The CI Top 14 is our fifth annual ranking of the leading worldwide manufacturers of advanced ceramics, glasses and refractories. To develop the CI Top 14, we evaluated information provided by company contacts, and combined it with additional details gleaned from annual reports, company websites, press releases, etc.
If you would like your company to be considered for the 2018 CI Top 14, or if you have any suggestions for future rankings, please contact Susan Sutton, editor-in-chief, at (248) 786-1704 or suttons@bnpmedia.com.
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The Top 14 List
Total sales for Saint-Gobain were fairly flat in 2016, reaching approximately €39.1 billion (~ $45.8 billion), compared to €39.6 billion (~ $46.4 billion at the current exchange rate) in 2015. Three business sectors comprise the group: Innovative Materials, which includes Flat Glass and High-Performance Materials (HPM); Construction Products, which is divided between Interior Solutions and Exterior Solutions; and Building Distribution.
Sales in the Innovative Materials segment (25% of total net sales for the group) increased 4.5% in 2016 on a like-for-like basis to €9.9 billion (~ $11.5 billion). Like-for-like sales in the Flat Glass business jumped 6.5% for the year, nearing €5.4 billion (~ $6.3 billion), led by both construction and automotive in Asia and emerging countries. In Western Europe, construction volumes and prices both improved, benefiting from higher float prices and an increase in the price of downstream glass. Sales in the High-Performance Materials business (which produces ceramic materials such as abrasives, glass textiles, and performance polymers) also increased, by 2.2% to reach €4.5 billion (~ $5.3 billion). Despite a decline in industrial markets in the U.S., all HPM businesses advanced in the second half of 2016, led by Asia and emerging countries. Though the Ceramics segment saw a less favorable mix in the second half, it stabilized over the year.
As a whole, Saint-Gobain reported over 172,000 employees worldwide in 2016. Of that total, more than 33,000 people work in Flat Glass in 42 countries, while the HPM business employs more than 27,000 people in 46 countries.
The Innovative Materials segment accounts for approximately two-thirds of Saint-Gobain’s total R&D spending. The group, which operates eight cross-business R&D centers in the U.S., Europe, China and India, invested €438 million (~ $512.7 million) on R&D in 2016, a slight increase compared to 2015. Worldwide, 3,700 employees were involved with R&D last year; 2,100 of those were in the Innovative Materials segment.
As a group, Saint-Gobain shifted down a bit in the Intellectual Property Owners Association’s (IPO) listing of granted U.S. patents in 2016, dropping to 158 (out of 300) from 126 in 2015.1 Saint-Gobain reports that it filed applications for 390 new patents in 2016; 211 patents were granted in the U.S. for the year.
Saint-Gobain received the Top Employers Institute’s Top Employer North America Certification for the second consecutive year in 2016. The Top Employers Institute, an independent organization that certifies employers around the world for excellence in the work environments they create for their employees, reportedly assessed Saint-Gobain’s employee offerings on the criteria of talent strategy, workforce planning, on-boarding, learning and development, performance management, leadership development, career and succession management, compensation and benefits, and company culture.
“Optimal employee offerings and HR best practices ensure that people develop themselves personally and professionally,” said David Plink, CEO of the Top Employers Institute. “This, in turn, enables companies to grow and develop, maximize organizational performance, and attract and retain the best talent. Our comprehensive research concluded that Saint-Gobain provides an outstanding employee environment and offers a wide range of creative initiatives—from benefits and learning and development opportunities to well-thought-out career management programs—that are truly aligned with the company’s culture.”
In June, Saint-Gobain announced that it is building a new flat glass (float) production line in Saltillo, Mexico. The plant, scheduled to come on stream at the beginning of 2020, will manufacture glass for the automotive and construction sectors. This investment will reportedly complement the company’s manufacturing base in the region, with the Cuautla site already including two floats and their associated lines for mirrors and laminated glass, as well as one thin-film coater line in operation and another under construction.
Saint-Gobain acquired the share capital of Romania-based Pietta Glass Working near the end of last year. Pietta Glass sales reportedly reached €20 million (~ $21.2 million) in 2016, with a strong potential for growth over the next few years. The Flat Glass business was reportedly already established in Romania, with a float glass plant and coater. Saint-Gobain expects that the acquisition will allow it to expand the business’ industrial footprint in order to better serve the growing façade markets while rounding out its position in industrial applications with an optimized cost base.
Earlier this year, Thomas Kinisky was appointed president and CEO of Saint-Gobain Corp., the group’s North American holding company. In this role, Kinisky is Saint-Gobain’s North American representative, overseeing the family of companies in the U.S. and Canada. Kinisky was also appointed senior vice president for Saint-Gobain and is a member of the company’s Global Management Committee.
“Saint-Gobain has been one of the top global innovators for more than 350 years, and North America will continue to play a vital role in the company’s innovation legacy, which includes a host of products and materials we rely on in our homes, offices, hospitals, and even other planets to make these spaces healthy, energy efficient, accessible, safe, and aesthetic,” said Kinisky. “The key to continuing our storied history of innovation will lie in our ability to unlock the innovation potential of our entire workforce and to attract top talent to join that effort. I believe this passion to embed innovation in everything we do can and will lead to disruptive solutions for our customers that will benefit the world at large.”
Source: company website, annual report, press releases
Total net sales for Corning increased by 3% in 2016, reaching nearly $9.4 billion. The company’s reportable segments include: Display Technologies, Optical Communications, Environmental Technologies, Specialty Materials and Life Sciences. Corning employed almost 41,000 people in 2016, with 98 manufacturing plants in 17 countries around the world.
Display Technologies, which represented 34% of total sales in 2016, produces glass substrates for LCDs. Sales increased 5% for the segment in 2016, climbing to over $3.2 billion. Comprising 32% of Corning’s 2016 total sales, the Optical Communications segment produces optical fiber, cable and connectivity solutions. Following a strong year in 2015 (12% increase vs. 2014), net sales in 2016 inched up 1% to $3 billion.
