2021 CW Top Shops highlights strengths of top composites facilities

B&T Composites

Response from Kosmas Tiriakidis, production manager

Location: Florina, Greece

Date founded: 2006

Facility size: 53,000+ square feet

Materials: Carbon, glass, basalt, aramid/Kevlar fibers

Processes: Filament winding, vacuum infusion, wrapping, hand layup

End markets served: Mostly industrial and wind; also marine, aerospace, energy storage

B&T Composites’ facility in Florina, Greece.
Photo Credit: B&T Composites

How has your company adjusted to or overcome challenges over the last year? “Our only way to go on was to think out of the box. We quickly modified our production into carbon fiber, high-end products. Our strength is also based on our cooperation with technical universities in Greece. We are lucky to have fruitful cooperation with the fields of mechanical engineering, material engineering, aerospace engineering and, recently, with photonics engineering, introducing a new smart composites series with optical sensors.”

How does your company employ Industry 4.0/data within your operations? “We have installed sensors in all production steps [controlling temperature, viscosity of the resin, fiber tensioning, humidity]. We also use sensors for preventive maintenance of our machines. Moreover, we have developed a tracking system with unique serial numbers for each of our products. With a serial number [QR code], we have all steps of production [raw materials, machines used, procedures, etc.] for perfect traceability for all of our products.”

How does sustainability factor into your facility’s operations? “We use solar energy for a high percentage of our electricity needs, including lighting for our production area and water heating.”

Bucci Composites

Response by Andrea Bedeschi, general manager (see full CW Trending interview with CW Editor-in-Chief Jeff Sloan here)

Location: Faenza, Italy

Date founded: 1988

Number of employees: 250

Materials: Carbon fiber composites

Processes: Hand layup/autoclave, infusion, wet layup, LP-RTM, HP-RTM, compression molding

End markets served: Automotive, motorsports, aerospace, marine, construction, industrial

What were the original goals of the company? “Originally, we started as a Formula 1 supplier particularly for Ferrari in Italy. Our first name was RIBA Composites, but in 2020, we changed the name to Bucci Composites, because last year was the 20th anniversary of the acquisition of RIBA Composites by the industrial group Bucci Industries. In that time, we moved to larger production in automotive and aerospace.”

How has your company adjusted to or overcome challenges over the past year? “The situation in Italy started out pretty badly [due to COVID-19], but now it seems like the situation is getting better, we hope. Business-wise, last year was not so terrible for us, because we were able to continue work on existing projects. A potential risk this year has been that many programs stopped development last year and those effects continue into this year. Starting about March of this year, OEMs are starting again to develop new products.”

What are your thoughts or expectations going into the rest of this year and 2022? “We have a lot of projects under development, especially in automotive. This year will be a transition year, but we expect next year to be a very good year. We’re also investing in new presses, and in 2022-2023, we plan to significantly enlarge the shop floor area to follow the company’s growth.”

Cecence Ltd.

Response from Samantha Bunyan, co-founder and head of industry engagement and sustainability

Location: Salisbury, U.K.

Date founded: 2014

Facility size: 24,000 square feet

Number of employees: 40

Materials: Rapid-cure, low-temperature, FST-compliant prepregs (woven carbon or glass fiber, recycled carbon fiber, natural fiber, phenolic/bio-resin-based materials)

Processes: Thermo compression molding

End markets served: Aerospace, rail, sports and recreation, defense, space

What sets your company apart? “Cecence is a close-knit team who pulls together to find the best solutions for our clients. Mutual respect across all levels of the company is important, and in the same way, as we drive innovation through collaboration with partners and customers, we encourage this internally, enabling members of the team to grow and develop as part of an interdisciplinary approach.”

UltraSlim aircraft seatback. Photo Credit: Cecence Ltd.

How has your company adjusted to or overcome industry challenges over the past year? “One of the positives is the ‘pause’ button pressed by the pandemic, offering an opportunity to push through R&D and new development programs. We have used this time to invest in a formulation lab and increased investment in sustainable materials and processing development.” With support from Innovate UK, the Temporary Sustainable Framework program and the KTN Women in Innovation program, new R&D includes development of an UltraSlim sustainable aircraft seatback incorporating recycled carbon fiber and bio-resin, and a sustainable aircraft tray table.

