Sapa Group - Shape Magazine 2009 #1

Shape A magazine from the Sapa Group • # 1 2009 › BRIGHT FUTURE FOR LIGHTING DESIGN › THE ARTIST WHO SWITCHED FROM PAINT TO ALUMINIUM › NEW SURFACE FINISH STOPS CORROSION › SOLAR-POWERED BILLBOARD SAVES ENERGY windS OF CHANGE SAPA ON CONTRACT FOR WORLD’S BIGGEST WIND FARM 8› PAGE # 1 2009 SHAPE • 1

CONTENTS #1 Closer to you Aluminium profiles are becoming increasingly popular in the furniture and lighting industry. Optimised design using S 03 apa is expanding into new markets. We are recruiting tal- aluminium profiles can deliver savings ents of all nationalities and growing stronger internationally of up to 50 percent in manufacturing to help our global customers even more with their specific costs, according to Sapa in Spain. needs. Our presence in 29 countries enables us to work more closely The world’s largest ocean-based wind with customers during every stage of development. Together, we farm is being built in the North Sea. can solve the challenges of making products designed specifically 08 The wind farm consists of 80 turbines for your market. that will start generating electricity Making customised products can be a complicated business. in autumn 2009. We are well aware of the efforts that are required to create clever solutions. A close working relationship between suppliers and customers helps achieve this. That is why, wherever you are, we Geometric art works created from aim to be there too, for instance through Sapa’s three global busi- aluminium profiles have become the ness segments – Mass Transportation, Thermal Management and signature of Lars Erik Falk. Automotive. 11 “I didn’t want to use a beautiful Finding ways to reduce CO² emissions is one of the automo- material … it detracts from the impact tive industry’s greatest challenges. Pressure is on the industry to of the composition,” he says. produce vehicles that consume less fuel and emit less CO². One solution is to build lighter, aluminium vehicles, since they use less fuel and release fewer CO² emissions than heavier, steel vehicles. Sapa’s contribution is to increase the share of aluminium parts. Sapa’s business segment managers talk One of our customers, Audi, was one of the first car manufac- about globalisation and the benefits of 14 turer to produce an aluminium car. Today we have the technology working closely with customers. Early to serial produce aluminium cars and most vehicle manufacturers involvement right from the design stage are moving towards using more and more light-weight aluminium can be the key to a successful solution. in their vehicles. At Sapa, we are working hard to not only facilitate the manufacturing of aluminium cars, but to find ways to do so at a reasonable A new surface treatment for the car cost. Investing in such activities is especially worthwhile when the 18 industry from Sapa Components gives world is looking for solutions to environmental problems. aluminium parts better protection from Our goal is to develop an aluminium solution suitable for your corrosion due to alkaline chemicals. business, no matter what industry you are in, or where you are located in the world. Let Sapa add value to Editor-in-Chief: Eva Ekselius Sapa is an international indus- Editor: Anna-Lena Ahlberg trial group that develops, your business by making Graphic design: manufactures and markets it our business. value-added aluminium profiles, Karin Löwencrantz Production: OTW Publishing profile-based components and Printing: Strokirk-Landströms, systems, and heat exchanger strips in aluminium. Sapa has Lidköping, Sweden Changes of address: Customers annual sales of approximately SEK 35 billion and roughly should inform their contact person 15,000 employees in compa- at Sapa, employees their sal- nies throughout Europe, and in ary department and others the North America, Central America Communications Department on Ole Enger, and China. Shape is the Sapa +46 (0) 8 459 59 00. President and CEO Group’s customer magazine, and is issued twice annually in 14 languages. Shape is also available at www.sapagroup.com Shaping the future 2 SHAPE • # 1 2009

DESIGN Aluminium has many properties that make it suitable for furniture and lighting. it is strong, practical, BRIGHT weather-resistant – as well as aesthetically attractive. Sapa Profiles in Spain has chosen FUTURE to invest in the furniture and lighting industry by working closely with customers right from the design stage. for aluminium ›