Net sales for the Environmental Technologies segment, which produces ceramic substrates and filter products for emissions control applications, represented 11% of the company’s 2016 total net sales. Segment sales dipped slightly (down 2%) to $1 billion. In Specialty Materials, sales recovered from a tough 2015 (down 8% vs. 2014) to $1.1 billion (a 2% increase). The segment, which accounted for 12% of Corning’s sales in 2016, produces formulations for glass, glass ceramics and fluoride crystals.
Corning’s R&D spending declined by 4% to $742 million in 2016. The company ranked at 101 on the IPO list of granted U.S. patents in 2016, dropping from the prior year’s rank of 91.1 According to Corning, it was granted 460 patents in the U.S., as well as over 1,100 in other countries.
Apple® announced in May that Corning will receive $200 million from Apple’s new Advanced Manufacturing Fund as part of the company’s commitment to foster innovation among American manufacturers. The investment will support Corning’s R&D, capital equipment needs and state-of-the-art glass processing. Corning’s 65-year-old Harrodsburg, Ky., facility has been integral to the 10-year collaboration between these two companies and will be the focus of Apple’s investment.
“Corning is a great example of a supplier that has continued to innovate, and they are one of Apple’s long-standing suppliers,” said Jeff Williams, Apple’s chief operating officer. “This partnership started 10 years ago with the very first iPhone, and today every customer that buys an iPhone or iPad anywhere in the world touches glass that was developed in America. We’re extremely proud of our collaboration over the years, and we are investing further with Corning who has such a rich legacy of innovative manufacturing practices.”
In February, Corning announced that it had collaborated with Micromax for its Vdeo smartphones, which are reportedly designed for the “value-segment” consumer. The recently launched devices are among the first across India’s mobile phone entry segment to incorporate Corning Gorilla Glass to help protect against damage.
“Value-segment smartphone customers typically spend a significant portion of their income buying a device,” said John Bayne, vice president and general manager of Corning Gorilla Glass. “Many of these first-time smartphone users simply cannot afford to repair or to replace a damaged device. That’s why it’s essential to protect these devices with a material such as tough, damage-resistant Corning® Gorilla® Glass.”
In May, Corning announced Samsung Display’s selection of Corning Lotus™ NXT Glass as the carrier glass for its line of polyimide (PI) low-temperature polysilicon (LTPS) organic light-emitting diode (OLED) panels, which power the Samsung Galaxy S8 and S8+. Both the Galaxy S8 and S8+ contain a flexible OLED panel, which requires a carrier glass to support the panel’s PI substrate during a demanding manufacturing process.
“Together with Samsung Display, we are enabling consumer electronic devices with leading industrial design, while improving the user experience,” said Michael Kunigonis, business director of High Performance Displays for Corning Glass Technologies. “Lotus NXT Glass, the product of Corning’s world-class glass formulation and fusion capabilities, helps panel makers compete in the dynamic mobile LTPS-OLED market. We optimized Lotus NXT Glass as both a carrier glass for flexible OLED panels and as a glass substrate for rigid OLED panels. We’re excited to keep enabling the future of handheld OLED devices.”
Corning and Stevanato Group announced a new collaboration agreement in July that is focused on supplying Corning Valor™ glass to the pharmaceutical industry. Valor is reportedly a high-quality glass container designed for the storage and delivery of injectable drugs. Corning and Stevanato have been working together since 2011 to enable higher quality pharmaceutical containers. The latest agreement extends that relationship and combines Stevanato’s state-of-the-art converting technology with Valor glass to provide pharmaceutical customers with high-quality pharmaceutical containers.
Corning announced near the end of last year that it is expanding its Environmental Technologies manufacturing facilities in Kaiserslautern, Germany, and Shanghai, China, to increase production capacity of its DuraTrap® GC gasoline particulate filter (GPF) product line. The $100 million investment in these two facilities reportedly will enable Corning to address growing demand from automakers for filters that help them comply with new Euro 6c and China 6 emissions standards, which are slated to go into effect in 2017 and 2020, respectively.
“We see the development of this significant new gasoline-particulate filter market opportunity as an exciting new chapter in Corning’s 40-plus year history of serving the auto industry and global clean-air initiatives,” said Hal Nelson, vice president and general manager of Corning Environmental Technologies. “Investing in our Kaiserslautern and Shanghai facilities demonstrates our commitment to helping our customers meet evolving emissions regulations with innovative emissions-control products and reliable supply.”
Source: company website, annual report, press releases
With 204 consolidated subsidiaries, AGC has operations in 30 countries/regions worldwide. Subsidiaries are located in Europe (99), Japan and Asia (86), and the Americas (19). Of the group’s almost 51,000 employees in 2016, 30,000 were located in Japan and Asia, 16,700 in Europe, and 4,300 in the Americas.
AGC achieved total group sales of ¥1,283 billion (~ $11.6 billion) in 2016, down 3.3% from the prior year; operating profit increased by 35.3% for the year. Four segments comprise AGC’s group operations: Glass (53% of total sales), Electronics (20%), Ceramics/Other (2%), and Chemicals (25%).
Glass operations include Flat Glass (including float flat, figured, polished wired, low-e, decorative, and fabricated architectural glasses) and Automotive Glass (tempered and laminated glass). Sales for the Glass segment in 2016 declined by 1.9% to ¥680 billion (~ $6.1 billion). Shipments of architectural glass were strong in Europe and North America, but flat in Japan and other Asian countries. Shipments and sales of automotive glass increased in 2016, due to increased automotive production in Europe, China and North America. AGC expects shipments of architectural glass to make a gradual increase in many regions in 2017, while automotive glass shipments are projected to remain stable.
The Electronics business includes Display (LCD glass substrates, specialty glass for display applications, cover glass for car-mounted displays, glass for solar power systems, and fabricated glass for industrial uses) and Electronic Materials (semiconductor process materials, optoelectronics materials, lighting glass products, and laboratory glass). Electronics sales dropped by 10.5% to ¥258.1 billion (~ $2.3 billion) in 2016. Shipments for LCD glass substrates and cover glass for car-mounted displays increased compared to 2015, but specialty glass for display applications saw a decline, as did shipments of glass for solar power systems. Optoelectronic materials shipments decreased as well, despite a recovery in the second half of the year. The group anticipates increased shipments for nearly all Electronics-related products in 2017.
