Toray Newsletter 1 - Eng

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October 09

Edito his first issue of the TORAY Films Europe newsletter gives us the opportunity to demonstrate that our Company is now operating with our new name and ready for the challenges of the future. Oriented towards innovation and achievement, TORAY Films Europe, the new business entity of the TORAY group is structured to provide products and services that will best fit your needs whilst making sustainable development a priority. Particularly committed to be environmentally friendly, the TORAY group has distinguished itself by setting an example and received the 2008 Humanitarian Award from the United Nations Association. Encouraged by this acknowledgement, all corporate branches of the group have benefited from this recognition and it has boosted them to be more involved in a responsible approach to sustainable development. As you will notice in this current issue, TORAY Films Europe is taking firm action in order to down play the impact of its activities on the environment. As a result, the Carbon Footprint Programme evaluation has been carried out on the Saint Maurice de Beynost site. Minimising environmental impact is also expressed through TORAY’s choices for product development: For example our new range of recyclable films for photovoltaic panels and metallised OPP film for flexible packaging which gives enabling resource savings in comparison with existing market solutions. These innovations are backed up by TORAY Films Europe’s R & D dynamism and outstanding experimentation facilities of the Saint Maurice de Beynost site As you will see, this active drive is strong and will lead to an increase in TORAY Films Europe’s production capacity starting from February 2010, with the new production unit of bi-oriented polypropylene films (BOPP). Today, TORAY Films Europe has at its disposal all the assets required to strengthen its leading position in Europe and is ready to assist you with tomorrow’s challenges.

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Osamu INOUE - TFE Chairman  AGENDA October 2009 : the site will operate under the new TFE company name February 2010 : start up of operation of the new Torayfan production unit

Product Torayfan® the ultimate high barrier OPP film orayfan® has a very high barrier against moisture and oxygen, with many potential uses in a variety of laminate designs, reducing the manufacturing costs in the process... Acclaimed by the food market in North America, Torayfan® offers all the qualities required to reach the top rank of European food packaging. This bi-axially oriented polypropylene (OPP) film combines TORAY’s advanced film making processes and proprietary metallising technology, delivering a metallised OPP with up to four-fold improvement in moisture and oxygen barrier performance, compared to other barrier OPP films on the market today (see table). This means the film meets the needs

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Property

Traditional Metallized OPP

Torayfan® Metallized OPP

Potential Benefits

Moisture

0.6

<0,15

Improved Product Quality and Shelf Life

Oxygen

60

<15

Improved shelf life

Seal Initiation Temperature

105°C

85°C

Improved Packaging operations

Thin film

20µm

11/12.5/15µm

Source reduction

of the food packaging market and provides a solution to keep food products fresh for long periods, whilst maintaining their original flavour. In many cases food shelf-life can be doubled. Torayfan® provides the printability required to enhance the finished goods on-shelf appeal which makes it very attractive to

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I nnovation ••• many brand owners. The manufacturing process of Torayfan® uses lighter materials and does not require the use Aluminium foil for barrier properties. Torayfan’s advanced technology produces thin-gauge films without compromising key performance attributes like barrier and sealant performance. This means the manufacturing process for Torayfan® produces high performance, high yield films offering less weight per a square meter of packaging. These properties make Torayfan® MET OPP ideal for foil replacement projects by providing improved barrier durability, enhanced package esthetics and controlled costs. Torayfan® is specifically designed for the packaging of salty snacks, cookies, confectionery, chocolate, powdered beverages, soups, seasonings, etc... In response to expanding European demand for high-barrier thin-gauge films, TORAY has established a film production facility in Saint-Maurice-de-Beynost, France. Production of Torayfan® Metallised OPP is to start in February 2010.

 News ECOPOLY : waste recovery and recycling of PET PVDC / PET PVDF Co-branded with the technology clusters Axelera and Plastipolis, this innovating project ECOPOLY has received funding from the French administration (FUI). TORAY Films Europe as a project leader will focus with the project team (industries and research laboratories) on two main targets: • develop new recycling methods for halogen coated PET • reduce usage of oil based raw materials by polymers increasing the recycling of PET PVDC / PET PVDF

Photovoltaic modules: A New Generation of Protective Films

For the last 30 years, TORAY has been active in the Japanese solar power field. This has led to a proficiency enabling the Company to develop a new range of “all PET” protective films for PV modules. These polyester films present a real change on the solar energy market, thus increasing its production capacity and introducing a more competitive offer. hotovoltaic (PV) modules are made of several individual solar cells used for generating electric power converted from the sun’s energy. When processing the modules, the solar cells are arranged in series and then protected from any external threat by a bonding of protective glass on the front and laminate of plastic films on the back. This ensures electrical insulation as well as a protection against UV and hydrolysis. To ensure such properties, market laminates conventionally combine a PET efficient for its insulating properties with other components, which are difficult to recycle. Fluoride films are an example of one of these problem components.

