innovative specialties
Transcription
innovative specialties
IN BRIEF 2013 IMERYS, MINERAL SOLUTIONS FOR A CHANGING WORLD _ 2013 IN BRIEF 1 Profile Contents IN BRIEF 2013 PRESENCE ON A GREAT NUMBER OF MARKETS WE ARE IMERYS _ • 03 Presence on a great number of markets • 04 Our business: turning minerals into innovative specialties • 05 Specialties for a wide range of applications • 06 Leadership in four business groups • 08 For a changing world: the six main lines of the Imerys model • 09 Innovating to develop new applications • 10 Expanding the Group’s geographic footprint • 12 Broadening the activity portfolio • 13 Banking on operating excellence and disciplined financial management • 14 Fostering diversity of talent • 15 Sustainable Development, a global strategic orientation Imerys serves a wide range of industries, guaranteeing balanced exposure to different economic cycles. The Group’s sales are spread across 20 or so markets, including these examples. The world leader in mineral-based specialty solutions for industry, Imerys transforms a unique range of minerals to deliver essential functions – heat resistance, mechanical strength, conductivity, coverage, barrier effect, etc. – 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 international teams constantly identify new applications and develop high value-added solutions, in line with its determined approach to responsible development. 3,698 M€ revenue 50 countries 477 M€ current operating income 15,805 employees 245 industrial sites CONSTRUCTION DECORATIVE MATERIALS Roof tiles, cement AND FITTINGS manufacturing, window profiles… Sanitaryware, tableware, flooring, paint, floor tiles… STEELMAKING AND METALLURGY PAPER Catalogues, advertising materials, brochures, magazines, specialty papers… Refractory linings for furnaces… ENERGY AGRI-FOOD ELECTRONICS Batteries, photovoltaic cells and panels, oil and gas fields… Filtration of beer, wine, drinking water and fruit juice… Device structure, processors, semiconductors… HEALTH, BEAUTY & CARE Deodorant, skin creams, toothpaste, hygiene products… 3 AUTOMOTIVE, INDUSTRIAL EQUIPMENT AND CONSUMER DURABLES Plastics, batteries, paint, tooling, bodywork… HORTICULTURE, PROTECTION OF FLORA Aquaponics, UV production, repellents… PACKAGING Board, plastic film… IN BRIEF 2013 IMERYS OUR BUSINESS: TURNING MINERALS INTO INNOVATIVE SPECIALTIES _ Analyzing customers’ needs, proposing relevant innovative solutions and transforming minerals to obtain the required properties: this is Imerys’ core business. SPECIALTIES FOR A WIDE RANGE OF APPLICATIONS _ Imerys produces mineral-based specialties that meet four types of industrial needs and represent a great number of product applications. _ _ HIGH-QUALITY MINERALS KNOW-HOW IN BENEFICIATION AND PROCESSING The Group mines or processes a range of about 30 minerals. On its 115 mining sites it holds an average of 20 years’ high-quality mineral reserves. Thanks to teams who are dedicated to exploring additional resources, Imerys guarantees its customers a lasting supply. In addition, a number of minerals (bauxite, alumina, zirconium, magnesia, etc.) are purchased from external suppliers for processing by the Group. 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. Minerals are processed to optimize their intrinsic properties in order to obtain the required characteristics and specifications, for example strength, conductivity, coverage or barrier effect. The Group thus calls substantial resources into play to innovate in line with its customers’ needs: 300 scientists, eight Research & Development centers, 20 market-focused regional laboratories and collaborations with renowned institutes. By selecting relevant techniques for the characteristics of every deposit, Imerys can extract minerals with an economically efficient yet environmentally-friendly approach. Sites at the end of their lives are restored in the best possible conditions. Restoration plans are studied from the outset of mine opening projects, under a Group-wide responsible management process. 4 1 2 3 4 THE FOUR PRODUCT TYPES: 1 Mineral components Here are some examples of mineral solutions. 2 Functional additives • 3 Manufacturing process enablers Graphite is converted to meet the specifications of mobile energy and precision engineering (lithium-ion batteries, brake pads). 