imf fall meeting - microsoft · 7/7/2015 · october 2010 imf fall meeting stollberg overview....

Niagara Falls, NYOctober 2010

IMF FALL MEETING

Stollberg Overview

Kenneth Hashimoto and Michael Frazee, District Managers

STOLLBERG OVERVIEW

• S & B Industrial Minerals

• Stollberg Group Worldwide

• History of Stollberg, Inc.

• Stollberg Organization

• Production Capabilities

• Products and Process Flow

• Improvements and Future Projects

Welcome from


S&B INDUSTRIAL MINERALSOVERVIEW


STOLLBERG OVERVIEW

S&B North America


THE GROUP

STOLLBERG GROUP


STOLLBERG GROUP


Stollberg Germany & France

Stollberg Brazil

Stollberg US

Stollberg India

Stollberg Korea & China

STOLLBERG GROUP: WORLDWIDE FACILITIES

STOLLBERG GROUP

The STOLLBERG Model

• Seven global manufacturing sites• Common Production Equipment• International technology base• Local technical sales and service personnel• Educational seminars and training services• Experienced product development laboratory and staff• Competitive pricing• Rapid response time• Short delivery time• ISO certification• Patented mold flux feeding equipment• SAP based software system• Engineered solutions to technical problems


History of Stollberg, Inc.

STOLLBERG HISTORY

1982 Start-up of marketing activities for mold powders in North America.

1984 Foundation of Stollberg, Inc. with location in Niagara Falls, NY.

1985 Construction and start-up of production facilities in Niagara Falls with a 4,000 ton mixingand packaging operation.

1986 Start-up of laboratory with X-ray, carbon, fluorine and moisture analyzer, hot stagemicroscope, viscometer, and other sample preparation and melting equipment.

1989 Acquisition of Mobay’s Mold Flux business.

1990 Completion of bulk bag unloading stations and second packaging line with a capacityincrease to over 6,000 tons.

1993 Increase in Share Capital to $1.8 million. $7 million investment into fully automatedmold powder plant including spray drying facilities for the production of granular(spherical) product, with a total capacity of over 20,000 tons per year.

STOLLBERG HISTORY

1994 Acquisition of TAM Ceramics’ Mold Flux business.Continuation of License Agreement for Mold Fluxes with Nippon Thermochemical.

1997 ISO-9002 Certification.

1998 $4 million investment for plant expansion including second spray dryer for theproduction of granular (spherical) mold powders, new lab facilities including labequipment, and additional warehouse space.

1998 Acquisition of Latimer Co.’s mold flux business.

1999 Acquisition of CV Materials (CVM) mold flux business.

2003 Acquisition of NATCO mold flux business.

2004 Stollberg Group purchased by S&B Industrial Minerals S.A.

2009 ISO 9001-2008 Certification

STOLLBERG HISTORY

Plant Construction1992-1993

Plant Expansion1998-1999


Stollberg, Inc.• Organization

• Capabilities

• Products

• Process Flow

• Process Improvements – Past and Future

STOLLBERG OVERVIEW

STOLLBERG ORGANIZATION

The STOLLBERG TEAM

• 41 Full Time Production Employees• 8 QC and Innovation Team Employees• 4 Purchasing, Logistics and Office Employees• 13 Technical Sales Engineers

(Geographically Located)


• 2 Spray Dry process lines

Capacity of 30000 MT/year

• 3 Dry Mixing Process Lines

2 Plow Mixers, 1 Air Mixer

• 3 Pneumatic Transporters

Batching, Bulk Bag Unloading,Small Bag Unloading

• Packaging Lines

Bulk Filling, Automatic PolyBaggers, Impeller Packagers

• 36 Raw Material Silos

• PLC Controlled Batching Car

STOLLBERG PRODUCTION CAPABILITIES


STOLLBERG PRODUCT MIX:Granular conversion for continuous casting

• Granular materialAccounts for 98% ofcontinuous castingfluxes

– Better flowability

– Superior Homogenation from slurrypreparation

– Large batch sizes

– Dust free

– Automatic feeding

– Improved quality


STOLLBERG PRODUCT MIX 2010

For continuous casting, the product mix is nearly all granular forenvironmental and performance benefits.

