.”
Tom Clarke,
Senior Director,
West Pharmaceutical
Services
2020 Strategy 27Business case studies
The test of time
Over the past 24 years Anecto has evolved from
being an electronics device test laboratory to
having a state-of-the-art test facility serving
multiple sectors including 80% of the world’s
top 20 medtech companies.
O
ne of the standard, Medtech and life sciences the case by looking at plastic packaging of a medical device
and perhaps now account for 60% of performance. If the packaging was causing it not to seal
surprising, tests Anecto’s business, followed is problematic, we figure out properly. Rather than the
Anecto carries by energy and power, which what we can do about it in a company having to reengineer
out for automotive makes up a quarter of its cost efficient manner.” everything, we found that a
manufacturers is to see what turnover. Electronics and On the product side, small formula change to the
happens when sun tan lotion mechanical and packaging are medtech companies face adhesion component meant
is put on the internal plastics its other main areas of focus. a range of challenges and the problem was solved.”
in a car. “The size of the medtech issues involving polymers and Anecto won Partner/
“Plastic can discolour in industry in Ireland – with plastics. Anecto assesses Supplier of the Year 2017 at
instances when you put sun key players having a base everything from making sure the Medtech Rising: The Irish
tan lotion on it,” says Mike here, including nine of the Luer fittings don’t crack and Medtech CEO Conference
Connolly, sales director and world’s top ten medtech leak to testing the bendability and Awards hosted by Ibec’s
director of testing services at companies – was perfect of catheters. “We always Irish Medtech Association,
Anecto. “The performance of for a company such as ours look at performance issues Enterprise Ireland and IDA
a product largely depends on to develop expertise. It gave against standards but can also Ireland.
the stresses plastics are going us a competitive advantage evaluate against a database
to get, including vibration, to expand throughout of similar products,” says
heat, cold and compression. Europe,” says Connolly. “In Connolly.
Our job is to establish how a some European markets the He believes where Anecto
product made out of plastic medtech industry was too is of real value to clients
will perform in real life.” small to concentrate on, while is in understanding why
The Galway-based company in others, such as the UK and something happens,
offers a full range of services Germany, there was so much rather than just reporting
that support companies in their testing going on in so many what has happened – it
efforts to increase product areas that it wasn’t important is the expertise beyond
reliability and reduce the risk of to specialise in medtech.” the test.
failure throughout the product Regarding polymers, there “For example, we
lifecycle. are two strains to Anecto’s identified that the
Currently employing over work with medtech companies interaction between
90 people, its 40,000 sq ft – packaging and products. three components
facility contains over €2.5 “The challenge for medtech in the
million worth of equipment, companies is to deliver their
including vibration systems devices sterile at points of use
and specialist medical device anywhere in the world. The
systems. “Our engineers will product may have a five-year
design and build specialist shelf life, but still has to be
test equipment to meet a sterile,” explains Connolly.
specific need if it is not already “We work with medtech Mike Connolly, Sales
available,” notes Connolly. companies to ensure that is Director and Director of
Testing Services, Anecto
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