4 Finished products • Diatomite and perlite are filtration agents for edible beverages. • Electrofused magnesia is used in domestic appliances (dishwashers, cookers…) to guarantee high electrical resistance and low heat conductivity. • Monolithic refractories are used as linings in hightemperature industries (steelmaking, foundry…). The Group’s mineral-based specialties deliver functionalities ranging from impermeability, whiteness and strength to energy efficiency, conductivity, purity and even longevity. 5 IN BRIEF 2013 IMERYS LEADERSHIP IN FOUR BUSINESS GROUPS Energy Solutions & Specialties Filtration & Performance Additives 3% 4% 8% Carbonates 49% Performance & Filtration Minerals 32 % Monolithic Refractories 40% High Resistance Minerals Ceramic Materials Building Materials 42% 58% 32 % Minerals for Ceramics Kaolin Graphite & Carbon Fused Minerals 46% 50% 41% Kiln Furniture Refractory Minerals 59% Oilfield Solutions 75 28 €1,248 million 64 17 €1,132 million 71 18 €703 million 34 12 €654 million The business group is comprised of four activities: Carbonates, Monolithic Refractories, Graphite & Carbon and Oilfield Solutions. It serves the following industries in particular: personal care, health & beauty, paper, steelmaking, foundry, mobile energy, oil and gas fields. The Performance & Filtration Minerals and Kaolin activities cover a wide range of applications in technical fields, e.g. plastics, paint, rubber, personal care, health & beauty, and paper. Through its three activities, the Ceramic Materials business group is active on a great number of markets, including construction, renewable energies, electrometallurgy, sanitaryware & tableware. It offers innovative products such as photovoltaic and clay roof tiles, high-performance ceramic solutions or high-temperature kiln furniture. The business group, positioned upstream of the industrial equipment chain (steelmaking, industrial and automotive sectors), has expertise in manufacturing processes in high-temperature environments. It designs mineral specialties with functionalities such as heat resistance, strength, abrasiveness, purity and conductivity. World #1 in minerals for breathable polymer films World #1 in talc for plastics, paint, paper, ceramics, health & beauty French #1 in roof tiles World #1 in silico-aluminous minerals for refractories World #2 in carbonates for paper World #1 in mica World #1 in silico-aluminous monolithic refractories World #1 in diatomite- and perlitebased products for filtration World #1 in conductive additives for Li-ion batteries World #1 in kaolin for paper industrial sites industrial sites countries countries revenue in 2013 (34% of Group total) revenue in 2013 (30% of Group total) 6 industrial sites industrial sites countries countries revenue in 2013 (19% of Group total) revenue in 2013 (17% of Group total) World #1 in raw materials and ceramic bodies for sanitaryware World #2 in kaolin for glass fiber World #1 in fused minerals for abrasives World #1 in kiln furniture for roof tiles World #1 in fused zirconium 7 IMERYS 2012 IN BRIEF 2013 INNOVATING TO DEVELOP NEW APPLICATIONS With 1.6% of its revenue given over to Research & Development, Imerys is achieving its aim of making innovation the driver of its organic growth. Understanding our customers’ businesses, solving their technical problems, meeting their expectations and anticipating their needs is the starting point for Imerys’ Innovation approach. The Group’s 28 research centers are comprised of eight main facilities (specialized in certain minerals) and 20 regional laboratories. This closeness to customers enables teams to identify new expectations and therefore develop new solutions. SUPPORTING GROWTH FOR A CHANGING WORLD THE SIX MAIN LINES OF THE IMERYS MODEL In a fast-changing world, Imerys is staying on course by founding its development strategy on innovation, geographic expansion, and activity diversification into high-growth markets. This model makes sustainable development an integral part of business. 