In June, AGC announced its decision to sell all shares of AGC Flat Glass Philippines, Inc. (AGPH) to TQMP Glass Manufacturing Corp. by the end of December. (The sale is subject to approval by Philippine antitrust authorities.) Intensified competition in the Philippines in the past few years has led to a persistent decline in financial performance. With the sale of this stock, AGC will withdraw from the manufacture of architectural glass in the Philippines. However, the company plans to strengthen sales of high-value-added products such as solar control glass and mirrors produced at other bases.
In May, the company announced that it will invest approximately ¥19 billion (~ $170.5 million) to relocate a float furnace and mirror manufacturing facility from the Jakarta Plant to the Cikampek Plant of PT Asahimas Flat Glass, Tbk (AMG). The float furnace will be used to manufacture architectural glass; mass production is scheduled to begin in the first quarter of 2019. According to AGC, the new float furnace and mirror manufacturing facility will increase production capacity by 40% and 30%, respectively. Following the relocation, AMG’s Jakarta Plant will cease all production activities, and the property will be sold.
AGC announced near the end of last year that it had opened a new production base for TFT-LCD glass substrates in Shenzhen, Guangdong Province, China. After a new company is jointly established with Shenzhen China Star Optoelectronics Semiconductor Display Technology Co., Ltd., a glass substrate processing line will be installed at the plant. Mass production is reportedly planned to start in 2019. AGC has been enhancing its supply system to meet expanding demand for glass in China by establishing processing bases that support the eighth generation of glass substrates in Kunshan, Jiangsu Province, and Shenzhen, Guangdong Province, as well as a base to manufacture raw glass for TFT-LCDs in Huizhou, Guangdong Province. This new glass substrate processing base, supporting the 11th generation, will be established to meet demand in the Chinese market, which is expected to expand in the future.
Source: company website, annual report, press releases
Total net sales for Murata in the company’s fiscal year 2017 (ended March 31, 21017) were approximately ¥1,136 billion (~ $10.3 billion), a decrease of about 6.2% compared to fiscal 2016. The company operates with two main business segments: Components (63% of total sales), including Capacitors, Piezoelectric Components, and Other Components; and Modules (37% of total sales), including Communication Modules and Power Supplies and Other Modules.
Sales in the Components segment were flat compared to the prior fiscal year, at around ¥761.8 billion (~ $6.9 billion). Capacitor sales were flat at ¥369.5 million (~ $3.3 billion). Sales quantities of multilayer ceramic capacitors for communication equipment increased due to improvements in smartphone functions, but a stronger yen and price declines negatively affected sales figures. In addition, sales of components for car electronics increased substantially as a result of the progress in the electrification of vehicles. Products for computers and peripheral equipment were also successful in this segment.
The Piezoelectric Components segment, which produces surface acoustic wave (SAW) filters, ceramic resonators, piezoelectric sensors and ceramic filters, saw sales increase 5% to ¥170 billion (~ $1.5 billion) in the 2017 fiscal year. Sales of SAW filters increased due to the penetration of multi-band smartphones. Sales also increased for ultrasonic sensors for automotive safety equipment, as well as well as actuators for hard disk drives.
Murata’s goal is to grow total sales by 5-10% per year, which it will work to achieve by pursuing medium- to long-term sales expansion in focus markets such as automotive, energy and health care, in addition to growth in existing markets (particularly in communications). The company aims to have new products account for 40% of sales.
In the fiscal 2017 year, Murata invested ¥81.8 billion (~ $739.6 million) on R&D, an increase of 7.2% over the prior fiscal year. The company improved its ranking on IPO’s list of granted U.S. patents in the 2016 calendar year, climbing from 99 to 86.1 The company was granted 468 U.S. patents in 2016, a 24.5% increase over 2015.
Source: company website, annual report, press releases
The Morimura Group comprises multiple ceramic-focused companies, including Noritake, TOTO Ltd., NGK Insulators, Ltd., NGK Spark Plug Co., Ltd., and others. Net sales for NGK Insulators in the fiscal 2017 year (ended March 31, 2017) declined 7.9% to ¥401.3 billion (~ $3.6 billion) from fiscal 2016’s ¥435.8 billion (~ $4 billion). The business operates in three segments: Power (insulators, sodium-sulfur batteries, among other products); Ceramics (automotive ceramics for exhaust gas purification, corrosion-resistant ceramic components, refractory products); and Electronics (ceramic components for semiconductor manufacturing and electronics). The Power business segment saw a sharp decrease of 36.8% in fiscal 2017, to ¥52.8 billion (~ $478.9 million), due to low replacement demand in North America.
In NGK Insulators’ Ceramic segment, sales dipped 2.4% in the 2017 fiscal year, to ¥245.2 billion (~ $2.2 billion), due primarily to the strong Japanese yen. Sales volumes of automotive ceramics (e.g., substrates for catalytic conversion and NOx sensors) increased as a result of favorable sales of passenger cars in the European market. Capital investments by semiconductor manufacturers helped the Electronics business segment see a 2% increase for the year, reaching ¥103.5 billion (~ $938.4 million).
With 59 consolidated subsidiaries, NGK Insulators employs approximately 17,500 around the world. R&D spending jumped by over 14% in fiscal 2017 to ¥7.3 billion (~ $66.6 million). The company ranked 253 on the IPO list of U.S. patents granted in 2016, with 130 patents granted.1
NGK Spark Plug operates two main business segments: Automotive Components (spark plugs, glow plugs, automotive sensors, ceramic engine parts), representing 52% of sales; and Technical Ceramics (Semiconductor, which produces IC packages and other semiconductor components; and Ceramics, which produces cutting tools and other industrial ceramic products), representing 47% of sales. Total net sales for NGK Spark Plug declined to ¥372.9 billion (~ $3.4 billion) in fiscal 2017 from ¥383.3 billion (~ $3.5 billion) the prior year.
Net sales in NGK Spark Plug’s Automotive Components group declined to ¥318.1 billion (~ $2.9 billion). Total net sales for the Technical Ceramics group dropped to ¥51.3 billion (~ $465.2 million). The Semiconductor segment saw the biggest decrease, to ¥19.4 billion (~ $176.3 million) from ¥23.8 billion (~ $216 million) the prior year. Sales in the Ceramics segment dipped to ¥31.9 billion (~ $288.8 million) from ¥32.8 billion (~ $297.4 billion) in the 2016 fiscal year.