2010 PROJECTED TONNAGE (MT) VOLUME %

GRANULAR 23,00066%

TUNDISH 5,00014%

BOTTOM POUR 1,5004%

HOT TOPPING 1,0003%

POWDER 6002%

INSULATING COVERS 4,00011%

35,100


• Continuous Casting Mold Flux

• Synthetic Blends and Granulated

• Tundish Covering


• Bottom Pour Flux


• Hot Topping Compounds

• Synthetic Blends

• Insulating Covers

STOLLBERG PRODUCTS


RawMaterials

ToProcess

QC

QC

QC

RawMaterials

IntoPlant

w

w

w w

STOLLBERG PRODUCTION: PROCESS FLOW

Powder Production


QC

QC

QC

QC

QC

QC

QC

QC

w

FinishedGoods toWarehouse

RawMaterials

To PowderProduction


Powder Production


ToPackaging

RawMaterials

To GranularProduction w

w

w

w

w

QC

QC

QC

QC


Granular Production


From Spray DrierProduction

ToWarehouse

QC

QC

QC

QC

QC

QC

QC

QC


Granular Production


2001WinCCSCADAsystem

Siloproject

2005-6

2003-4Productivityimprovement

NetTonsGranularProducedPerProductionDay(2Spraytowers)

(2002- present)

50

60

70

80

90

100

110

120

130

140

Se

p-0

2

De

c-0

2

Ma

r-03

Ju

n-0

3

Oc

t-03

Ja

n-0

4

Ap

r-04

Au

g-0

4

No

v-0

4

Fe

b-0

5

Ma

y-0

5

Se

p-0

5

De

c-0

5

Ma

r-06

Ju

l-06

Oc

t-06

Ja

n-0

7

metr

icto

ns/d

ay

SprayTowertons/hr Output

2.002.102.202.302.402.502.602.702.802.903.003.103.203.303.403.50

20

03

20

04

Ja

n-0

5

Feb

-05

Ma

r-05

Ap

r-05

Ma

y-0

5

Ju

n-0

5

Ju

l-05

Au

g-0

5

Sep

-05

Oc

t-05

No

v-0

5

STOLLBERG: PROCESS IMPROVEMENTS


2007-8AutomaticPackagingEquipment

2008-9Viscometers,AutomaticPumpPressureControl

-5

-3

-1

1

3

5

7

9

11

13

15

17

19

21

23

25

27

29

31

33

12:00:00 AM 2:24:00 AM 4:48:00 AM 7:12:00 AM 9:36:00 AM 12:00:00 PM 2:24:00 PM

Ba

gC

ou

nt,

Tre

eP

res

su

re,P

um

pP

res

su

re

-50

0

50

100

150

200

250

300

350

400

Flo

wR

ate

(/1

0),

YV

isc

os

ity

Bag Count OSPump1 G13852

OSTrPrAvg G13852 OSSlurryFlow/10 G13852

OSViscosity G13852

Rejected

Bags 17 and

18 made

here

Rejected

bag 8

made here

Rejected

bag 16

made here

STOLLBERG: PROCESS IMPROVEMENTS


• 2011 - Replacement of Impeller Packers

– Improved efficiency, filling, sealing, andrecording of weight, bag identification

• 2012-2015- Mixer upgrade and spray dry towerreplacement

– Larger batch sizes, replacing older equipment

– Replacement of tower due to age

STOLLBERG: FUTURE PROCESS IMPROVEMENTSHIGHLIGHTS


WELCOME TO STOLLBERG

We look forward to havingyou visit our facilitiestomorrow.

If you need safety glasses ora hard hat, let us know andwe will supply them.

Thank You!

WELCOME IMFMEMBERS

imf fall meeting - microsoft · 7/7/2015 · october 2010 imf fall meeting stollberg overview....

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