How does sustainability factor into your operations? “Cecence’s ambition is to be the market leader in lightweight, sustainable composite solutions for the mass transportation sector. We have always focused on manufacturing using low energy, rapid processing and increasingly have been able to feed in recycled carbon and natural fiber composites into our product portfolio.”

Champion Fiberglass

Response from Goran Haag, president

Location: Spring, Texas, U.S.

Date founded: 1988

Facility size: 110,000 square feet

Number of employees: 140

Materials: Fiberglass and epoxy

Processes: Filament winding, compression molding and a hybrid process between vacuum infusion and RTM

End markets served: Infrastructure, industrial

What can you share about your facility’s strategy for quality management? “We are one of the few in our industry that are both ISO 9001 and ISO 14001 certified and in a few months we will also be ISO 45001 certified [internal safety/OSHA].”

The company specializes in fiberglass conduits and fittings. Photo Credit: Champion Fiberglass

How does your company employ Industry 4.0/data within your operations? “We are moving strongly towards automation in many parts of our manufacturing. We will implement complete robotics in our entire filament winding units within a couple of years.”

How does sustainability factor into your operations? “We are just about to install the first part of a recycling unit that should be operational towards the end of the year. We have also installed a new water purification unit and we are working on reducing our overall water usage and try to recycle more where feasible.”

EPP Composites

Response from Jayraj Shah, managing director

Location: Rajkot, India

Date founded: 1986

Facility size: 850,000 square feet, with 10 plants

Number of employees: 1,500+

Materials: Glass fiber; polyesters, vinyl esters, epoxy, bisphenol; sheet molding compound (SMC), bulk molding compound (BMC) and dough molding compound (DMC)

Processes: Compression molding, injection molding, vacuum infusion, hand layup, RTM/LRTM/VARTM, multi-axis and continuous filament winding, hoop-chop winding, pultrusion

End markets served: Building/construction, infrastructure, industrial, oil and gas

What was the original goal of your company? “EPP was established in 1986 with the intention to develop its place in the composites market with a focus on corrosion-resistant product solutions for the industry, by introducing new processes and applications to replace conventional, metal-based product applications, and a strong commitment to quality and customer service.”

How has your company adjusted to or overcome challenges over the past year? “Though the past year has posed innumerable challenges, we have kept the continuity of all aspects of manufacturing to support our customers. Challenges have included availability of raw materials, slowdown of receivables and available manpower. These were mitigated to a great extent with calibrated action plans, including EPP’s automated production plan and ERP system that have been in place since 2008.”

How does your company employ Industry 4.0/data within your operations? “EPP’s immediate roadmap to Industry 4.0 is in four areas: smart innovation, smart factory, smart solutions and smart supply chain. Actions underway include upgrades to capital equipment, redesigning workflows to require fewer experienced operators by replacing more information systems, automating the order process, improving product quality and shortening delivery times.”

GSE Dynamics Inc.

Response from Anne D. Shybunko-Moore, owner and CEO

Location: Hauppauge, N.Y., U.S.

Date founded: 1971

Facility size: 30,000-square-foot corporate headquarters/manufacturing facility, and 57,000-square-foot composites/machining facility

Number of employees: 80

Materials: Woven/unidirectional carbon fiber, quartz, E-glass, S-glass; toughened epoxy, polyester, cyanate ester, BMI; film adhesives; metallic and non-metallic core; carbon foam

Processes: Prepreg/autoclave, vacuum infusion, adhesive bonding, additive manufacturing, multi-axis machining, assembly, non-destructive testing, material qualification and quality conformance testing

End markets served: Defense, aerospace

What was the original goal of your company? “Daniel J. Shybunko founded the company in 1971. He was working as a structural engineer at Grumman Aerospace at the time and received support to open a small manufacturing company on Long Island that could function as a subcontractor for smaller structures. In 1978 he departed Grumman after 25 years of service and put all of his efforts into expanding GSE’s capability. GSE has demonstrated steady growth for more than 50 years with a broad range of experience on numerous complex structures that support our military operations.”

What are your thoughts or expectations going into the rest of this year/2022? “There continue to be concerns on the effects of COVID-19 in our industry, and currently our biggest concern is the procurement of raw material in terms of lead time and increasing costs. Our industry is also faced with workforce challenges as we look to train the next generation in manufacturing and technology. I am optimistic on all fronts — our industry is very driven to meet the needs of our customers and we will do what needs to be done.”