Operating at 72 facilities in 21 countries around the world, NGK Spark Plug has 41 consolidated subsidiaries. R&D spending dropped dramatically in the 2017 fiscal year, by 24.3%, to ¥4.1 billion (~ $37.1 million). With 123 U.S. patents granted in 2016, the company ranked 269 on the IPO annual list.1
Source: company website, annual report, press releases
Despite strong sales in multiple markets, total revenue for NSG in its 2017 fiscal year (ended March 31, 2017) declined by approximately 7.7% to ¥580.8 billion (~ $5.3 billion) due to the strong Japanese yen. Cumulative operating profits were 54% higher than the previous year.
NSG operates in three main product segments: Architectural (41% of total group sales), Automotive (51%) and Technical Glass (8%). Fiscal year 2017 revenue for the Architectural segment, which manufactures flat glass and glazing solutions for commercial and residential markets, as well as glass for solar energy applications, dropped to ¥237.7 billion (~ $2.1 billion). At constant exchange rates, revenues for the segment increased slightly due to improved prices in Europe and North America.
NSG’s Automotive segment produces a wide range of automotive glazing for both new vehicles and the replacement market. Segment revenue declined to ¥296.6 billion (~ $2.7 billion) in fiscal year 2017, again due to the stronger yen. Increased volumes in Europe and North America led to increased revenues at constant currency rates.
Technical Glass, which produces thin glass for displays, lenses and light guides for printers, as well as glass fiber products such as battery separators, experienced declining revenue due to challenging conditions in the display glass markets and a volume decline for components used in multi-function printers. Fiscal 2017 revenue for the segment dropped to ¥46.1 billion (~ $416.6 million).
NSG’s R&D spending declined in the 2017 fiscal year, to approximately ¥8.5 billion (~ $76.7 million). As of March 31, 2017, the group employed nearly 27,000 people in 59 facilities around the world. Employees are located in Europe (12,400), Japan (4,400), South and Southeast Asia (1,900), South America (2,300), China (1,400) and North America (4,600). According to NSG, 38% of its fiscal 2017 total sales were in Europe, 25% in Japan, and 20% in North America; the remaining 17% of sales were mainly generated in South America, China, and Southeast Asia.
In July, NSG Group and Solaria Corp. announced that the Pilkington Sunplus™ BIPV powered by Solaria had passed testing by Kiwa Netherlands according to IEC61215 and IEC61730 certification standards. The receipt of this certification from Kiwa confirms that Pilkington Sunplus BIPV architectural solar products comply with the product safety, design and quality tests. Pilkington Sunplus BIPV is powered by Solaria’s PowerVision™ technology, an architectural solar glass solution that reportedly combines attractive aesthetics with effective daylighting, glare control, superior thermal performance and energy generation.
NSG announced in February its decision to restart a suspended architectural glass float line at the site of its wholly owned subsidiary in Venice, Italy, in the third quarter of its 2018 fiscal year. With process modifications associated with the restart, the Venice line will reportedly become capable of producing value-added products. By restarting the Venice line, NSG intends to ensure the stable supply of architectural glass in response to robust market demand in Europe, in view of the planned cold repairs of the group’s operating float glass lines in Europe in the coming years, as well as to drive the group’s shift to a higher value-added sales ratio.
Also in February, NSG announced that its rear window glass had been selected by Toyota Motor Corp. for the new Prius PHV (plug-in hybrid), which was launched on February 15. Made possible by NSG’s mold design, which is the result of simulation technology and proprietary rear glass press equipment, the “double bubble” rear window, with two curves and a groove in between, reportedly helps reduce drag by drawing cabin-side airstream toward the rear glass.
NSG is making significant technology and manufacturing upgrades at its automotive glass plant in Versailles, Ky. Scheduled to start this spring, the $7.5 million investment is expected to utilize a modern advanced press bend (APB) process for laminated windshields. Developed for manufacturing complex-shaped windshields with tighter tolerance, NSG’s technology for the APB process will support the production of laminated windshields with head-up display (HUD), an increasingly popular option for new cars.
The planned investment, which is partially supported by the Kentucky Economic Development Finance Authority, will involve the installation of new equipment and an upgrade to existing equipment at the Versailles plant. Established in 1987 and operated by Pilkington North America, Inc., the plant employs about 300 people.
Source: company website, annual report, press releases
For its 2017 fiscal year ended March 31, total advanced ceramics revenue reported as approximately $2.7 billion represents primarily revenue from Kyocera Corp.’s consolidated Fine Ceramics and Semiconductor Parts segments, with revenue from certain non-ceramic products subtracted. Individually, total revenue within the company’s consolidated Fine Ceramics segment increased by 2.5% to ¥97.4 billion (~ $870 million), while total revenue within the company’s consolidated Semiconductor Parts segment increased by 4% to ¥245.7 billion (~ $2.2 billion) during the 2017 fiscal year.
Kyocera invested about ¥6.9 billion (~ $61.9 million) in its 2017 fiscal year in advanced ceramics-related R&D, mainly within its consolidated Fine Ceramics and Semiconductor Parts segments. This figure represents an increase from the prior-year spending of approximately ¥5.9 billion (~ $52.6 million). (Kyocera’s total ceramics business includes other segments in addition to these. However, the other ceramic-related segments also include non-ceramic products that cannot be easily subtracted from the total. Therefore, to ensure true and conservative numbers, these other segments have been omitted from the reported R&D investment.)
Despite strong R&D spending, Kyocera Corp.’s rank on the IPO listing of companies with granted U.S. patents declined in 2016.1 The company dipped to 103 from 95 in 2015, with its number of granted patents declining by 3%.
Toshiba Materials Co., Ltd. and Kyocera Corp. announced in June that they have agreed to start full-scale collaboration on the development and production of nitride ceramic components. Used as heat-dissipating and insulating parts in power semiconductors, demand is increasing for nitride ceramic components possessing excellent thermal conductivity and mechanical properties, as energy-saving requirements heighten in the automotive and railway industries. It is also expected that adoption of nitride ceramics will expand in semiconductor production equipment (SPE), since these components enable precise temperature control at higher temperatures in the production process.
