From the Sector

Stahl has published its 2023 Environmental, Social and Governance (ESG) Report. The report outlines Stahl's recent progress on its ESG Roadmap to 2030 and the steps the company is taking to live its purpose of Touching lives, for a better world.

Stahl’s ESG Roadmap to 2030 includes interim targets for 2023, making this a year in which Stahl reached several important milestones. For example, the company reduced its scope 1 and 2 greenhouse gas (GHG) emissions by 22% versus 2022. Furthermore, in 2023 the Science Based Targets initiative (SBTi) validated Stahl's scope 1, 2 and 3 targets, making it one of the first coatings companies on the SBTi-approved list.

To reduce its GHG emissions, Stahl is actively increasing its use of clean energy. At the end of 2023, renewable energy generation, such as solar panels, had been installed at four Stahl sites, compared to its target of three.

Measuring – and reducing – the impact of products is an important step in the company’s scope 3 emissions. As such, 353 Stahl products now have either life cycle assessment (LCA) or product carbon footprint (PCF) data, far exceeding the 2023 target of 50.
 
New ratings and certifications
In 2023, 2,161 of Stahl's products were certified by Zero Discharge of Hazardous Chemicals (ZDHC), in line with ZDHC MRSL V3.1. These products represented 70% of the company’s sales revenue, demonstrating increased demand for coatings with a lower risk to health and the environment.

Stahl was also proud to achieve a Platinum rating from EcoVadis for the second year in a row, which places it in the top 1% of companies evaluated. Stahl also exceeded its 2023 target of an average EcoVadis rating of at least 60/100 for their top ten suppliers, with an average rating of 68/100 reported in December 2023.
Fostering a safe and welcoming work environment

A core pillar of Stahl’s ESG approach is how it supports its employees’ physical and mental well-being. The 2023 ESG Report outlines several examples of this commitment, such as improvement in its key safety KPIs for the third year in a row.

Besides keeping people safe, Stahl continues to make progress in fostering an open and inclusive workplace. For example, in support of diversity, equity and inclusion (DEI), Stahl appointed its first female leadership team member, trained 98% of its staff in DEI and established DEI committees at all Stahl sites. In addition, to strengthen communication, engagement and collaboration across the workforce, Stahl also established an internal workplace hub, MyStahl.

Carbitex – a leader in flexible carbon fiber composites focused on footwear, travel, and accessories – announces the appointment of Filippo Sartor to Vice President of Global Sales and Sam Gardner to the role of Vice President of Engineering and Operations. After a restructuring of manufacturing operations and the return of Carbitex founder, Junus Khan, as company president in 2023, the brand welcomes two strategic hires to catalyze the next phase of the leading materials brand.

With over 20 years in the footwear industry, including nearly 11 years as the Global Senior Sales Manager at JV International, official worldwide licensee for Michelin Soles, Sartor brings high level sales expertise within performance footwear and material innovation. With extensive focus on building new business in the US and Far East, and based in Milan, Italy, Sartor is uniquely positioned to help propel Carbitex globally into the next chapter.

Gardner, based in Renton, Washington, will manage product development and manufacturing at Carbitex. With time at Square One Distribution - a long-time Carbitex brand partner in the wake and waterski segment - and most recently as VP for Union Aquaparks, Gardner has considerable experience designing new products and managing sourcing, logistics, and supply chain. His background will help Carbitex strengthen both factory and brand partner relations and push product innovation.

These recent hires position Carbitex to better serve strategic brand partners, achieve forecasted growth in the short and long term, and expand global market presence.

• Three out of four business units with record sales and results
• Carbon Fibers business weighs on the Group's profitability
• Group sales of €1,089.1 million (-4.1%) and adjusted EBITDA of €168.4 million (-2.5%) in a difficult market environment
• Sales and earnings forecast for 2023 achieved despite drop in demand from key market
• 2024 further capacity expansion in graphite components for silicon carbide-based semiconductors

In fiscal year 2023, SGL Carbon achieved the sales and earnings targets set at the beginning of the year despite the drop in demand from the important wind market and an increasingly challenging economic environment. Group sales decreased slightly by €46.8 million (minus 4.1%) to €1,089.1 million (previous year: €1,135.9 million). At € 168.4 million, adjusted EBITDA, a key performance indicator for the Group, was also down slightly (minus 2.5%) compared to the previous year (€172.8 million) but was clearly within the forecast range for 2023 of €160 to 180 million.

While the positive sales development of the Graphite Solutions (+€53.5 million to €565.7 million), Process Technology (+€21.6 million to €127.9 million) and Composite Solutions (+€0.8 million to €153.9 million) business units had a positive effect, the Carbon Fibers business unit had a negative impact on Group sales with a sales decline of €122.3 million to €224.9 million.