DESIGN › SHAPE ASKED A FEW OF SAPA’S CUSTOMERS IN I t may seem remarkable today, but in the early 20th century, before aluminium began to be used industrially, it was regarded as an expen- THE LIGHTING sive and exclusive material, and was often used by designers and artists of that period. Today, this once exclusive material has INDUSTRY WHY THEY become a utility material thanks to improvements in technology. As a result of growing general interest in interior design, aluminium USE ALUMINIUM PROFILES. has also become more relevant in high-quality applications where design, innovation and aesthetics are important factors. Nowadays aluminium is more often associated with futuristic concepts and high-tech design, which makes it a prime candidate for the manufacture of furniture and lighting. SAPA IN SPAIN has seen increased use of aluminium profiles in the furniture and lighting industry, and is strongly committed to the industry and its cus- industrial aspects; they have to combine aesthetic, Ataro, made from a continuous aluminium profile. tomers. In Spain alone, production in the furniture production and technical requirements.” and lighting industry rose by 10 percent in 2007, Sapa Profiles in Spain offers a collaborative part- compared with the previous year, and exports nership with customers in order to develop practi- climbed by 22 percent between 2006 and 2007. cal solutions together. The plant in La Selva has The combination of good design with the vari- specialist expertise in this area, and Sapa has recent- ous advantages of aluminium can create numerous ly opened a new application centre for research and benefits. development in Navarra, where customers can get “Good design should not make the end prod- advice from experts and engineers during the product more expensive – just the opposite. A well- uct development phase. One of the companies designed product can instead be cheaper to make,” with which Sapa has entered such a partnership says Raquel Fernández Campaya from the market- is the lighting company Ornalux, which among ing and communication department, adding that other products, makes advanced lighting for hospi- optimised design can cut manufacturing costs by tals, trade fairs and exhibitions. as much as 50 percent. “Working with our customers right from the design stage is important, as it means we can BECAUSE ALUMINIUM is recyclable it enables practi- contribute our experience from the outset,” says cal design to be combined with ethical values. It Matteo Luppi, managing director of Sapa in Spain. is also possible to integrate several functions in a “In future we aim to become an integral element single profile, making production more efficient, in the client’s value chain, in order to provide a glo- which can ultimately lead to a product that is even bal service. We offer collaboration in the design of more innovative and attractive, explains Raquel profiles, mechanical solutions and surface finishes, Fernández Campaya. so that customers can concentrate on their core “Designers today cannot focus solely on the business – design.” elegance of the finished product and ignore the TEXT JESSICA JOHANSSON “Good design should not make the end product more expensive – just the opposite. A well-designed product can instead be cheaper to make” 4 SHAPE • # 1 2009

3 1 Hoffmeister Leuchten GmbH in Modular Lightning Germany manufactures, among Instruments in the other things, utility lighting Netherlands produces inno- products for architect-designed vative lighting designs for indoor and outdoor settings. concert halls, private homes Frank Lesch, purchasing and offices. Tom Samyn, marketing manager, manager, replies. answered as follows. why do you use aluminium profiles in your why do you use aluminium profiles? “Aluminium profiles are incredibly versa- products? “It’s the best solution for creating lamp hous- tile, which is essential for products that are Bibox spotlight. ings with the same cross-section but in different ordered by length. Modular uses 15 different lengths. Aluminium profiles are also light, and with aluminium profiles, each with a unique design. an anodised finish you also get good corrosion It’s not just the visible shape of the profile that Have you encountered any challenges in pro- protection. We use aluminium profiles for indoor is important, but also the internal channels, ducing furniture and lighting in aluminium? and outdoor lighting, and for lighting tracks.” “The main challenges in the design of new lamp which are part of the design of the profile and housings lie in meeting the designer’s requirements help to make installation easier.” what are the benefits? “Aluminium profiles are light, they’re easy to for thin walls and creating new, contemporary what do you use the material for? machine and they have good thermal conductivity.” shapes in the manufacturing process.” “Aluminium profiles are used in our light profiles business area. This division specialises in products that are ordered by length. We start with aluminium profiles with a maximum length of six metres. We cut the profile to the desired 2 length and make holes for mounting different The Waldmann Group is one of types of light sources. Each order is unique, the leading lighting companies in with different designs, lengths and configura- Germany, and designs lighting for tions.” offices and the workplace, as well what are the benefits of this material? as medical lighting. We talked to Aluminium is an incredibly flexible material. Wolfgang Auber, marketing manager. It can also be 95 percent recycled, which is an increasingly important factor due to concerns over the environment and sustainability.” which products do you use aluminium profiles for, and why? what do you see as the biggest trend in “For desk lamps, floor lamps and industrial lighting products at the moment? lighting. Aluminium profiles are high-quality “Right now it is fashionable to use coloured materials with a long life and excellent thermal aluminium profiles. White and black profiles conductivity, which is especially important when are very trendy, whether they are anodised or lamps are fitted with LEDs.” lacquered.” what are the advantages of this material? “We buy in semi-fabricated profiles and it’s relatively easy to add other components, using screw fasteners or by bonding, for example.” what quality requirements do you impose when choosing materials for a new product? “Long life, the right material properties for each application, the ability to apply surface finishes in different colours, manufacturing requirements, the ability to recycle the material, and materials handling requirements for production.” what was the main challenge with your new Ataro lamp? “The challenge lay in bending the long aluminium profile and thus creating a one-piece aluminium frame without joints.” Lighting profiles for offices. # 1 2009 SHAPE • 5