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A renewable PET, UV and hydrolysis resistant Several years of research and development have been rewarded by the development of an ”all PET solution” based on a new generation of films suited to meet the requirements of solar panels. Indeed, resistance to UV and hydrolysis are not

inherent properties to PET. Yet TORAY took up the challenge in designing a PET able to ensure these functions with a long lifespan. This solution also represents a real alternative to fluoride products that are used for their outstanding properties but presenting a major downside with regards to recycling which is demanding on an economical and technical standpoint. TORAY provides the market with the first “all PET solution”; recyclable and dedicated to the protection of the back of solar panels.

Meeting market demand The new generation of Lumirror PET Films, specially developed for photovoltaic modules is made by laminating an anti-UV film to one with increased hydrolysis resistance. From 2010, a single film combining these two properties will meet market demand in two ways: • It will increase the production capacity in a booming market which will have to absorb an annual 25 % production growth forecasted in the next five years.

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E nvironment ••• • It offers a wide range suitable to meet the local standards of markets, depending on their primary criteria: cost, efficiency, or a balance between the two. Lastly, the versatility of the range meets the expectations of our converters who have specialised knowledge of the manufacture of laminates designed for the backsheets of PV modules. An active development plan for 2011-2012 is being implemented to further improve the material performance and develop new products. The main Japanese leaders in the manufacturing of solar cell panels are already using the new generation films. These film’s many technical benefits, in addition to their competitive cost, positions them as a promising alternative for solar cell protection in Europe.

EcoChallenge : Sustainable development in the centre of TORAY’s activity aunched in Japan in 2008, the EcoChallenge project gives priority to sustainable development in all the TORAY group activities in order to help reduce environmental impact. All products are concerned, including

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manufacturing processes. This plan was established for all companies in the group, and TFE has in this prospect, taken the initiative to assess the carbon footprint of its Saint Maurice de Beynost site.

EcoChallenge: 5 scopes of action, concrete achievements

Development of new bio-based polymers from sustainable sources: • from oil based material to PLA (polylactic acid) • DIFEX-BIO project (Plastipolis)

Bio-based polymers

Sustainability oriented products: photovoltaic modules, lithium-ion batteries, capacitor for hybrid vehicles…

New Energy Energy efficiency

• Weight of aircraft lighten by 20% • Manufacturing process using less water and steam • Local sourcing policy…

Innovation by Chemistry

Our portfolio Electrical Insulation

Lumirror® 60.01/250

UV reflection, White

Lumirror® 50E20F

Hydrolysis resistant

Lumirror® 50X10S

UV & Hydrolysis resistant

Lumirror® 50XTRM-PV

Water purification • Water purification system: 14 Millions Tons of cleaned water per day • Increases fresh water availbality

 News TORAY Films Europe (TFE), TORAY new European entity TORAY reinforces its position in Europe by expanding its production capacity with: • The setting up of its new production unit of polypropylene bi-oriented metallized film under the Torayfan® brand with a 20kt per year production facility. • The reorganization of its Polyester Films production activity. Effective October 1st, these activities will be organized within TORAY Films Europe (TFE), the new entity resulting from their merging.

Since June 2009, TFE has been a member of the technology cluster: Tenerrdis Technologies New Energies Renewable Energies. This involvement is in line with the Company’s activity on renewable energies. www.tenerrdis.fr

n recognition of its overall efforts toward environmentally friendly business, TORAY received the 2008 Humanitarian Award from the United Nations Association. Two concrete developments have been awarded: • Carbon Fibres have been developed in order to lighten weight of aircraft of 20 % and will help reduce greenhouse gas emissions.

