MINERAL SOLUTIONS FOR A CHANGING WORLD

MINERAL SOLUTIONS
FOR A CHANGING
WORLD
IN BRIEF 2014
CONTENTS
04
Presence in a great
number of markets
05
Our business:
world leader
of specialty minerals
for industry
06
A leading position
in its four business
groups
08 OUR COMMITMENTS
10
Guaranteeing
the group’s growth
is preparing
for the future
12
Developping
know-how is preparing
for the future
14
Acting with a
responsible approach
is preparing
for the future
THE WORLD LEADER IN
MINERAL-BASED SPECIALTY
SOLUTIONS FOR INDUSTRY
Imerys transforms a unique range of minerals
to deliver functional specialty solutions (heat
resistance, mechanical strength, conductivity,
coverage, barrier effect, etc.) essential for its
customers’ products and manufacturing processes.
Whether mineral components, functional
additives, process enablers or finished products,
Imerys’ solutions contribute to the quality
of a great many applications in consumer goods,
industrial equipment and construction.
Combining expertise, creativity and attentiveness
to their customers, the Group’s teams constantly
identify new applications and develop high
value-added solutions, in line with a determined
approach to responsible development.
14,900
234
€3,688M
€495M
employees
revenue
industrial sites
current
operating income
50
countries
IN BRIEF 2014
ENERGY SOLUTIONS
& SPECIALTIES
FILTRATION &
PERFORMANCE ADDITIVES
CERAMIC MATERIALS
HIGH RESISTANCE
MINERALS
Kaolin
Carbonates
Fused Minerals
Filtration &
Performance Additives
Minerals for Ceramics
Monolithic Refractories
Refractory Minerals
Clay Roof Tiles
Graphite & Carbon
Oilfield Solutions
3
SOLUTIONS FOR A CHANGING WORLD
PRESENCE IN A GREAT NUMBER
OF MARKETS
Imerys serves a wide range of industries, guaranteeing
balanced exposure to different economic cycles.
The Group’s sales are spread across over 20 markets.
AUTOMOTIVE,
INDUSTRIAL EQUIPMENT
AND CONSUMER DURABLES
ENERGY
ELECTRONICS
CONSTRUCTION
Plastics, batteries,
paint bodywork,
tooling, etc.
Batteries, photovoltaic
cells and panels, oil
and gas drilling, etc.
Device structure,
processors,
semi-conductors, etc.
Roof tiles, cement
making, window profiles,
etc.
DECORATIVE MATERIALS
AND FITTINGS
STEELMAKING
AND METALLURGY
AGRI-FOOD
PAPER
Sanitaryware, tableware,
flooring, paint,
floor tiles, etc.
Refractory linings
for furnaces, etc.
Filtration of beer, wine,
drinking water
and fruit juice, etc.
Catalogues, advertising
materials, brochures,
magazines,
specialty papers, etc.
HEALTH,
BEAUTY AND CARE
HORTICULTURE,
PROTECTION OF FLORA
Deodorant, skin creams,
toothpaste,
hygiene products, etc.
Hydroponics,
UV production,
repellents, etc.
PACKAGING
Plastic film,
specific packaging, etc.
4
IN BRIEF 2014
OUR BUSINESS: WORLD LEADER OF SPECIALTY
MINERALS FOR INDUSTRY
Imerys dedicates 1.7% of its revenue to Research & Development.
This amount represents quite a significant share for the industrial
minerals industry and reflects the Group’s determination
to make innovation the driver of its internal growth.
HIGH-QUALITY MINERALS
The Group develops specialty
solutions by transforming
and formulating a range of
around 30 minerals.
Thanks to its mining sites,
where it holds on average
20 years’ high-quality mineral
reserves and with teams
dedicated to exploring
additional resources,
Imerys guarantees its
customers a lasting supply.
THE ART OF MINING
By selecting relevant techniques
for the characteristics of every
deposit, Imerys can extract
minerals with an economically
efficient, yet environmentallyfriendly approach.
Sites at the end of their
industrial lives are restored in
the best possible environmental
conditions. The Group has
established common responsible
management processes,
including for restoration plans
that are studied from the outset
of mine opening projects.
BENEFICIATION KNOW-HOW
To obtain the required properties
and so add value, minerals
are processed using various
technologies, many of which are
specific to Imerys, e.g. grinding,
grading, drying, calcination,
sintering, melting, bleaching,
surface chemistry, magnetic
purification and flotation,
but also shaping processes
such as pressing, extrusion,
granulation and casting.