DESIGN Etherea office lighting. Products from Ornalux in Spain include high-tech lamps for hospitals, official buildings, exhibitions and office environ- ments. We spoke to Isabel González de los Reyes, co-ordinator. why do you use aluminium profiles? “The main characteristic of the material is its flexibility – it’s possible to shape aluminium in so many different ways. You can produce a great variety of finishes to suit the image you want the product to convey and its intended purpose. The material also enhances designs; it is hard-wearing and completely recyclable.” which components do you use aluminium for? “For any components that have a regular cross-section, where we can exploit the mechanical properties of aluminium, such as its thermal conductivity, light weight and ability to take an anodised finish.” what are the design benefits of extruded aluminium? “It’s a material that stands for elegance, practicality, quality and concern for the 4 environment.” How have you benefited from Sapa’s services? “Sapa have made constructive sugges- tions that have improved our design.” 5 Imperial is a lighting manufacturer that has a market lead in Poland and sells a product range that extends to over 2,000 different lighting products. Export manager Bartłomiej Družba replied as follows. For which products do you use aluminium profiles? “We’ve designed our own aluminium profiles and we use them to produce the lamp housings for our Profi range of products.” what are the current trends in lighting in the Polish market? “The Polish lighting market has grown in recent years. Poland follows all the European trends in lighting. Suspended and recessed light fittings for T5 light sources with housings made from aluminium profiles are very popular. LED lighting is also popular.” what are the benefits of aluminium? “The most important benefits are reductions in product weight, better cooling for electronic components and all the design possibilities.” 6 SHAPE • # 1 2009

BRIEF NOTICES Designer shade and shelter > In the hotel and outdoor restaurant business they’re known as “jumbrellas” – those ultra-sized umbrellas or parasols that offer shelter from sun and rain. Take the Bahama Largo by the German manufacturer Becher Textil- & Stahlbau GmbH. A single unit provides up to 64 square metres of outdoor roofing. Unfolded, it can withstand wind gusts of up to 130 kilometres per hour. It looks like a stylish tulip, with built-in lighting and manoeuvring gear drive, and it can collect rainwater inside, draining it directly into the sewage system through the centre pole. Becher Textil- & Stahlbau has more than 30 years of experience in processing and even welding aluminium. The company appreciates Sapa’s reliable deliveries, readiness and flexibility to meet technical requirements and its ability to under- stand a customer’s particular needs. Finland’s Partnership aluminium delivers the mail boom > A letterbox in each door – rather than mailboxes at the entrance – has been the norm for apartment blocks in Sweden for some time. But > For decades, wooden interior wall this is about to change as a new company, Blockbox, aims to offer a totally systems and partitioning systems new alternative to the basic solutions that have been available so far. were the rule in Finland. But when things “We want residents to feel that home begins at the entrance to their apart- started to change, Finnish interior build- ment block,” says Markus Berglund from Blockbox. “In an age when interior ing and construction specialist Muotolevy design is so important, it’s only natural to expect a touch of elegance in the Oy didn’t want to be left behind. stairway.” “Architects love aluminium,” says Mika Kujanpää, sales manager for interior wall Blockbox mailboxes are available in a choice of styles, with replaceable systems. “Aluminium systems have been growing for years and are now at least as components. The company has given a lot of popular as wood.” attention to the design of the boxes, Muotolevy soon realised that a tailor-made design was needed to meet the even ensuring that the sound they requirements of sound isolation and flexibility. make is muted when opened and “Our cooperation with Sapa has been successful and we got a lot of valuable closed. advice when developing our product,” says Kujanpää. The Swedish post office’s requirement for central locking and architects’ requests for a modular Did you know that ... design were naturally taken into account at the design stage. … if the weight of aluminium cans Blockbox developed the range using aluminium profiles, in order were reduced by five percent it would to keep the investment and tooling costs to a reasonable level. “Sapa have been a valuable cut carbon dioxide emissions by 78,000 sounding board throughout the development process,” says Markus Berglund. tonnes in the European market alone. “Aluminium profiles make it easy to develop modular solutions. We can extend the width and height as required. And of course Sapa can supply an enormous variety of surface finishes, so we Source: Aluminiumriket can create a wide choice of variants based on just a few components.” (A Swedish aluminium business association) # 1 2009 SHAPE • 7