Outlook
The global economy will continue to face comparatively high interest rates and subdued growth prospects in 2024. Tighter financing conditions, weak trade growth and a decline in business and consumer confidence are also weighing on the economic outlook. In addition, heightened geopolitical tensions are contributing to increased uncertainty.

SGL Carbon expects different developments in our key sales markets in 2024. The most important sales and earnings driver will be demand for specialty graphite components for the semiconductor industry. In contrast, all indicators currently suggest that demand for carbon fibers for the wind industry will remain weak in 2024 and that the Carbon Fibers (CF) business unit will therefore continue to record operating losses. Even if demand picks up, SGL Carbon assumes that Carbon Fibers will require additional resources to make the most of market opportunities. With this in mind, teh company announced on February 23, 2024, that they are reviewing all strategic options for Carbon Fibers. These also include a possible partial or complete sale of the business unit.

SGL Carbon's sales forecast for the financial year 2024 takes all four operating business units into account, as the company is only at the beginning of evaluating the strategic options for CF. In line with the assumptions outlined, SGL Carbon is therefore expecting Group sales at the previous year's level (2023: €1,089.1 million).

In the earnings forecast, SGL Carbon has taken into account underutilization of production capacity in the Carbon Fibers business unit and the associated high idle capacity costs. The projected operating loss of CF will have a negative impact on the adjusted EBITDA of the SGL Carbon Group in 2024. Due to the expected positive development of Graphite Solutions, SGL Carbon anticipates an adjusted EBITDA of between €160 million and €170 million for fiscal year 2024, taking into account all four operating business units. Should the process of reviewing all strategic options for the CF business unit result in a sale, the forecast of adjusted EBITDA in 2024 would be between €180 - 190 million.

As of March 1, 2024, Dr. Denis Hinz will become new Head of SGL Carbon's Carbon Fibers Business Unit. The previous Head, Roland Nowicki, will leave SGL Carbon on May 31, 2024 at his own request to pursue new professional challenges. He will be available to the company as a consultant until his leaving date to support a smooth transition.

Roland Nowicki took over as Head of Carbon Fibers in November 2020 and has successfully driven forward the realignment of the business unit over the past three years.  

Dr. Denis Hinz has been with SGL Carbon for more than six years and has held various management positions during this time, including Head of Operations of the Fuel Cell Components division and Managing Director of SGL Fuel Cell Components GmbH in Meitingen since December 1, 2021. The graduate engineer from the Technical University of Munich is an experienced manager who is well networked within SGL Carbon and has closely followed the development of Carbon Fibers in recent years.

SGL Carbon SE is currently evaluating various strategic options for the Business Unit Carbon Fibers (CF). These include a possible partial or complete divestment of the Business Unit. In a first step, potential interested parties shall be approached with the general data of the Business Unit to determine their interest in an acquisition. If there is sufficient interest, a structured transaction process will be carried out in a second step. Overall, a share of sales amounting to around € 179.6 million after nine months in 2023 (9M 2022: € 269.0 million) is therefore under review. The CF sales share corresponded to 21.9% of SGL Carbon's consolidated sales after nine months in 2023 (9M 2022: 31.5%). Adjusted EBITDA of the Business Unit excluding the result from joint ventures amounted to minus € 10,9 million after nine months in 2023 (9M 2022: € 27,9 million). Despite the operating loss of CF after nine months in 2023, SGL Carbon maintains its guidance for fiscal year 2023. This shows the positive development of the three other business units and the resilience of SGL Carbon's business model.

Carbon Fibers manufactures textile, acrylic and carbon fibers as well as composite materials at seven locations in Europe and North America. Following the temporary drop in demand for carbon fibers from the important wind industry market, the Business Unit's sales and earnings fell significantly in the course of fiscal year 2023. Due to the importance of the wind industry for the European Green Deal, SGL Carbon and many experts assumed that the wind industry recovers quickly. Unfortunately, this is currently not the case. Even if demand picks up, the company assumes that Carbon Fibers will need additional resources to remain competitive in the international market environment and to exploit market opportunities in the best possible way. Against this background, SGL Carbon is reviewing all possibilities to support a positive further development of the Carbon Fibers Business Unit.

“From Earth to Earth”: The new plan defines goals and concrete actions in Environmental, Social and Governance (ESG) areas to foster value creation for all stakeholders and put new sustainability regulatory requirements at the centre of attention.