8 By creating new products and processes, the Group helps its customers to meet new challenges. “Disruptive” innovations, based on the development of new concepts, exist alongside “continuity” innovations that stem from improvements to the existing range. Together, they enable the Group to develop its product offering and its competitiveness. This strategy serves an ambitious objective: contributing €700 million in additional revenue by 2016. PROTECTING INNOVATION CAPITAL Innovation, a valuable asset for Imerys, is protected by a relevant i n te l l e c t u a l p ro p e r t y p o l i c y. Approximately 3,500 trademarks have been registered or are in the registration process, while the Group holds more than 1,000 patents and patent applications and over 220 industrial and utility models. This portfolio is regularly rationalized to optimize its cost. To ensure effective protection for its name, the Group has filed the “Imerys” trademark in 90 countries. Focus on… KERAVIVATM, A CONCRETE ALLY Patented by Imerys Ceramics, KeravivaTM involves hot-spraying a thin layer of colored ceramic onto concrete. This protects the material without affecting its mechanical properties. KeravivaTM resists frost, ultraviolet rays, chemicals and fire. It makes graffiti and lichens easier to clean off without impairing the original color. The many outlets range from street furniture and building facades to direction signage. €60 million Almost allocated to innovation in 2013 + 7% compared with 2012 65 More than new products launched in 2013 9 IN BRIEF 2013 IMERYS EXPANDING THE GROUP’S GEOGRAPHIC FOOTPRINT Imerys regularly invests to extend its geographic presence and, as a result, increase its exposure to fast-growing markets and sectors, in both mature economies and emerging markets. 26% of revenue achieved in emerging countries compared with 6% in 2001 2013 was marked by a gradual stabilization of the European economy. In North America, sustained demand was especially noticeable in construction and consumer durables. The growth rate was more moderate in emerging countries. More than ever, geographic diversification is a crucial factor in maintaining the Group’s profitability and seizing any internal and external growth opportunities. INCREASING PRODUCTION CAPACITIES Internal growth particularly includes strengthening production capacities worldwide. In 2013, Imerys built a lime plant in Doresópolis (Brazil) to beneficiate its local calcium carbonate reserves. In Bahrain, a fused alumina plant, the Group’s first production facility in the Middle East, started production in the first months of 2014. States, a ceramic proppant production complex, to bolster its industrial assets in Oilfield Solutions. In Asia, Imerys completed two acquisitions in Monolithic Refractories (cf. “Focus on…”). ESTABLISHING BASES IN EMERGING ZONES Emerging countries are a major growth lever for Imerys’ activities. The Group is building its development there and has increased its presence substantially in the past 12 years. Imerys targets the most attractive countries, i.e. those where it already has mining, industrial or commercial bases (Brazil, India, South Africa and China) and those which offer significant outlets for its mineral specialties and the possibility of building effective commercial partnerships (Indonesia, Malaysia, Thailand, Russia, Turkey, etc.). Energy Solutions & Specialties Filtration & Performance Additives Ceramic Materials Carbonates Graphite & Carbon Performance & Filtration Minerals Building Materials Monolithic Refractories Oilfield Solutions Kaolin Minerals for Ceramics Refractory Minerals Fused Minerals Focus on… CALDERYS INCREASES ASIAN PRESENCE Imerys’ joint venture with Indoporlen, the Indonesian leader in monolithic refractories (revenue €15 million in 2012) enables the Group to expand its industrial base in Indonesia, creating a robust platform for development. EXPANDING PRESENCE ON PROMISING MARKETS Imerys’ international expansion also entails a targeted external growth strategy. In April 2013, the Group acquired PyraMax Ceramics LLC in the United 10 High Resistance Minerals Kiln Furniture 11 In Japan, the acquisition of Tokai Ceramics, a renowned producer of monolithic refractories (approx. €7 million revenue in 2012) allows Calderys, which has been active in the country for more than 30 years, to hold a production facility for the first time. IN BRIEF 2013 IMERYS BROADENING THE ACTIVITY PORTFOLIO