ENVIRONMENT SAPA COOLS NORTH SEA WIND FARM The biggest ocean-based wind farm is currently being constructed in the North Sea. ABB has the task of linking the new wind farm to the German grid – a task that requires effective water cooling. “Continuous improvements are being made in the water-cooling system and Sapa have an active role in this,” says Pontus Mellung, who handles purchasing from Sapa at ABB’s HVDC division in Ludvika, Sweden. G erman energy company eon is responsible status and any faults is sent to a manned centre According to Tommy Lövehagen there is a great for constructing the wind farm that will onshore by fibre optic communication links.” deal of optimism about offshore wind farms: supply power to the German grid. The On the platform, electricity from the wind “It’s the first time such a big installation has output from the wind farm is equivalent to that farm is converted from alternative current been built offshore and it’s important that it is of the average coal-fired power plant, or half a to direct current and then fed by cable to an successful. This is a growing market and we’re Swedish nuclear plant. onshore receiving station, where it is converted working very hard to establish a strong position abb’s role in the project is to transfer power back to ac. in this field. We also have a unique technology from the wind farm. This is one of the biggest for this type of project.” single contracts for abb in 2007, with a value of ELECTRICITY IS CONVERTED at either end of the cable TEXT MATS LUNDSTRöM sek 2.7 billion. The contract is for an hvdc Light by converters known as valves. This process gen- system, a transmission technology in which abb erates heat, which has to be carried away by cool- has a strong lead. ing profiles made by Sapa in Finspång, Sweden. The wind farm in brief “It is proven technology, but this is the first “The high precision that is required for effi- time we are using it on our own offshore plat- cient cooling is achieved using profiles that are • The project is called NordE.ON 1 and the instal- form with an unmanned operating centre,” joined by friction stir welding (fsw),” says Rolf lation is located 128 kilometres off the North explains Tommy Lövehagen, overall project Pettersson, sales representative for cooling pro- Sea coast of Germany. manager at abb. files at Sapa. • The wind farm is made up of 80 wind turbines “This requires other solutions, since offshore A large number of water coolers of different that will be brought into operation in autumn installations increase the types are needed to keep temperatures down. 2009 and will have a combined output of need for automation and Sapa therefore maintains close contact with abb 400 MW. communications. The so that products can be continuously developed. • There are plans to build further large clusters of platform is 128 kilometres Numerous other aluminium products are also wind farms, with each cluster consisting of sev- offshore. We have to be able being supplied for the project. en to eight wind farms. The clusters are called to carry out most of the “We’re working together to develop new prod- Borkum 1, Borkum 2, Helgoland and Sylt. inspection and maintenance ucts and to refine existing ones. A team from abb • Germany is investing heavily in offshore wind without travelling out to the meets up regularly with representatives of Sapa,” power. By 2020 the total output is expected to Tommy Lövehagen platform. Information on says Pontus Mellung. be 12,000 MW. 8 SHAPE • # 1 2009

DENMARK BORKUM 2 Sylt 128 km helgoland NORDEN Cuxhaven Borkum Emden Wilhelms- Bremerhaven haven DIELE NEThERLANDS GERMANY # 1 2009 SHAPE • 9

