In an on-site interview with Plastics News, the company shared details of its strategies to grow the global market through aggressive innovation as well as capacity expansion.
“We focus on developing applications that don’t exist today, while most of our competition spends their time on replicating the applications that already exist. Our goal is to grow the market, I suspect most of our competition’s goal is to grow their share,” said Kevin Fogarty, president and CEO.
Kraton continues to expand its exposure to different end markets. Among Kraton’s latest and fastest-growing products, Cariflex synthetic polyisoprene rubber and latex are gaining popularity with the medical-supply and personal-care industries with their hypoallergenic nature, high tensile strength, and comfort. The products’ extremely high purity also benefits niche markets such as electronic coatings.
Kraton is the only company in the industry that uses an anionic solution polymerization process to produce this type of product. Kraton recently has added new Cariflex IR capacity in Belpre and expanded production capability in
The Belpre plant, which opened in 1961 with 129 employees, has expanded and modernized over the years. Today, the plant is reportedly the largest styrenic TPE production facility in the world. The campus covers more than 300 acres, with a workforce of about 600 employees and contractors. Payroll exceeds $200 million a year for employees and $8 million a year for contractors.
The facility consists of four polymer process units, four finishing/packaging operations, and a polymer compounding unit. It boasts 189 kilotons417 million pounds of annual capacity of both unhydrogenated SBC and hydrogenated SBC products, including 70 polymer grades in pellet, crumb and powder form.
Kraton launched solid isoprene rubber capacity at Belpre in June, replacing the capacity from the Pernis,
Innovation-centered growth
In order to continue to lead and grow the market, Kraton strives to beef up its global research and development capabilities. Kraton spent $24 million for R&D in 2010. More importantly, R&D productivity — the ratio of innovation revenue to R&D spending — reached a record high in 2010, more than doubling the 2005 level, said vice president of technology Lothar Freund.
In the same year, innovation revenue presented 13 percent of total revenue, compared to 5 percent in 2005. Freund hopes to raise the percentage even higher to 20 percent in the future.
The company also devised specific innovation objectives, including create new market for SBCs, develop technology platforms based on market needs, and deliver technology solutions for customers.
Kraton has innovation centers in
In
Biggest HSBC expansion
After years of anticipation of a plant in Asia, Kraton has finally announced a framework agreement to enter into a joint venture with Formosa Petrochemical Corp. to construct a new HSBC plant in
“It was a long process to decide where and how best to build the plant,” he said, citing threefold criteria: feedstock proximity, expandable location, and access to the engineering capabilities to ensure the success of the construction.
“In the context of the relationship with Formosa, we will have achieved all three of those goals,” he said, especially that the partnership with Formosa, once it is finally documented, may provide for additional features and capacity expansion for both HSBC and USBC. Once completed, the
As envisioned, for the first five years after the plant is constructed, Fogarty said, less than half of the HSBC produced in the Taiwan plant would go to mainland China, the rest would go to other regions of the world.
Unlike commodity resin production that focuses on cost and logistics, Kraton’s global manufacturing strategy focuses on the optimization of operations, he explained. Each of the SBC plants — in
Underweight in
Based on global sales revenue, Kraton currently is holding more than 50 percent of the HSBC global market share and about 33 percent for USBC. However, the 21 percent share of
The growth potential lies in innovation. In fact, much of Kraton’s innovation sales — defined as revenues from new products introduced in the last five years — are generated in
The company sees the rising demand for state-of-the-art products and applications from technology-focused customers in
Global medical-supply manufacturers include
Besides medical packaging, Kraton also expects to see growth in PVC replacement for wire and cable as well as slush molding for automotive components. Just like in North America and Europe, Fogarty noted, the key for developing markets in