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Recycle • Innovative products : PV backsheet • Optimised manufacturing processes: polymers and waste recycling. • ECOPOLY project ( Axelera & Plastipolis)

• The implementation of a of water treatment device which will enable to produce 14 million tons of clean water every day and will also support environmental stewardship. Conveyed by the TORAY group, this environment friendly culture gives a driving force to all subsidiaries of the group and more particularly to TORAY Films Europe.

Carbon Footprint, TFE environmental commitment ver the last years, TFE industrial site in Saint Maurice de Beynost volunteered to approach sustainable development: for instance, in keeping track of water consumption, in being in favour of more energy saving process or in setting a policy of close proximity of supply services…

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The Carbon Footprint plan, introduced in 2009, will give a detailed account of the outcome of all their actions. Presently the plan is carried out and will calculate the Carbon Footprint of the site using the method of assessment of products lifecycle. The appraisal report will be published in the course of 2010.

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Focus R&D Innovation targeted toward customers’ and market demands Paying particular attention to its customers and market requirements, TORAY Films Europe is equipped with a prototype line. Made up of several individual pilot plant units, it reproduces in miniature the overall process of film production. “Managing our R & D from within enables us to be more reactive”, specifies Jean-François Mengual, Technical General Manager. As examples of some major innovations by these pilot units and what they achieved…

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• The printing and laminating pilot unit is directed toward the end product. On one hand it tests the compatible nature of the respective films and on the other hand, the suitability of the product for end users. In the demanding packaging industry, properties such as ink adhesion, gloss, roughness, and tear- resistance… are kept under close attention and are adjusted according to the destination of the market. “These pilot units represent a real asset for the reactivity of our company. We are well able to meet our customers’ specific requests, be proactive in anticipating tomorrow’s market and specifically to launch an industrial range of reliable products in a very short time”, concluded Jean-François Mengual. These trials will be used as tests completed for the Plastipolis Cluster whose project aims at developing a reliable and environmently friendly plastics industry.

Finely designed properties to fullfil market demands. Few examples... Durable polyester films made specifically for the construction market Lumirror® XTRM UV

Non-slip properties to help transportation and storage of PET food bags Lumirror® 10.42

Resistant and durable films for decorative purposes or home appliances Matt films : Lumirror® 10.93 / 10.91 Lumirror® 60.11/ 60.12 Coloured white or gold films for the flexible packaging Coloured Films : Lumirror® 10.50 Lumirror® 10.55 Claryl® Gold High gloss metallised film CLARYL® for luxury packaging Claryl® BL

 News Influenza A / H1N1: preventive actions and plan of continuity of activity Being faced with the flu pandemic related to Virus A/H1N1, TORAY Films Europe has taken contingency mea-

Editorial Director: Osamu INOUE Editor-in-chief: Bertrand Dupeyroux Editorial Staff: Julien Faldysta, Stéphane Ferrarelli, Gérard Korn, Jean-François Mengual

sures on hygiene and safety, as early as May on this site. These measures were implemented in order to limit the spread of virus transmission and to ensure good protection. In order to anticipate the consequences

of a sudden evolution of the pandemic, as forecast for the fall season, TORAY Films Europe has devised a continuity plan for all its activities.

Marketing Lumirror® : Julien Faldysta ([email protected] - +33 (0)4 72 88 17 57) Marketing Torayfan® : Chris Voght ([email protected] - +33 (0)4 72 88 17 11) PR agency: Cathy Clément - [email protected] - +33 (0)1 30 82 66 65 Toray Films Europe - St Maurice de Beynost - 01708 Miribel Cedex Tel +33 (0)4 72 88 16 00 - Fax +33 (0)4 72 88 16 60

Trampo’Ligne 2009 - Crédits photos : Ragnarocks, Chips, Ewa Walicka, Leticia Wilson, Nath Photos, Robertas, Miyazawa - Fotolia.com

ur R & D pilot unit enables testing of the products designed in the laboratory under industrial conditions. They reproduce the films manufacturing process to the scale of 1/5°. • The polymer computer-generated pilot unit is used for the adjustment of the raw material: in order to comply with regulations (food safety, environment awareness for instance), optimize recycling during the process as well as the end product, make trial tests on renewable resources; they represent the main strategic research of this pilot. • The coextrusion pilot unit enables us to test new processes for the realization of multilayer structures and to test the compatibility of all polymers. • The pilot unit for industrial production enables small scale production of film samples. Their properties can then be tested, for example the resistance to the ageing process and UV for the films dedicated to photovoltaic panels.