BRIEF NOTICES 15,000 Pneumatic elevators cans were used to build break new ground a 12-metre tall model of the Eiffel tower, > A pneumatic elevator – sometimes called a pneu- which was exhibited matic vacuum elevator – is like a crystal tube containing a cabin that at the Aluminium 2008 travels up or down to the desired level through no visible means trade fair in Essen in of propulsion. Air, or rather the absence of air pressure, silently September. lifts the elevator to an upper floor, and atmospheric pressure gently pushes it back down to the ground Source: Aluminiumriket (A Swedish floor. A pneumatic elevator uses aluminium business association) a small amount of regular-voltage electricity on the way up and none First project for at all on the way down. This new kind of elevator, which unitised curtain wall was initially developed about 10 years ago, is rapidly gaining market share in single-family houses. The > Sapa Building System has won a project for new offices at the installation takes up no more than a square meter of space and doesn’t require Polish Academy of Sciences in Warsaw. It is the first application for a pit or a machine room. The devices are easy to install and you can even take the new unitised curtain wall. them with you when you move. A unitised curtain wall is a facade of panels – made of aluminium pro- Elevadores Neumáticos Ibéricos S.L. is a manufacturer building up a solid files – and glass that is put together in the factory and then installed on position in Spain and Portugal after just two years in business. Sapa supplies the building at the site. With the unitised system, the lead times at the site the aluminium profiles – bent, machined and finished according to Elevadores can be reduced substantially. Neumáticos’ own design and specifications – which are used for the tube’s “The first order is the ultimate test of all features of the unitised curtain frame, including rings and clasps. wall,” says Hans Johansson, business area president, Sapa Building System. On the right track > Switzerland-based Montech is a world leader in the automation of complex production and intralogistic processes. Its successful Montrac modular transport system, widely used across the world and industrial fields, relies on a monorail track made of clear anodised extruded aluminium supplied by Sapa. A wide range of standardised components, such as curves, shuttles, lifts, crossings and switches, allow a variety of layouts and configurations according to the customer’s needs. Since the length of these rail systems can amount to hundreds of metres of track, supporting an intense traffic of moving parts, extreme precision and a high resistance to torsion are required. “Aluminium profiles with a perfect and sustained quality level and a positive visual impact contribute a lot to the success of our products,” says Marco dal Maso, purchasing manager at Montech. 10 SHAPE • # 1 2009

PROFILE PHOTO: ANDERS BARKFELDT LARS ERIk FALk It was when his name appeared in Sweden’s National Encyclopaedia that Lars Erik Falk realised he had become a part of Swedish art history. Now he has written a book about life and art, › and a little about aluminium. # 1 2009 SHAPE • 11

› PROFILE H “If I don’t use paint, I use wax to create a slight is creations are geometric, often constructed using the same equal-sided, L-shaped sheen. I rub in car wax, and it turns out that Sapa aluminium profiles from Sapa. The racks in his attic studio does the same when they want a slight gloss” support metre after metre of the raw material. “My work isn’t based on real life. Instead I use the aluminium profiles to build my own reality. My sculptures are called modular I work at all. But I feel there is room for differ- He calls himself a constructivist, since he does not sculptures and modular reliefs. The modules are ent lines of attack.” portray what he sees around him, but creates his identical all the way, so I can build whatever I He always makes meticulous drawings first. And own worlds. want,” says Lars Erik Falk. he recommends younger artists to burn everything He has remained loyal to constructivism His studio is simply the top floor of the house they are not happy with, as he has done himself. since he first encountered it. In the 1940s he that he and his wife Margit have shared for dec- studied painting under ades. The walls are covered with drawings signed the Swedish artist Isaac MAGNUS GLANS by his children and grandchildren. Lars Erik has at Grünewald, who was least three work benches. When one becomes too infuriated by his student’s cluttered he simply moves to another. A bookshelf interest in the abstract. houses a personal library of books on constructiv- “SO, YOU’RE CREATING a new ists such as Olle Baertling, who always instructed reality – is this one not good taxi drivers to take an extra turn around Lars Erik enough for you?” Falk’s sculpture at Hornsplan in Stockholm. “The answer is that I hIS STUDIO IS FILLED WITh machinery and tools, since want the freedom to do he builds his sculptures himself. what I want; I don’t need “Obviously some of them won’t fit in here, as to spend my time paint- they can be twelve metres high. So I build them at ing people. That doesn’t a boatyard,” he says. mean that I set myself There are books and paintings on the stairs lead- above those who paint ing to the top floor. He has just completed two figuratively. A friend and I exhibitions, one in Stockholm and another in his often sit and philosophise hometown of Sigtuna. about the difference. We’ve “It’s hard work, you have to meet people and come to the conclusion sign books and hold an opening exhibition. I may that it doesn’t matter how also have an order for a public artwork, but I can’t it looks, as long as the art is talk about that yet; it’s too early. You often get good,” he says. enquiries, but then there’s so much bureaucracy that it can sometimes fall apart. So I’ll probably get ALThOUGh hE DESCRIBES contemporary art in his to grips with that once I’ve had a little time off.” book as “young women His new book Life/Art Lars Erik Falk is mostly with figurative period self-biographical. Many unsuccessful artists passed pains”, he is more diplo- through the doors of the cut-price hotel that Lars matic in real life. Erik’s father owned in Uppsala. Sometimes his “My approach isn’t at all father had to accept paint in lieu of payment for intellectual or about work- hotel bills that never were paid. His parents were ing with installations. You sceptical of his artistic ambitions, and as a result his know, the idea of setting a debut came later than usual. His first independent tiger trap and creating an exhibition was in 1952. Lars Erik Falk is one of few Lars Erik Falk’s distinctive leaning profiles, seen here on Karlavägen in interior. That’s not the way artists who has not followed trends and fashions. Stockholm. 12 SHAPE • # 1 2009