BANKING ON OPERATING EXCELLENCE AND DISCIPLINED FINANCIAL MANAGEMENT Imerys’ mineral specialties, already present on many markets, are set to win over new sectors with high growth potential. Imerys constantly optimizes its industrial assets to adapt them to market trends, control costs and increase its flexibility and competitiveness. Mobile energy, packaging, environment, non-conventional oil and gas fields, health and beauty, automotive, aerospace and more: Imerys is active in all of these promising sectors, guiding its choices for capital expenditure and acquisitions. DEVELOPING IN OILFIELD SOLUTIONS For several years, Imerys has sought to establish itself on non-conventional oil and gas field operations in the United States through ceramic proppants. With the prospect of a highly promising market, the Group undertook research, filed patents, built an initial plant in Georgia in 2012, then acquired PyraMax in 2013 (cf. “Focus on…”). TARGETING MOBILE ENERGY Other profitable segments, including mobile energy for electronic devices and electric vehicles, are the focus of capital expenditure and a development driver for the Graphite & Carbon activity. For example, the carbon black plant in Willebroek, Belgium, doubled its production capacity. MOVING INTO RENEWABLE ENERGIES In 2011, the Group joined forces with Norwegian Crystallites AS to meet growing demand for high-purity quartz, particularly for the photovoltaic industry. The Group is also innovating in sustainable housing with its readyto-fit photovoltaic tiles for new or renovated roofs. MAKING THE RIGHT CHOICES A focus on high-growth sectors entails the rationalization of less dynamic activities. Under that rationale, the Group completed the divestment of its Imerys Structure activity (wall and partition bricks, chimney blocks) to Bouyer-Leroux. Imerys also divested four calcium carbonate production sites serving the paper market in Europe and the United States. 12 Focus on… STRATEGIC ACQUISITION OF PYRAMAX With the acquisition of PyraMax Ceramics LLC in 2013, Imerys gained a new proppants production unit, strengthening its industrial assets in Oilfield Solutions in the United States. This will enable the Group to increase its production capacity from 100,000 to 325,000 tons and ramp up faster to serve the booming non-conventional hydrocarbons market in the USA. The Group is aiming for €150 million revenue in this area by 2016. Imerys is a decentralized group but in 2012 it set up an Industrial Department with the role of disseminating best practices and techniques. In addition to cost reduction, this approach comes under an overall continuous improvement process designed to combine efficiency and effectiveness. CREATING AN INTERNAL FRAMEWORK A key component of this operating excellence approach is the monitoring of 14 key indicators rolled out on all production sites since the end of the first half of 2013. Calculated using a common, Group-wide methodology, they are tracked site by site and consolidated at activity, business group and, Group levels. Positive fallout has been recorded since the indicators were set up, in terms of energy consumption in Europe and North America, and supply and production processes in South America. INSTILLING A MINDSET To ensure all units have a common culture and practices, “Imerys Operational Excellence” training is being rolled out for both management and the teams on the ground. The aim is to center processes on employees by engaging them in a continuous improvement dynamic. Three pilot sessions took place in Europe in 2013 and will be continued in 2014 with around ten new sessions, expanding into the Americas. ROLLING OUT PERFORMANCE Launched in 2014, the “Imerys Industrial Improvement” program will strengthen ownership of the performance by all employees and enhance their grasp of industrial processes to improve the results of the Group’s mines and plants. Around 10 reference sites will be named to set up operational excellence tools and a crossfunctional team will be formed to speed up dissemination of best practices. 