The two companies reportedly decided to work together in order to blend the material technologies on nitride ceramics possessed by Toshiba Materials with the special ceramic processing technologies possessed by Kyocera. The goal of the collaboration is to achieve higher competitiveness in the ceramics market by providing highly functional products such as power semiconductor components with high heat-dissipating properties, as well as components for SPE that allow precise temperature control under high temperatures—both of which cannot be realized with conventional technologies.
Kyocera International, Inc. conducted a grand opening ceremony in April for a $10 million expansion of its manufacturing operations in Vancouver, Wash. The newly constructed building on the Kyocera site expands the company’s local 40,000-sq-ft manufacturing presence by more than 50%, to 63,000 sq ft, and could create up to 50 new employment positions over the next few years.
Hideo Tanimoto was promoted to president of Kyocera Corp., effective April 1, following a recent unanimous vote of the board of directors. Tanimoto, previously director and managing executive officer, took over the duties of president, representative director and executive officer from Goro Yamaguchi, who became chairman and representative director.
“Today, Kyocera supplies a diverse range of products, from semiconductor components and electronic devices to solar modules, document equipment and mobile phones,” said Yamaguchi. “At our core is the fine ceramic components business, which has continued to grow in step since the company’s founding in 1959. Tanimoto will bring best practices from that pioneering division and implement fresh ideas to help maximize profits for all Kyocera business units.”
Source: company website, annual report, press releases
SCHOTT sells specialty glass and glass-ceramics into industries such as: automotive (hermetic packages for electronics and sensors, lighting solutions, glass tubing), pharmaceuticals (tubing, packaging), electronics (hermetically sealed housing, components), home appliance (cooktop panels, custom glass solutions, door and frame solutions), optics (optical glasses, components), and aircraft (electronic components, hermetically sealed housings, specialty glass solutions for cockpit instrumentation). Total sales in the 2015-2016 fiscal year (October 1, 2015-September 30, 2016) increased by 3% to approximately €2 billion (~ $2.3 billion).
The company employs about 15,000 people in 35 countries. In Europe, 8,900 employees helped generate 45% of total sales for the fiscal year. Asia generated 26% of sales, with 2,800 employees, while North America’s 2,000 employees generated 23% of the company’s sales for the fiscal year. Total R&D spending declined for SCHOTT in the 2015-2016 fiscal year, dropping by 6% to about €73.6 million (~ $86.7 million).
In July, SCHOTT announced a partnership with Chinergy Co., Ltd. and Jiamusi Electric Machine Co., Ltd. to help support the safe and cost-efficient operation of the Shidaowan twin-reactor high-temperature reactor (HTR) through the use of ETERNALOC® electrical penetration assemblies (EPAs). SCHOTT’s electrical penetrations, made with glass-to-metal sealing technology, can reportedly be used in the primary loop of an HTR due to their ability to withstand the high temperatures and pressures of the environment.
The key function of EPAs in nuclear power plants is to provide the pass-through for power, control and instrumentation cables to the thousands of instruments, control panels, electric motors, and many other electric and electronic devices within. According to SCHOTT, its glass-to-metal sealing technology allows the safe conduction of electricity through the fire-protective, pressure-resistant and hermetically sealed containment walls of nuclear power plants.
BLACK ROCK screen protector products have begun using SCHOTT AS 87 eco with a thickness range of 0.1-0.3 mm, SCHOTT announced in June. The glass is manufactured at SCHOTT’s production site in Gruenenplan, Germany, and processed into a screen protector by BLACK ROCK’s Chinese partners. The screen protector is compatible with a number of current smartphone models, including Apple iPhones and the Samsung Galaxy S7. A variation of the glass with slightly curved edges protects the outer curved exterior of the Samsung Galaxy S8 Infinity Display.
SCHOTT announced in May that the 39-m primary mirror for the Extremely Large Telescope (ELT) will soon be made up of 798 ZERODUR® glass-ceramic components. SCHOTT plans to deliver a total of 949 mirror substrates, including spares, made of ZERODUR to the European Southern Observatory (ESO). By 2024, the ELT will be used to discover unexplored galaxies and exoplanets, and to deliver unprecedented image quality. The gigantic primary mirror, known simply as Mirror 1 or M1, has the main function of collecting light from the cosmos and transferring it farther via additional mirrors onto the observatory’s scientific instruments.
“We are very proud to play a significant role in the ELT project. We are also extremely pleased that because of our know-how, distant galaxies can finally be viewed with unprecedented sharpness,” said Frank Heinricht, Ph.D., chairman of the board. “The ESO order for the production of substrates for the ELT primary mirror represents the single-largest contract in terms of astronomical projects that SCHOTT has ever been awarded. At our ZERODUR competency center in Mainz, we have invested more than €10 million [~ $11.8 million] over the last several years to secure and expand our excellent market position for the future.”
Source: company website, annual report, press releases
From 600,000 sq ft of manufacturing space in 50 facilities worldwide, CoorsTek serves customers in a range of industries with 300+ technical ceramic formulations. R&D centers are located in Europe, Japan and the U.S.; in 2016, the company finished the first phase of its new $120 million Center for Advanced Materials in Golden, Colo.
“Growth in advanced ceramics is fueled by new applications,” says Michael Coors, co-CEO. “Gone are the days when a few standard materials met general market requirements. Both the variety of our customers’ applications and their demands for unique, high-performance properties continue to grow. So CoorsTek is investing in R&D, and we are partnering with customers to develop new application-specific materials and scalable, production-ready manufacturing processes. We continue to see more and more opportunities where engineered ceramics can help our customers and help make the world measurably better.”
In May, CoorsTek announced that its CeraShield™ ceramic armor won the 2017 Silver Edison Award in the category of Applied Technology. “Every day, CoorsTek ceramic products used in armor systems help protect the law enforcement, security, and military personnel who protect us—uniquely combining light weight with unsurpassed hardness to counter the increasing lethality of armor-piercing ammunition and other ballistic threats,” said Timothy Coors, co-CEO. “We are honored to be recognized by the Edison Awards for our ongoing innovation and persistent application of materials science and engineering to save lives.”