MAGNUS GLANS These 16-metre tall aluminium profiles reach for the sky from the platform at Kista underground station in Stockholm. Lars Erik Falk also chose the colour scheme for the entire station. “I’m glad I did. It’s no fun to see work that’s minium, the material that has since become his not good. And it’s immoral if people buy it for signature. The artist in close-up good money.” “I didn’t want to use a beautiful material, Lars Erik grew up in an environment that was which is not to say that aluminium is ugly. If social democrat in every respect. His sons were you use copper, it is beautiful in its own right. It active in the radical student movement of the late detracts from the impact of the composition.” 1960s, and Lars Erik designed posters in protest You can also paint aluminium. Lars Erik’s against the commercialisation of Christmas, sculptures are often painted in bold, primary among other things. colours. It’s a time-consuming job to get the finish just right, which he does himself. hOWEVER, hIS OWN art carries no political or emo- “If I don’t use paint, I use wax to create a tional message. slight sheen. I rub in car wax, and it turns out “It’s easier to write about that than to paint that Sapa does the same when they want a slight Born: 1922 in Uppsala, Sweden. it. I also feel that art takes place in the eye of the gloss,” he says. Trained: By Otte Sköld and Isaac Grünewald. beholder,” he says. Studied graphic design at Beckmans College The constructivists are a small group, with a ALUMINIUM IS ALSO IDEAL in another respect. It of Design. It took until the 1980s to make a liv- not entirely fashionable perspective towards art, works well on a large scale. ing from his art. in an age when controversial photo-art and dia- “It’s part of my approach to art, that I see Family: Sons Hans, Johan and Gunnar, with mond-studded skulls are in the media spotlight. and express the full extent of the images I work his former wife Kerstin, and son Mikael with his “There’s so little left when you distil a theme with. I’ve naturally pictured in my head how it present wife Margit. as I do, so what remains can sometimes be per- would look if it were full size. But there’s still an Home: Sigtuna in Sweden. ceived as cold. But we have a passion like any element of uncertainty. Will it be good? Will it Other interests: Enjoys reading proletar- other artist.” appear as I hope? How will it be received? It’s ian authors; the books he has most enjoyed From painting the Uppsala plains in the hard work, and it keeps me awake at night. I’ve recently are those of Elsie Johansson. 1940s, he progressed into cubism and geomet- never been disappointed yet, but it’s still just as Favourite work of art: A cardboard guitar by ric cardboard figures, when painting became difficult every time.” Picasso. too two-dimensional. Then he turned to alu- TEXT EMMA OLSSON # 1 2009 SHAPE • 13