How does sustainability factor into your operations? “Within our manufacturing process, we are reducing our electrical consumption, improving power quality/factor/voltage, increasing our electrical system capacity, reducing unnecessary heat, improving the cooling capacity of our air conditioning and freezers and installing lighting with extended life, improved light quality and reduced energy consumption. We have also enrolled in a New York State program, Recharge NY, that provides electricity through hydropower to manufacturing companies.”

The Gund Co.

Response from Michael Moran, VP, business development

Location: St. Louis, Mo., U.S.

Date founded: 1951

Facility size: 12 manufacturing locations in five countries

Number of employees: 600-650

Processes: Compression molding, hand layup, RTM/VARTM, autoclave, injection molding, filament winding, CNC machining

End markets served: Electrical, aerospace, medical, transportation, oil/gas

Gund Co.’s on-site CNC machining center.
Photo Credit: Gund Co.

What was the original goal of your company? “The Gund Company is a third-generation family business established in 1951 by Ed Gund. The business started as a manufacturer’s representative organization for electrical insulation composite materials. Some 25 years later, with son Paul Gund on board, The Gund Company began to distribute and fabricate composite materials. Rich and Steve Gund joined in the 1990s and continued to focus on expanding fabrication and manufacturing capabilities. Since then, the company has grown into one of the largest manufacturers and fabricators of composite, thermoplastic and elastomeric materials.”

What sets your company apart? “We offer more than 300 standard products, but enjoy the opportunity to work closely with engineers to design new products for specific applications. Engineers appreciate the rapid prototyping and testing that we can provide to help speed up their projects. The Gund Company has extensive composite testing capability and development engineering resources available to assist customers with new projects. The Gund Company has always taken an application engineering approach to the business. We want to understand the application, so we can provide solutions for our customers.”

Oribi Manufacturing

Response from Matt Christensen, chief commercial officer (see full video interview with CW Editor-in-Chief Jeff Sloan)

Location: Commerce City, Colo., U.S.

Date founded: 2008

Facility size: 50,000 square feet

Number of employees: 60+

Materials: UD continuous fiber-reinforced thermoplastic tape; glass or carbon fiber; PP, PET, PEEK, PEKK, LMPAEK, PA6, PA6/6, PA12, PPS

Processes: All processes are developed in-house, including automated tape layup, blank consolidation, forming (hybrid process between thermoforming and stamp forming), CNC trimming/waterjet, light assembly

End markets served: Aerospace, industrial, medical, personal protective equipment (PPE), sporting goods, transportation, unmanned mobility, renewable energy, oil and gas

What sets your company apart? “Unlike many in the composites industry who started with thermosets and then migrated to thermoplastics, we’ve focused only on thermoplastics over these last 13 years. Our founder, Jack Wilfley, developed automation and robotics for the production of continuous fiber thermoplastic structures and components. This combination provides very fast cycle times for composite component production and this is what really sets Oribi apart. We approach every project with what we call a rate-target approach. Often there is a chasm where clients want to transition to composites, yet they require very high volumes along with price points that historically push composites out of reach. Oribi helps clients transition to composites through creative engineering and high-volume manufacturing within a cost structure that makes U.S. manufacturing competitive once again. Oribi has continued to build on this premise over the last 13 years.”

How has your company adjusted to or overcome challenges over the past year? “We’re feeling optimistic. The last year has been a challenge for most everyone; fortunately, we rely on automation and robotics so heavily, the impact on production was minimal in comparison to other industries. That said, we have fantastic employees that stuck with us through the challenging situations and have enabled Oribi to support our customers and keep things moving. Especially when we support critical customers within the energy, military and law enforcement sectors, there are no acceptable supply chain gaps — we have to keep product moving.”

What are your thoughts or expectations going into the rest of this year/2022? “As we look forward into 2022 and beyond, we’re looking into a wide variety of markets which can benefit from our processes, materials and U.S. manufacturing footprint. For example, we have developed wheels for the transportation and powersports market and are putting more focus within the UAV/UAM market. This past year has certainly affected major markets like aerospace, but we anticipate growth for the composites industry as a whole through 2022 and beyond.”