CoorsTek’s ceramic plates are integrated into body and vehicle armor systems used by the military and law enforcement. As ballistic threats have become more sophisticated, CoorsTek has reportedly continuously improved armor protection systems by providing ceramic plates that weigh less (in order to maximize mobility) and have greater hardness to address increasing ballistic penetration power. The company has developed over a dozen unique engineered ceramic formulations optimized for different armor applications and ballistic threat levels.
The U.S. District Court for the District of Colorado ruled in favor of CoorsTek Medical in January in its lawsuit challenging the trademark and trade dress claims of CeramTec GmbH in the U.S. to the color “pink” for implantable ceramic hip components. CoorsTek Medical initiated the suit against CeramTec in 2014 in response to a cease-and-desist letter and attempt by CeramTec to claim trademark and trade dress protection of the color pink for its implantable CeraSurf®-p ceramic components.
The court’s decision removed any encumbrance for orthopedic device companies to access a second source for implantable ceramic components that are used in hip replacement systems in the U.S. The court acknowledged that CeramTec currently controls roughly 95% of this market.
In August 2016, CoorsTek announced that a team of scientists from CoorsTek Membrane Sciences, the University of Oslo, and the Instituto de Tecnología Química (Spain) had developed a new process to use natural gas as a raw material for aromatic chemicals. The process uses a novel ceramic membrane to make the direct, non-oxidative conversion of gas to liquids possible for the first time, which reduces cost, eliminates multiple process steps, and avoids any carbon dioxide (CO2) emissions. The resulting aromatic precursors are source chemicals for insulation materials, plastics, textiles and jet fuel, among other products. Direct activation of methane, the main component of biogas and natural gas, has been a key goal of the hydrocarbon research community for decades.
“Consider the scale of the oil, gas, and petrochemicals industry today,” said Jose Serra, Ph.D., professor at Instituto de Tecnología Química. “With new ceramic membrane reactors to make fuels and chemicals from natural gas instead of crude oil, the whole hydrocarbon value chain can become significantly less expensive, cleaner, and leaner. By using a ceramic membrane that simultaneously removes hydrogen and injects oxygen, we have been able to make liquid hydrocarbons directly from methane in a one-step process. As a bonus, the process also generates a high-purity hydrogen stream as a byproduct.”
Source: company website, annual report, press releases
Total revenue for Morgan Advanced Materials increased by 8.5% to £989.2 million (~ $1.3 billion) in 2016; on a constant currency basis, revenue declined by 1.5%. Major end-use markets include industrial (45.4% of 2016 revenue), transportation (21.7%), petrochemical (8.5%), energy (6.7%), security and defense (6.3%), healthcare (5.6%) and electronics (5.8%).
The company operates in three main business units: Thermal Products (comprising Thermal Ceramics and Molten Metal Systems); Carbon and Technical Ceramics (Electrical Carbon, Seals and Bearings, Technical Ceramics); and Composites and Defence Systems. Revenue in the Thermal Products segment increased by 10.8% in 2016, to reach £456.8 million (~ $603.6 million); revenue was essentially flat on a constant currency basis. In Carbon and Technical Ceramics, revenue climbed 6.4% to £502 million (~ $663.3 million) but dipped by 3.5% on a constant currency basis due to declines in Electrical Carbon and Technical Ceramics. Reported and constant currency revenue for Composites and Defence Systems jumped 9.7% to reach £30.4 million (~ $40.2 million).
Morgan Advanced Materials employs approximately 8,900 people around the world and has manufacturing facilities in 30 countries. R&D spending jumped 15% in 2016, reaching £29.2 million (~ $38.6 million) and representing 3% of sales.
Last fall, Morgan announced that it had developed a dedicated volume silicon carbide manufacturing facility in Stourport, UK, with the goal of increasing capacity to augment sales in Europe and worldwide with higher performing silicon carbide materials. Morgan produces both sintered silicon carbide and graphite-loaded silicon carbide materials, primarily for mechanical seals and radial bearings.
“This extensive investment enables us to offer seamless production of silicon carbide seal and bearing products, from raw materials to finished parts manufacture at one single site,” said Chris Paine, business development manager. “This means that we can provide the requisite quality assurance for all our products while responding to global demand for high-volume manufacturing capabilities.”
Morgan announced in January that it opened a new office in Delhi, India, to deliver a larger range of advanced electrical carbon products, seals and bearings to the region. The opening of the new office is reportedly the first stage of a wider strategy that will see Morgan aim to increase its share of the Indian market for carbon electrical products over the next five years.
In May, Morgan announced a partnership with Airbus Safran Launchers (ASL) to develop and manufacture ceramic thruster chambers to aid satellite propulsion using ion beam engines. The products are being developed using Morgan’s proprietary high-performance alumina materials. When in orbit, components are often subjected to sudden, yet drastic variations in temperature, ranging from extreme drops in temperature at points that are hidden from direct sunlight, to intense bursts of heat from igniting plasma. To balance these variations, components must have excellent levels of thermal shock resistance.
“In an industry like ours, trust is everything,” said Joerg Krueger, head of ASL Product and System Engineering. “We can confidently say that Morgan has become a valued partner over the years, helping us to continually lead the way in driving technological innovation in the aerospace sector.”
Morgan announced in June that it had been awarded AS9100 accreditation in China. The AS9100 is a standard quality management system for the aerospace industry. Morgan was able to demonstrate its status as a quality supplier of materials following the successful completion of an in-depth audit process that began in March 2015. The AS9100 accreditation, which also includes ISO 9001:2008 and AS9100C, is a first for Morgan’s JMCC operation in China, which specializes in the manufacture of sacrificial ceramic cores and other ceramic injection products for use in investment casting processes.
In October 2016, Morgan announced that it had developed the capability to produce complex ceramic acoustic reflectors used in ultrasonic flow meters, drawing on research carried out in conjunction with Loughborough University, ensuring consistent measurement accuracy over a longer projected lifespan. Morgan reportedly discovered a pioneering approach to developing ceramic reflectors using injection molding technology, meaning it can now accommodate a wider range of bespoke designs with complex geometries to meet the requirements of industry. This method also allows Morgan to tune the sensors to the correct beam width and acoustic properties, ensuring maximum sensitivity by potentially reducing the turbulence of the water flow path around wedges.