INSIGHT: BUSINESS SEGMENTS THrEE mArkETS – ONE PHILOSOPHY Sapa Profiles’ three strategic business segments serve three different markets but share one philosophy: to move the operation from the supply of profiles to the delivery of solutions. SAPA PROFILES’ BUSINESS SEGMENTS have been estab- philosophy that drives the business forward. teams of sales, marketing and technical experts lished to harness the Group’s global resources in All three are challenging markets, and to in the markets, developing specialised knowledge order to meet the specific requirements of cus- become part of them, Sapa has recognised the and a close understanding of how the key players tomers in the automotive, rail and marine, and need to become much more than simply a sup- work and exactly what they want from their sup- telecoms and electronics industries. Although plier of aluminium profiles. One of Sapa’s key ply partners. The key objective that the business quite different markets, they share certain charac- strategic pillars is customer intimacy: each busi- segments share is to add value and move from sup- teristics that have enabled Sapa to develop a single ness segment has set itself the task of immersing plying profiles to delivering solutions. Victor Schneider Tolga Egrilmezer Lars-Inge Arwidson Lars Forsberg 14 SHAPE • # 1 2009

Matching global footprints A key feature in the business segments’ markets is globalisation. and the next we might be visiting an Asia- Pacific shipyard. “The major players in each segment operate globally and look “In rolling stock there is growing emphasis for supply partners that can match their global footprint,” says Lars on public transportation, and we’re seeing major developments in everything from trans- Forsberg, head of business segments. continental high-speed trains to tram and metro networks. “OUR BUSINESS SEGMENTS build one-to-one rela- “If we’re working with our customers from “Some significant high-speed train projects tionships with customers and identify design the outset, we can carry out the necessary are coming up in North America in the next 10 and supply solutions, then operate across all thermal calculations to arrive at the optimum to 15 years, and aluminium is still in its infancy Sapa territories to ensure a seamless supply design,” Arwidson says. “Take heat sink devel- in this market,” Egrilmezer says. “We need to operation when and where in the world the cus- opment: with involvement at an early stage, we be able to talk to our customers’ customers to tomer wants it,” Forsberg says. can advise the customer how best to design for encourage the specification of aluminium.” Forsberg has overall responsibility for two maximum efficiency to extend component life. business segments, Sapa Thermal Management with Alcoa has had a major A jOINT VENTURE and Sapa Mass Transportation. encompass any application impact on the size and structure of Sapa “OUR MARKET CAN Sapa Thermal Management, with its roots in where you need to get heat away from elec- Profiles’ business. “Shortly after the formation the telecoms industry, began by working with tronic components. We’re looking to build on of the joint venture there was a major strategic Ericsson on enclosures. When a push from the our established base in telecoms where we’ve review, and we committed to growing our market drove production towards Asia, Sapa set developed expertise alongside market leaders business by 150 percent,” Forsberg says. “To up a manufacturing facility in Shanghai. like Ericsson and Nokia, into applications such meet this target, it is essential that we bring the Sapa Profiles business segments work as part as power, consumer products, windmills and right people on board – people who have direct of the customer’s design and development team, hybrid drives.” industry experience and technical experts who which they describe as engineering in partner- Sapa Mass Transportation is the smallest can help us build close relationships with our ship. “As an integral part of the customer’s segment with the biggest global ambition, customers by combining their specific industry design team, we can help produce better solu- segment manager Tolga Egrilmezer says. knowledge with Sapa Group’s wider compe- tions,” says Lars-Inge Arwidson, Sapa Thermal “One week our team can be working on a tence. This will enhance our value offering to Management’s manager. high-speed passenger train project in Europe, customers across the globe.” # 1 2009 SHAPE • 15