INDUSTRIAL AND
TECHNOLOGICAL SKILLS
The Group calls substantial
resources into play to innovate
in line with its customers’
needs: 300 scientists based
in market-focused Research
& Development centers across
the world, and collaboration
with renowned institutes.
The Group has developed
many exclusive processes,
technologies and products
that it strives to protect.
5
SPECIALTIES FOR
WIDE-RANGING APPLICATIONS
Imerys’ mineral-based
specialty solutions can be
used in four different ways
in the industrial chain:
- mineral components
- functional additives
- amanufacturing
process enablers
- finished products
A WIDE VARIETY OF USES
• Graphite to meet the
specifications of mobile
energy and precision
engineering industries
(lithium-ion batteries, etc.)
• Monolithic refractories
for high-temperature industries
(steelmaking, foundry, etc.)
• Diatomite and perlite
to filter edible beverages
• Electrofused magnesia
for domestic appliances
(dishwashers, etc.)
SOLUTIONS FOR A CHANGING WORLD
A LEADING POSITION IN
ITS FOUR BUSINESS GROUPS
7%
43%
Carbonates
100%
Monolithic Refractories
Filtration
& Performance Additives
Graphite & Carbon
9%
ENERGY
SOLUTIONS
& SPECIALTIES
41%
1,279
€
million revenue
(35% of Group total)
Oilfield Solutions
FILTRATION
& PERFORMANCE
ADDITIVES
28 countries
76 industrial sites
4,958 employees
€
658
million revenue
(18% of Group total)
The Energy Solutions & Specialties
business group manufactures and sells
high-performance mineral solutions for various
demanding industries: the consumer goods and paper
sectors with Carbonates, high-temperature industries
served by Monolithic Refractories, Graphite & Carbon
applications linked to mobile energy, and oil
and gas exploration served by the
Oilfield Solutions activity.
16 countries
45 industrial sites
2,518 employees
The Filtration & Performance Additives business group
is a supplier to a great number of industries
(agri-food, plastics, paint, rubber, catalysts, paper,
pharma, personal care & beauty, etc.).
Its activity is driven by trends in consumer goods
(beverages, food, packaging, etc.), capital goods
(particularly automotive) and construction
(new buildings and renovation).
WORLD #1
WORLD #1
in minerals for breathable
polymer films
in talc for plastics, paints, paper,
ceramics, health & beauty
WORLD #2
WORLD #1
in carbonates for paper
in mica
WORLD #1
WORLD #1
in alumino-silicate monolithic refractories
in mica for engineered plastics
and high-performance coatings
WORLD #1
in graphite for alkaline batteries
WORLD #1
WORLD #1
in diatomite-based and
perlite-based products for filtration
in conductive additives for Li-ion batteries
6
IN BRIEF 2014
The composition of Imerys’ business groups was changed in 2014 as a result
of the acquisition project of S&B. The Kaolin activity was integrated into the Ceramic Materials
business group and S&B’s activities were integrated into the Filtration & Performance Additives
business group on March 1st, 2015. All 2014 financial data are therefore presented
under the new organization.
27%
40%
Kaolin
41%
Minerals for Ceramics
59%
Fused Minerals
Refractory Minerals
Clay Roof Tiles
CERAMIC
MATERIALS
HIGH RESISTANCE
MINERALS
33%
1,157
€
million revenue
(31% of Group total)
21 countries
84 industrial sites
4,269 employees
€
642
million revenue
(16% of Group total)
The Ceramic Materials business group is organized
around Clay Roof Tiles (France’s largest producer of clay
roof tiles and roof accessories), Minerals for Ceramics and
Kaolin activities. The Minerals for Ceramics activity
mainly addresses the ceramic industries (tableware, tiles,
technical ceramics), but also other markets such as
fiberglass. Imerys kaolins are a key component of many
products including consumer goods (paper, packaging,
paints, plastics and polymers).
14 countries
29 industrial sites
2,841 employees
The High Resistance Minerals business group
is positioned upstream of the industrial equipment chain
(steel production, industrial and automotive sectors).
The business group leverages on sophisticated
manufacturing processes for high-temperature
operations, to offer mineral-based specialties
with key functionalities: refractoriness, abrasiveness,
mechanical resistance, purity and conductivity.