13 Focus on… DISCIPLINED CASH MANAGEMENT In a difficult economic context, optimizing working capital requirement (WCR) and cash-flow control drives cash generation and strengthens Imerys’ ability to finance its internal and external growth. The entire company has rallied round this goal through a great number of initiatives, including a dedicated intranet, bespoke training, and specific assignments to identify improvement areas and propose customized support in rolling out action plans. 14 key industrial performance indicators 80% of production managers trained in operating excellence in 2014 IN BRIEF 2013 IMERYS FOSTERING DIVERSITY OF TALENT SUSTAINABLE DEVELOPMENT, A GLOBAL STRATEGIC ORIENTATION Imerys would be unable to develop or evolve without the quality and commitment of its employees. Its teams, made up of men and women from every profession and every background, are united by their spirit of enterprise. Sustainable Development is a crucial component of Imerys’ long-term strategy, in order to support growth and promote responsible social and environmental management. In 2013, the Group continued to develop its organization, making many career developments possible. Training efforts and the rollout of certain sustainable development goals were stepped up. Finally, the Group made its compensations and benefits policy more efficient. SUPPORTING AND TRAINING To evolve in line with changes in organization, Imerys kept up its recruitment and internal mobility efforts and stepped up its training actions in 2013. Imerys Learning Center launched two new programs, “Sales Excellence”, designed to improve teams’ commercial & marketing performance, and “Operational Excellence”, which gives managers tools to improve the performance of industrial facilities. In addition, the “Senior Leadership Programme” created with INSEAD in 2012 improved the management and leadership skills of many current or future Group executives. SHARING CORPORATE CULTURE Cohesive relations between employees and the strength of their connection to the Group are important aspects of Human Resources policy. Many initiatives were rolled out internally for that purpose, including cross-Group seminars by profession to share best practices, a magazine, an enterprise social network and multi-media tools for sharing information. HARMONIZING COMPENSATION SYSTEMS The business units in the various countries where the Group is active are gradually aligning their compensation and benefits practices on the highest international standards. In Brazil, for example, across-the-board salary increases will now be limited to an annual compensation ceiling. In Indonesia, Indoporlen, a company acquired in 2013, also improved its complementary benefits system with the setup of life insurance coverage for all employees and better healthcare coverage for management personnel. 14 Focus on … A STRONG COMMITMENT TO DIVERSITY One of Imerys’ strengths is the diversity of its employees: men and women from many nationalities and cultures who work together and share common goals. The Group’s Diversity Charter sets down Imerys’ commitment in this area. Diversity programs were set up in five countries in 2013. A Women’s Mentoring Programme was launched in late 2013, to focus on the women career development, especially those in operational positions. 31% share of women in the workforce (salaried employees category) 1,000 hours hours training given out by Imerys Learning Center In 2013, after analyzing the most significant Sustainable Development issues and the relevant stakeholders, Imerys decided to strengthen its process along three main lines focusing on social, environmental and governance issues. All units have set up an Environmental Management System (EMS) and 81 of them are also ISO 14001 or EMAS certified. These EMS are fully integrated into the Group’s EHS (Environment, Health & Safety) audit program, with 15 sites visited in 2013. KEEPING EVERYONE’S HEALTH AND SAFETY GUARANTEEING ETHICAL CONDUCT Preventing workplace health and safety risks is one of Imerys’ priorities. The Group’s action in this area is built on clearly defined lines: regular audits, a global training plan, a behaviorbased safety program, an accident analysis program and a serious accident prevention plan, as well as events designed to consolidate safety culture on key sites. As regards governance, a cornerstone of the Sustainable Development process, the Group promotes ethical business