“This development is the outcome of a unique collaboration between Morgan and Loughborough University and is a clear example of where we have pushed the boundaries in order to provide complete solutions for our customers,” said Charles Dowling, business manager. “Longevity is a key challenge for many of our customers in industrial metering, and we have optimized our ultrasonic sensors to deliver sustained performance over time compared to other materials. As a result, our customers can feel reassured that their flow meters will remain accurate for longer.”
Source: company website, annual report, press releases
Vitro operates in two main business segments: Glass Containers (sales of $240 million in 2016) and Flat Glass. Flat Glass sales jumped 19.3% to reach $802 million in 2016, up from $672 million in 2015, driven by growth in the construction and automotive industry, as well as the integration of acquired flat glass and coatings businesses. At the end of 2016, Vitro employed about 11,400 people, representing a 6.2% increase compared to 2015.
In October, Vitro announced that it had successfully concluded its acquisition of PPG Industries’ flat glass business. The acquisition included PPG’s entire flat glass manufacturing and glass coatings operations in the U.S. and Canada, including production sites located in Fresno, Calif., Salem, Ore., Carlisle, Pa., and Wichita Falls, Texas; four distribution/fabrication facilities located across Canada; and a research and development center located in Harmar, Pa.
“This transaction represents the end of an historic era for PPG as a manufacturer of flat glass, and it is another major step in our portfolio transformation to focus on paints, coatings, and specialty materials,” said Michael H. McGarry, PPG’s president and CEO. “Upon completion of this transaction, the flat glass operations will become part of a company that is focused on growing its core glass business.”
Vitro announced in March that it had completed its acquisition of Pittsburgh Glass Works’ (PGW) automotive original equipment manufacturer (OEM) glass business from LKQ Corp. Headquartered in Pittsburgh, Pa., PGW had seven manufacturing plants, two satellite facilities and two float glass furnaces in the U.S. It also had one manufacturing plant in Poland and owned an equity participation in two joint ventures, one each in Mexico and China.
“The experience and state-of-the-art technology PGW brings to our business will enhance our technical, research and development capabilities,” said Adrián Sada Cueva, CEO of Vitro. “It will further strengthen our company and create a business staffed by talented employees and strategically positioned for growth.”
Vitro broke ground in May on construction of a $55 million jumbo magnetron sputtered vacuum deposition (MSVD) coater at its Wichita Falls, Texas, plant. The new coater will reportedly enable the company to produce high-performing, energy-efficient low-emissivity (low-e) glasses in standard sizes of 130 x 240 in., with larger sizes available for special orders. The unit will apply Vitro Glass’s highest-performing solar control coatings on large-area glass while providing precision color control and aesthetics. According to the company, it also will be energy efficient, producing more glass per energy unit than most MSVD coaters currently in operation.
“The coater will create at least 50 new jobs at the facility, which currently employs 360 workers and staff, and provides regular work for another 100 to 150 local contractors,” said Bill Haley, manager of the Wichita Falls plant. “The development of this project shows how investments in research and technology can help create, secure and expand jobs in traditional manufacturing. This is a positive development, not just for our glass plant, but for the entire community.”
Source: company website, annual report, press releases
RHI employs approximately 7,500 people in 30 production facilities and more than 70 sales offices worldwide. R&D spending remained steady at about €20 million (~ $23.7 million) in 2016.
The group operates in three main business divisions: Steel, Industrial (including segments for cement/lime, nonferrous metals, glass, environment/energy/chemicals), and Raw Materials. Total group revenue amounted to nearly €1.7 billion in 2016 (~ $2 billion), a dip of almost 6%. The decline was primarily attributable to the continued moderate rate of worldwide steel production, as well as lower project deliveries in the business segments outside the steel industry.
In the Steel division, sales volume increased by 4.9% to approximately 1.2 Mt in 2016, due primarily to a significant expansion of business in the basic mixes segment. In addition to a major contract in Ukraine, the improved utilization of electric steel plants also contributed to this development. However, revenue declined by 2.6% to €1.1 billion (~ $1.3 billion) due to a weaker business development in South America, Europe and China, and to the extension of the product portfolio by lower-performance products.
Sales volume in the Industrial Division declined by 3.4% in 2016, as a result of lower deliveries in nearly all business units. Revenue dropped by 12.4% to €538.6 million (~ $637.6 million). In the cement/lime business unit, these reductions resulted from the lack of new construction projects and a declining construction industry in China, and in the glass business unit from the sale of the U.S. subsidiary RHI Monofrax, LLC in June 2016. In the environment/energy/chemicals business unit, a major contract in the coal and petroleum coke gasifier segment in India delivered in the previous year was not compensated. The decline in revenue in the nonferrous metals business unit was based on weaker demand in the important copper and nickel segment.
In October 2016, RHI and the controlling shareholders of Magnesita Refratários S.A. announced that they had reached an agreement to combine the operations of RHI and Magnesita to create a new refractories company, RHI Magnesita. RHI’s management board agreed to sign a share purchase agreement with Magnesita’s controlling shareholders regarding the acquisition of a controlling stake of at least 46%, but no more than 50%, plus one share of the total share capital in Magnesita, pending RHI’s supervisory board approval. The purchase price for the 46% stake will be paid in cash amounting to €118 million (~ $129.6 million), as well as 4.6 million new shares to be issued by RHI Magnesita, a new RHI entity to be established in the Netherlands and listed in London.
The migration of RHI to the Netherlands and the subsequent listing on the London Stock Exchange reportedly have the objective of reinforcing and underlining the international scope of the enlarged combined company, enhancing its capital markets presence and maximizing value potential for the company’s shareholders. The migration of RHI will be effected by RHI Magnesita becoming the ultimate holding company of RHI Group; the shareholders of RHI will cease to hold shares in RHI and instead hold RHI Magnesita shares. Following registration of the corporate restructurings, RHI’s shares will cease to be listed on the Vienna Stock Exchange. The place of effective management of RHI Magnesita will be Austria.