WORLD #1
WORLD #1
in raw materials & ceramic bodies
for sanitaryware
in alumino-silicate minerals
for refractories
WORLD #1
WORLD #1
in kiln furniture for roof tiles
in fused minerals
for abrasives
WORLD #1
WORLD #1
in kaolin for paper
in fused zirconia
EUROPEAN #1
in raw materials and ceramic bodies
for porcelain tableware
FRENCH #1
for clay roof tiles and accessories
7
OUR
COMMITMENTS
GRO
WT
H
W
-HO
OW
KN
IMERYS
RESPONSIBILITY
8
IN BRIEF 2014
PREPARING FOR
THE FUTURE TODAY
For Imerys, preparing for the future consists of three
commitments: to ensure the Group’s growth, develop
its know-how and be a responsible actor. To ensure
its growth, the Group is implementing a strategy based
simultaneously on innovation, geographic expansion, entry
into new growing markets and carefully targeted acquisitions.
Regarding know-how development, Imerys leads
a Human Resources policy promoting the evolution of
its employees and the recruitment of new talents. The Group
also seeks to develop and share, within the company, good
practices in operational excellence to improve and sustain
its industrial success.
To meet its growth targets while ensuring its social and
environmental responsibility, the Group is engaged
in performance improvement plans that encourages each
of its entities to implement concrete local initiatives whose
progress is assessed using performance indicators.
9
SOLUTIONS FOR A CHANGING WORLD
GRO
WT
W
-HO
OW
H
KN
IMERYS
GUARANTEEING
THE GROUP’S GROWTH
IS PREPARING FOR
THE FUTURE
RESPONSIBILITY
I merys has developed rapidly
since the early 2000s thanks
to a strategy based on
innovation, expanding its
geographic footprint and
activity portfolio, and stepping up
its presence on profitable markets.
the development of new concepts.
For 2014 alone, the new products
introduced over the last five years
have generated €449 million, i.e.
12% sales revenue. The vast range
of applications offers many
possibilities for our teams’ creativity.
STAYING ONE INNOVATION AHEAD
FOCUS ON GROWING MARKETS
Imerys innovates with and for its
customers. Three hundred
researchers and technicians are
mobilized at all times worldwide to
meet customers’ expectations
while the marketing teams try and
anticipate their needs. In 2014
Imerys launched 75 new products:
innovations stemming from
improvements to existing ranges,
Imerys focuses its research efforts
in the areas with the strongest
growth potential. The projects
launched in 2014 notably reflect
the dynamism of the plastics
markets, recycling, lithium-ion
batteries and organic agriculture.
or disruptive innovations based on
production capacities to continue
PRODUCTION CAPACITY DEVELOPMENT
Imerys has developed new
10
its development on growing
markets identified as having the
highest potential. In Brazil, the
Group unveiled a new blending
S&B
ACQUISITION
With the integration of
S&B’s activities into the
Filtration & Performance
Additives (F&PA) business
group, Imerys counts on
a number of synergies:
business’ exposure on
existing and growing
markets, increased
geographic presence
and innovation potential
development.
IN BRIEF 2014
INNOVATION
Anticipating our
customers’ needs
_
platform for the Minerals for
Ceramics activity. The High
Resistance Minerals business
group launched a new production
line in Austria for ultrafine alumina.
The Energy Solutions & Specialties
business group opened a new
natural graphite quarry in Canada
and commissioned a third
production line for monolithic
refractories in India. The new
production line in Willebroek
(Belgium) enabled Imerys
Graphite & Carbon to double its
capacity for carbon black.
Imerys’ innovative solutions are appreciated on every continent.
In Europe, the C-NERGYTM materials for electrodes have become
a benchmark for high-performance battery manufacturing;
Steagreen™ talcs are used to restore mechanical properties
to plastics compounds; the ImerCare™ Scrub range, based
on engineered perlite, was developed in response to growing
demand in the cosmetics industry for natural ingredients.
In North America, the JetWhite® references, functional additives
for polymer compounds, are used in color-sensitive automotive
and appliance end uses. In Asia customers benefit from
CerafluxTM, a new range of fluxes for glazes developed to lower
sintering temperatures, thus reducing tile production costs and
subsequent environmental impacts.
extensively through organic
In the regions identified as high
potential development sources,
growth projects, acquisitions or
partnerships. The Group has
completed the acquisition of
Termorak, a Finnish refractory
material producer, and Kinta
Powdertec Sdn Bhd, a Malaysian
producer of ground calcium
carbonates. Imerys also set up its
first industrial facility in the Middle
East with a fused alumina plant in
Bahrain, built under a joint venture
with the Al Zayani Investments
group, extending its geographic
footprint in a strategic area for the
Group. With the S&B acquisition,
Imerys accelerates its
development and increases its
offer in mineral-based specialty
the
solutions for industry.