A project, designed to enhance RadiciGroup's transparency and commitment to develop a responsible business along its entire value chain from an economic, social and environmental perspective and focus on the ever more widespread and stringent sustainability regulatory requirements. These are the features and goals of the Sustainability Plan presented by the Group and called "From Earth to Earth", precisely to emphasize the intent to focus on the Earth and future generations.

In the context of a complex and constantly changing scenario, the Group has therefore decided to capitalize on the goals achieved and look beyond them with a plan defining the medium-term targets and the actions to be taken to fulfil them and covering all areas considered to be "material”, i.e., relevant from the point of view of ESG and financial risks, opportunities and impacts. Indeed, the ultimate goal of "From Earth to Earth" is to support business continuity and the growth of the company and all its stakeholders.

The project was the result of a multi-year collaboration with Deloitte, which contributed an external and objective viewpoint on the definition of the material targets and themes. However, it was not an armchair exercise, but the result of an extensive listening process involving internal and external stakeholders, all of whom were sustainability experts who helped define a shortlist of strategic themes for both the Group and its main stakeholders. These issues were then analysed in detail using working tables on the different themes to identify the objectives in Environmental, Social and Governance areas and the related concrete actions needed to achieve them, in line with the European decarbonization and energy transition policies and the
United Nations Sustainable Development Goals, a global blueprint for sustainable growth.

In particular, RadiciGroup’s environmental goals include: a 20% increase and differentiation in renewable source electricity consumption, an 80% reduction in total direct greenhouse gas emissions by 2030 compared to 2011, attention to water consumption to limit the impact on local communities and biodiversity, the extension of Life Cycle Assessment (LCA) methodology to measure the environmental impact of 70% of the products (in terms of weight) manufactured by the entire Group, collaboration among the various actors in the supply chain from an ecodesign perspective and the search for increasingly more sustainable and circular packaging solutions.

Solvay is partnering with transportation providers KIITOSIMEON and ADAMS LOGISTICS to reduce the carbon footprint of its facility in Voikkaa, Finland. Known for its hydrogen peroxide technology, the site has a yearly capacity of 85 kilotons, making it the largest hydrogen peroxide unit in the country and one of the largest in Europe. However, the transportation of its products results in more than 850 tons of CO2 emissions annually, attributed to the several thousands deliveries conducted each year.

While the Voikkaa site has been operating on 100% wind-generated electricity since 2023, the journey towards decarbonization takes another step forward as it transitions transportation fuel from diesel to biofuel in the first quarter of 2024. This shift will result in a significant annual reduction of over 700 tons of CO2 emissions, representing more than 8O% reduction in the site's transportation carbon footprint.

As part of its commitment to carbon neutrality by 2050, Solvay has outlined a sustainability roadmap with around 40 energy transition projects. These projects focus on eliminating coal usage, emphasizing renewable energy sources, prioritizing energy efficiency, and driving process innovation. Solvay has further committed to reduce its emissions* along the value chain by 20% by 2030.

*scope 3 emissions, focus 5 categories, 2021 baseline

SGL Carbon relies on climate-friendly manufacturing processes in the production of its own carbon fibers. By using renewable energy, the carbon footprint of SGL fiber can be reduced by up to 50% compared to a conventional fiber.  

SGL carbon fiber is produced at the Lavradio (Portugal) and Moses Lake (USA) sites. When the Moses Lake site was selected in the 1990s, the use of hydropower as an energy source played a particularly decisive role. As a result, around 75,000 tonnes of CO₂ can be saved in Moses Lake by purchasing electricity from hydropower plants compared to a fossil fuel-based electricity mix.

As part of the consistent implementation of its climate strategy, SGL Carbon will be using a CO₂-neutral biomass system to generate energy from the beginning of 2024, which will make the production system, which was previously based on natural gas, more flexible and climate-friendly. At full capacity, the biomass system in Lavradio can save more than 90,000 tons of CO₂.

The raw material used is wood pellets, which are sourced from a radius of 250 kilometres via short transport routes.

The climate-friendly energy supply at the site in Moses Lake (USA) combined with the new biomass plant in Lavradio (Portugal) lead to a reduction in CO₂ emissions of up to 50% in the production of SGL's own carbon fibers compared to conventional fibers. With the investment in the biomass system, SGL Carbon is pursuing its climate strategy. The target is to save 50% CO₂ emissions by the end of 2025 compared to the base year 2019 and to be climate-neutral by the end of 2038. In the period 2019 to 2022, SGL Carbon has reduced its CO₂ emissions by 17%.