conduct rules and deploys training programs and selfassessment systems to check that practices are compliant. These efforts were continued in 2013, including an update of the anti-fraud and anticorruption policy. CONTROLLING ENVIRONMENTAL IMPACTS Imerys’ activities involve natural resources such as minerals, soil, energy and water. The Group constantly strives to reduce its environmental footprint and use those resources efficiently through a common approach across all of its activities. Focus on… ENCOURAGING CONSTRUCTIVE DIALOG Under its “Community Relations” protocol, Imerys officially delegates responsibility for community relations to the most senior employee in charge of managing each facility. The protocol requires every site to map its stakeholders and draw up an action and continuous improvement plan. It also encourages constructive dialogue with stakeholders and requires a response to any admissible complaints they make. 1.31 combined lost-time accident frequency rate (-57% vs. 2009) 100% of sites have an EMS 15 IMERYS ENERGY SOLUTIONS ENERGY SOLUTIONSCERAMIC MATERIALS CERAMIC MATERIALS & SPECIALTIES & SPECIALTIES Building Materials: Building Materials: www.imerys-toiture.com www.imerys-toiture.com Carbonates: Carbonates: www.imerys-rooftiles.com www.imerys-rooftiles.com www.imerys-carbonates.com www.imerys-carbonates.com www.e-toiture.com www.imerys-lqm.com www.e-toiture.com To find out more, www.imerys-lqm.com d out more, www.imerys-solaire.com www.imerys-solaire.com Monolithic Monolithic Refractories: e websitesvisit of the theGroup websites of the Group Refractories: Minerals for Ceramics: Minerals for Ceramics: merys.com www.imerys.com www.calderys.fr www.calderys.fr www.imerys-ceramics.com www.imerys-ceramics.com s activities and its activities Graphite & Carbon: www.imerys-aurora.com Graphite & Carbon: www.imerys-aurora.com ww.thequartzcorp.com ww.thequartzcorp.com www.imerys-graphite-and-carbon.com www.imerys-graphite-and-carbon.com Kiln Furniture: Kiln Furniture: Oilfield Solutions: Oilfield Solutions: www.ikf-solutions.com www.ikf-solutions.com www.imerys-oilfieldsolutions.com www.imerys-oilfieldsolutions.com FILTRATION & PERFORMANCE FILTRATION & PERFORMANCE HIGH RESISTANCE HIGH MINERALS RESISTANCE MINERALS ADDITIVES ADDITIVES www.carrd.at www.carrd.at Performance & Filtration Performance Minerals: & Filtration Minerals: Refractory Minerals: Refractory Minerals: www.imerys-perfmins.com www.imerys-perfmins.com www.imerys-refractoryminerals.com www.imerystalc.com www.imerystalc.com www.imerys-refractoryminerals.com www.damrec.comwww.damrec.com www.imerys-filtration.com www.imerys-filtration.com www.ceminerals.com www.ceminerals.com www.celitecynergy.com www.celitecynergy.com www.ags-mineraux.com www.ags-mineraux.com www.advancedminerals.com www.advancedminerals.com www.imerys-molochite.com www.imerys-molochite.com www.insulation.imerys.com www.insulation.imerys.com www.imerplast.com www.imerplast.com Fused Minerals: Fused Minerals: www.imerys-specialitiesjapan.com www.imerys-specialitiesjapan.com www.imerys-fusedminerals.com www.imerys-fusedminerals.com www.imerysvermiculite.com www.imerysvermiculite.com www.ifme.eu www.ifme.eu Kaolin: Kaolin: www.imerys-paper.com www.imerys-paper.com www.imerys-perfmins.com www.imerys-perfmins.com www.imerysnopara.com.br www.imerysnopara.com.br Design and production: Design and production: e de l’Université 154, rue de l’Université Paris– France 75007 Paris– France Photo credits: MichelPhoto Bost •credits: Dominique Michel Lecuivre • Bost • Dominique Claire Morel Lecuivre • Fatio • Claire Morel Fatio • Nicolas Richez • Howard Nicolas Spiers • Heiko Richez • Howard Schnitzer Spiers • Heiko • Imerys Talc Schnitzer photo library • Imerys Talc photo library hone: + 33Telephone: (0) 1 49 55+ 63 33 00 (0) 1 49 55 63 00 Getty Images J. Sierpinski. • • iStock • Thinkstock • Imerys Getty Images • iStock • Thinkstock • Imerys photo library, photo library, 33 (0) 1 49 Fax:55+ 63 33 01 (0) 1 49 55 63 01Europe: J. Sierpinski. •Europe: RR, X RR, X Print: TI Médian impressions. Print: TI Médian impressions. This document is printed This document on FSC certifi is printed ed paper on FSC certified paper containing Imerys pigments. containing Imerys pigments. 16 16