TARGETED EXPANSION
G ro u p
is
ex p a n d i n g
11
€242
million
industrial investments
in 2014
75
new products
marketed in 2014
SOLUTIONS FOR A CHANGING WORLD
W
-HO
OW
GRO
WT
H
KN
IMERYS
DEVELOPING
KNOW-HOW
IS PREPARING FOR
THE FUTURE
RESPONSIBILITY
D riven by entrepreneurship
and focused on sound
values, the Group implements a Human Resources
policy that is consistent
with the changes in today’s world.
TRAINING TO ENHANCE EXPERTISE
To accompany its strategy
implementation, the Group has
designed training programs
through Imerys Learning Center
(the Group’s training center), and
its business groups, on security,
industrial performance, etc. Imerys
Learning Center provides training
on all continents to allow
employees to develop their skills,
broaden their internal network and
share the Group’s culture. In total,
over 10,200 employees, e.g. 66%
of the average annual workforce,
were trained during 2014.
ALL ONLINE
In 2014, the Group decided to
extend the scope of its training
t h ro u g h I M - P u l s e, a n ew
e-learning solution. The aims of
this online training platform are
to reach as many employees as
possible, especially in the most
remote regions, and to offer
personalized training. More than
4,000 employees will eventually
benefit from this new ongoing
training offering from 2017.
A SHARED CORPORATE CULTURE
All over the world, the Group’s
12
men and women add to its value,
build its success and forge its
reputation. Many in-house
initiatives are taken to strengthen
this company spirit. Cross-division
seminars are organized by function
to share best practices. External
and internal communication
support information sharing
(electronic newsletters, social
networks and videos published
online via YouTube on Imerys
Replay channel).
WELCOMING NEW EMPLOYEES
To facilitate new employees
integration, a welcome program
c a l l e d “ O n b o a rd i n g ” wa s
launched in 2014. This program,
based in part on the best
IN BRIEF 2014
OPERATIONAL EXCELLENCE
Developing and sharing
best practices
_
practices of the Group’s entities,
includes a practical presentation
kit on Imerys, its businesses and
its sustainable development
policy, as well as essential
information for smooth
integration. “Welcome Sessions”
for new employees are organized
several times a year in Europe,
North America and Asia. In 2014,
a session was organized in Brazil
for the first time.
A Group-wide analysis of industrial assets showed
performance levels that varied from site to site.
To reach a common standard of operating excellence,
Imerys implemented in 2014 a program to improve its
industrial processes called Imerys Industrial Improvement
(I-Cube). The implementation of the program follows
a three-phase roadmap expected to conclude in 2018.
The program is a new guarantee from Imerys on its
commitment to supply increasingly high-performance
products that meet strict quality criteria.
employee benefits had to be
harmonized if not identical, the
Group set down the principle of
gradually aligning its subsidiaries’
compensation and benefits. In
2014, Imerys updated its Code of
Ethics and Business Conduct to
strengthen policies and
procedures against fraud and
corruption.
221,000
training hours
were allocated to 10,200
employees
75%
of employees
are covered by
a collective agreement
SOCIAL MODEL, ETHICS
AND BUSINESS CONDUCT
With bases in almost
50 countries, Imerys also has to
take account of specific social
legislation and practices that can
vary widely. Considering that its
13
SOLUTIONS FOR A CHANGING WORLD
W
-HO
OW
GRO
WT
H
KN
IMERYS
ACTING WITH
A RESPONSIBLE
APPROACH
IS PREPARING
FOR THE FUTURE
RESPONSIBILITY
T o reconcile its growth
ambitions with its social
and environmental
responsibilities over the
long term, the Group has
ce n te re d i t s S u st a i n a b l e
Development strategy on three
main areas: social, environment
and governance.
CONSERVING THE ENVIRONMENT
All of Imerys’ facilities worldwide
have set up an Environmental
Management System (EMS) and
81 of them are ISO 14001 or Eco
Management and Audit Scheme
(EMAS) certified. An EMS enables
each operation to manage and
control the risks and issues
relating to the protection of the
environment. The systems are
fully integrated into the Group’s
environment, health & safety
site. In addition, a restoration
program is systematically set up
for the site’s entire lifespan. On
(EHS) audit program. Every site
has to measure its water, ensure
waste water is recycled and
check the quality of discharged
water. These actions have
achieved tangible results as the
Group’s total water withdrawals
have been cut by 13.2% since 2013
and by almost a third over the
past five years.