The kick-off meeting for the "Trends and Design Factors for Hydrogen Pressure Vessels" project, recently held at AZL Aachen GmbH, was a successful event, bringing together more than 37 experts in the field of composite technologies. This event laid a solid foundation for the Joint Partner Project, which currently comprises a consortium of 20 renowned companies from across the composite pressure vessel value chain: Ascend Performance Materials, C evotec GmbH, Chongqing Polycomp International Corp. (CPIC), Conbility GmbH, Elkamet Kunststofftechnik GmbH, F.A. Kümpers GmbH & Co. KG, f loteks plastik sanayi ticaret a.s., Formosa Plastics Corporation, Heraeus Noblelight GmbH, Huntsman Advanced Materials, Kaneka Belgium NV, Laserline GmbH, Mitsui Chemicals Europe GmbH, Plastik Omnium, Rassini Europe GmbH, Robert Bosch GmbH, Swancor Holding Co. Ltd. Ltd., TECNALIA, Toyota Motor Europe NV/SA, Tünkers do Brasil Ltda.

The project follows AZL´s well proven approach of a Joint Partner Project, aiming to provide technology and market insights as well as benchmarking of different material and production setups in combination with connecting experts along the value chain.

The kick-off meeting not only served as a platform to foster new contacts and get informed about the expertise and interests of the consortium members in the field of hydrogen pressure vessels, but also laid the groundwork for steering the focus of the upc oming project's ambitious phases. As a basis for the interactive discussion session, AZL outlined the background, motivation and detailed work plan. The central issues of the dialogue were the primary objectives, the most pressing challenges, the contribut ion to competitiveness, and
the priorities that would best meet the expectations of the project partners.

Discussions covered regulatory issues, the evolving value chain and the supply and properties of key materials such as carbon and glass fibres and resins. The consortium defined investigations into different manufacturing technologies, assessing their matu rity and potential benefits. Design layouts, including liners, boss designs and winding patterns, were thoroughly considered, taking into account their implications for mobile and stationary storage. The group is also interested in cost effective testing m ethods and certification processes, as well as the prospects for recycling into continuous fibres and the use of sustainable materials. Insight was requested into future demand for hydrogen tanks, OEM needs and strategies, and technological developments to produce more economical tanks.

The meeting highlighted the importance of CAE designs for fibre patterns, software suitability and the application dependent use of thermoset and thermoplastic designs.

The first report meeting will also set the stage of the next project phase, which will be the creation of reference designs by AZL's engineering team. These designs will cover a range of pressure vessel configurations using a variety of materials and production concepts. The aim is to develop models that not only re flect current technological capabilities, but also provide deep insight into the cost analysis of different production technologies, their CO₂ footprint, recycling aspects and scalability.

AZL's project remains open to additional participants. Companies interested in joining this initiative are invited to contact Philipp Fröhlig.

Felix Pohlkemper and Tim Röding from Institut für Textiltechnik (ITA) of RWTH Aachen University are developing a technology with their start-up CarboScreen GmbH that makes complex carbon fibre production controllable through sensor monitoring. With the help of CarboScreen technology, it should be possible to double the production speed from the current 15 m/min to 30 m/min in the medium term. The doubling of production speed alone could result in an increase in turnover of up to €37.5 million per year and production plant. Felix Pohlkemper and Tim Röding were awarded third place in the AVK Innovation Award 2023 in the Processes and Procedures category for this ground-breaking development. The award ceremony took place during the JEC Roof Forum in Salzburg, Austria.

The production of carbon fibres is highly complex. In the current state of the art, however, the manufacturing process is only monitored manually by semi-skilled workers. However, even minimal fibre damage during production leads to a reduction in the quality of the carbon fibre. In extreme cases, it can also lead to plant fires. To ensure production quality, the production speed is currently limited to a maximum of 15 m/min. In fact, the production speed of the systems could be higher. The sensor-based online monitoring of Carbo-Screen makes it possible to increase the production speed to 30 m/min in the medium term. As a result of the increased production volume per system, the specific production costs of the carbon fibre are reduced, which can result in lower prices.

A reduced sales price would make it possible to use carbon fibres and their composite materials even more widely in traditional markets such as aerospace technology and wind energy, as well as for mass production in the automotive industry.

The CarboScreen online monitoring system is currently being developed for industrial use. It is to be validated at an industrial plant in 2024. CarboScreen GmbH was founded as part of EXIST funding and offers AI-supported sensor systems for carbon fibre production. The sensor technology continuously monitors the fibre throughout the entire production process. Deviations are detected automatically.

The winners of the AVK Innovation Award are honoured annually by the AVK Industrievereinigung Verstärkte Kunststoffe. Companies, institutes and their partners are honoured in three categories: products and applications, processes and procedures, and research and science.