In July, RHI announced that the Brazilian antitrust authority CADE had granted its approval regarding the planned combination. In addition, the EU Commission has granted merger control clearance, subject to several conditions. The first condition is the divestment of dolomite production sites in Marone, Italy, and Lugones, Spain. These sites comprise RHI’s dolomite business (production, sale, etc.) in the European Economic Area. This condition will include an investment in a tunnel kiln in Marone, if the Lugones production site is not transferred.
The second condition is the divestment of a Magnesita production site in Oberhausen, Germany, which comprises the entire Oberhausen business (production, sale, etc. of magnesia-carbon brick and basic mixes) in the European Economic Area. Finally, the potential buyer will receive supply contracts for sintered magnesia amounting to a maximum of roughly 43,000 tons.
Source: company website, annual report, press releases
Total revenue for Vesuvius reached £1.4 billion (~ $1.9 billion) in 2016, representing an increase of 6%; revenue declined by 4% on an underlying basis. Two business segments comprise Vesuvius’ operations: Steel (including Steel Flow Control, Advanced Refractories and Technical Services), and Foundry.
Overall, the Steel division reported revenue of £942 million (~ $1.2 billion), an increase of 4.9%, in 2016; within the division, revenue in the Advanced Refractories segment grew 5.3% to reach £398.8 million (~ $526.9 million). On an underlying basis, revenue in Steel declined by 4.8% and Advanced Refractories was down 3.3%. Reported revenue for the Foundry division grew 8.3% to £459.4 million (~ $607 million); revenue declined by 2.5% on an underlying basis.
More than 10,800 people work for Vesuvius worldwide: 3,186 in the Americas; 4,422 in EMEA; and 3,232 in the Asia-Pacific region. With a presence in 38 countries, the company has 91 sales offices, 66 production sites and 17 R&D centers. Vesuvius invested £28.6 million (~ $37.8 million) on R&D in 2016, an increase of nearly 11% over 2015.
Patrick André, president of the Flow Control division, succeeded François Wanecq as chief executive of Vesuvius, effective September 1; André also joined the Vesuvius board of directors. Wanecq remains with the group following his retirement until December 31 to assist with the transition of responsibilities. André continues to be responsible for the Flow Control business until a suitable replacement is found.
“Having undertaken a comprehensive review of external and internal candidates, we are delighted to appoint Patrick André as the group’s next chief executive,” said John McDonough CBE, chairman. “Since he joined us last year, he has displayed significant drive and energy in strengthening the Flow Control business. It is this commitment, together with his industry experience, strategic vision, constant customer focus and proven record of delivery, that will enable him to lead the group in the next stages of its development.
“On behalf of the board, I would like to thank François Wanecq for leading the business through a period of significant change and many challenges, with the market turmoil of 2008, the subsequent years of retrenchment, the establishment of Vesuvius as a stand-alone listed business in 2012, and the refocusing, restructuring, and performance improvement that has been achieved since then. Throughout that time, François has worked tirelessly to strengthen Vesuvius’ business and to champion safety and quality throughout the group.”
In December 2016, Vesuvius acquired a Brazil-based mold and tundish fluxes business for £9.2 million (~ $11.4 million). According to Vesuvius, the acquisition will broaden its steel flow control offering and is complementary to the previous acquisition of Metallurgica.
Source: company website, annual report, press releases
CeramTec produces specialized high-performance ceramic components in two main segments: Medical Products (primarily hip implant components) and Industrial (various components for automotive, defense, electronics, industrial, and other applications). Total revenue in 2016 was €493.3 million (~ $582.8 million), a decrease of 1.6% compared to 2015.
Revenue in the Medical Products segment, which represents 38% of total sales, increased 1.5% to €185.6 million (~ $219.7 million). Continued volume growth reportedly overcompensated for adverse pricing effects. In the Industrial segment (62% of total sales), revenue was down 3.4% to €307.8 million (~ $364.4 million) due to poor performance in several business units.
CeramTec’s R&D spending dropped over 11% in 2016, to €19.9 million (~ $23.6 million), driven by the streamlining of R&D in the Medical segment and the refocusing of the organization through the recently launched Innovation Excellence Initiative. According to CeramTec, the initiative aims to realign resources to the most attractive, customer-driven projects in the pipeline based on a structured opportunity management process. The company employs almost 3,200 people at 20 production sites and other offices around the world.
CeramTec announced in February that it would acquire Morgan Advanced Materials’ UK Electro-Ceramics business, comprising two sites at Ruabon and Southampton, which produces a range of piezo and dielectric ceramic products used in a wide range of industrial, electronics, medical, and defense applications. In 2016, UK Electro-Ceramics generated an operating profit of £6.2 million (~ $7.7 million) on revenue of £22.7 million (~ $28 million).
“We are excited by the prospect of bringing together the significant expertise and knowledge in piezo and dielectric ceramics, which complement each other perfectly,” said Henri Steinmetz, CEO of CeramTec. “This transaction opens the door to many new opportunities and possibilities for CeramTec: new markets, new application areas, and new developments. Together, we are stronger and we will be able to offer our customers an even broader spectrum of products and applications. The significant demand for sensors and measurement technology, as well as control and monitoring systems, provides the best opportunities for a successful future.”
In December, CeramTec announced that CeramTec North America in Laurens, S.C., had obtained AS9100 certification. AS9100 is based on the ISO 9001 standard and specifies additional requirements for the reliability of products for the aviation and space industries. For AS9100, CeramTec North America reportedly introduced a comprehensive quality management system (QMS) that focuses on quality management and continuous improvement. The QMS sets standards for product planning and ensures that customer-specific requirements are met via constant quality management of the products.
Source: company website, annual report, press releases
Reference
1. “Top 300 Organizations Granted U.S. Patents in 2016,” Intellectual Property Owners Association, www.ipo.org.
Editor’s note: The CI Top 14 ranking is based, in part, on publically available financial information, including annual sales, along with details supplied by company contacts and other sources. Information was verified whenever possible. In some cases, details such as annual sales figures for privately held companies have been withheld on request. Financial figures are generally rounded, and the timing of currency conversions may impact specific results.
Where specific and verifiable information was not readily available, some companies unfortunately had to be left out. For details regarding how to have your company considered for future CI Top 14 rankings, contact Susan Sutton, editor-in-chief, at (248) 786-1704 or suttons@bnpmedia.com.
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