A s fa r a s b i o d i ve r s i t y i s
concerned, Imerys pledges to
respect the ecosystems around
its facilities and conserve their
value. In-depth studies are
conducted on fauna and flora
before any operations start on a
a Group scale, the measures
taken since 2009 in favor of
14
TAKE 5
In 2014, Imerys rolled
out “Take 5” in all its
operations worldwide.
Each employee without
exception is asked to
acquire the habit of taking
five safety steps before
starting any task. This
initiative was the focus
of a broad awareness
campaign.
IN BRIEF 2014
ENVIRONMENT
Environmentally-friendly
cement
COMMUNITY
Fine perlite for local
population activity
_
_
With Andalusite quarries close to the Pretoria
Portland Cement (PPC), Imerys was able to
offer a more efficient and environmentallyfriendly product than fly ash from thermal
power plants transported over long distances
before going into cement production.
re n ewa b l e o r l ow- c a r b o n
energies have already led to a
decrease in atmospheric CO 2
emissions.
SPREADING SAFETY AWARENESS
The Imerys Safety System is a
program based on compliance,
continuous improvement, and
communication/training. The
purpose of this integrated
approach is to communicate the
Group’s safety culture and ensure
compliance with the same safety
standards and rules at all of its
activities worldwide. It presents
the
main
continuous
improvement levers for safety.
The disciplined rollout of the
Imerys Safety System has helped
Used as a clay replacement to manufacture
bricks, fine perlite, transformed in our factories,
is a sustainable and economical solution, which
helps to develop local activity but also to stop
degradation and protect flora and fauna.
to cut the lost-time accident rate
(including subcontractors) by
61% in five years. Prevention
efforts have been stepped up
since 2013, leading to a 27%
reduction in frequency.
BEING AN INTEGRATED PARTNER
Building and sustaining the best
possible relations with the
communities near its sites is an
essential condition for Imerys’
successful growth. The Group
integrates social responsibilities
into its sustainable development
policy based on respect for its
neighbors, leading to tangible
actions on education, culture or
health. A specific protocol on
community relations has been
15
published, translated into seven
languages and has been
implemented at all Imerys sites.
More than one-third
of the
75
new products
launched in 2014 are of benefit
to the environment.
-61%
in five years
for the frequency rate
of lost-time accidents
(including subcontractors).
SOLUTIONS FOR A CHANGING WORLD
ENERGY SOLUTIONS
& SPECIALTIES
To find out more?
To find out more,
visit the websites of the
Group www.imerys.com
and its activities
Carbonates:
www.imerys-carbonates.com
Monolithic Refractories:
www.calderys.fr
Graphite & Carbon:
www.imerys-graphite-and-carbon.com
Oilfield Solutions:
www.imerys-oilfieldsolutions.com
FILTRATION &
PERFORMANCE ADDITIVES
Filtration & Performance
Additives
www.imerys-perfmins.com
www.imerystalc.com
www.imerys-filtration.com
www.celitecynergy.com
www.advancedminerals.com
www.insulation.imerys.com
www.imerplast.com
www.imerys-specialitiesjapan.com
www.imerysvermiculite.com
CERAMIC MATERIALS
Clay Roof Tiles:
www.imerys-toiture.com
www.imerys-solaire.com
Minerals for Ceramics:
www.imerys-ceramics.com
www.imerys-aurora.com
www.thequartzcorp.com
www.ikf-solutions.com
Kaolin:
www.imerys-kaolin.com
www.imerys-perfmins.com
www.imerysnopara.com.br
HIGH RESISTANCE
MINERALS
Refractory Minerals:
www.imerys-refractoryminerals.com
Fused Minerals:
www.imerys-fusedminerals.com
www.ifme.eu
154, rue de l’Université – 75007 Paris
Telephone: + 33 (0) 1 49 55 63 00
Fax: + 33 (0) 1 49 55 63 01
Design and production:
TRANSFORM TO PERFORM
Print: TI Médian impressions.
This report is printed on paper produced from sustainably
managed forests. The paper is FSC certified and contains
Imerys pigments.
Photo credits: G. Carillo • Fotolia • Imerys • Kwestion • N. de La Falaise •
D. Lecuivre • Thinkstock • P. Wiangnont