INSIGHT: BUSINESS SEGMENTS SPEAkinG the automotive language build a strong automotive network inside The automotive industry plays an important part in Sapa’s growth Sapa’s operating companies around the world strategy, and changes in the market offer major opportunities for Sapa to enable them to relate to the industry in Automotive. Environmental issues call for a new approach to their regions. We are developing people who know the automotive business, who speak the design, and extruded aluminium is an ideal materials choice. customer’s language and know the customer’s expectations.” VICTOR SChNEIDER, vice president Sapa Auto- Sapa Automotive’s approach to the market is motive, has joined the business with a 25-year based on customer value management, work- ThE AUTOMOTIVE INDUSTRY is not only globalised track record in the automotive industry. A ing closely with customers from an early design but also very standardised. “To be a key supplier mechanical engineer by profession, he has stage to ensure that the optimum solutions are to the automotive industry it is not enough to worked in the automotive industry in the identified. Key account managers are supported simply offer good technology or product inno- United States and Europe, spending the last 10 by dedicated engineering experts. “Our mission vation,” Schneider says. “We must also under- years with a Tier 1 supplier in France. “Light is a total focus on the automotive industry, and stand the way in which the industry as a whole weight design is a major driver towards the we have developed an engineering competence works. It is an industry that expects all the play- reduction of fuel consumption for lower co2 dedicated to that market,” Schneider says. ers to work to the same sophisticated manage- emissions,” he says. “Aluminium is an ideal ment procedures and standards. These systems material for both cars and trucks because of its FROM ITS STRONG position in the Nordic market, are the baseline of good business development excellent weight-to-strength ratio, good corro- Sapa Automotive is now embarked on a and are part of the automotive ‘language’ – the sion resistance and ease of processing. With our strategy to extend its automotive business language that Sapa Automotive is committed technological know-how and manufacturing model globally. “To achieve this we have to to speak.” capabilities we are confident that we will be able adapt ourselves and develop our organisation TEXTS LINDA TROTMAN to offer more and more innovative solutions for to reach new customers in other regions,” PHOTO ED SHAW a wide range of automotive applications.” Schneider says. “A key to our success is to 16 SHAPE • # 1 2009

A tent protects workers and the bridge structure during repairs. GIANT TENTS ENABLE FLEXIBLE CONSTRUCTION A lightweight material that is easy to erect and easy to form – these were the main criteria that made aluminium profiles the choice of Norwegian company OB Wiik, for its storage tents and weather protection. ITS hEADQUARTERS ARE located in Norway, but OB a better working environment for the builders. Aluminium profiles are also used as the sup- Wiik sells its products all over the world – at “The weather protection is designed to meet porting structure for some of OB Wiik’s storage the South Pole, in Siberia, Malmö, Oslo and the market’s high demands for flexibility. The tents – a flexible alternative for those who need Hamburg – wherever there is a need for tempo- framing system for the walls and roof is built to be able to erect and dismantle storage facili- rary storage or to protect building projects from using an aluminium beam that Sapa machines ties quickly. the wind and weather. and assembles according to our specifications,” “We’re seeing growing demand for this type “Moisture during the building stage is one of says Lars Dalgaard. of warehouse facility. In many cases it’s a better the biggest problems for the building industry solution than a traditional building, especially if today. That’s why we build more and more hE EXPLAINS ThAT steel was the first choice of you’re unsure how long you’ll need storage for, under cover. Demand from building contrac- material for this type of structure for a long or if you don’t have the resources to buy a per- tors and developers is growing,” says Lars time, but in the last five years OB Wiik has manent warehouse,” says Lars Dalgaard. Dalgaard, managing director of OB Wiik. increasingly been using aluminium. Reduced Once again aluminium is increasingly replac- The product that makes this possible is weight is naturally one of the benefits, but Lars ing traditional steel-framed solutions for this weather protection, which basically consists of Dalgaard also points out that aluminium is type of product. a tent that is erected over the building. It can be easier to form to precisely the shape you desire. “The biggest advantage is speed of erection. used for new builds and for roof replacement or “That’s important for us, as we’ve come up If a structure has to be erected and dismantled extensive renovation projects. As well as elimi- with a special design that makes it easier to several times, aluminium is the best choice.” nating damp problems this solution also creates attach the tent material to the frame.” TEXT SUSANNA LIDSTRöM # 1 2009 SHAPE • 17

TODAy’S TECHNOLOGy › The new coating from Sapa has been tested on roof rails, window surrounds and grilles, with good results. 18 SHAPE • # 1 2009

TODAy’S TECHNOLOGy WAR ON CORROSION cleaning. Strong alkalis degrade anodised automotive companies but not yet achieved Growing use of aluminium by aluminium coatings quickly, and the growing practically. Experimentally, Sapa has dem- car makers has increased the use of aluminium by vehicle manufacturers onstrated that 13.0 pH resistant coatings are has prompted intense development activity possible. vulnerability of vehicles to to address this issue. To give some idea of the As well as benefiting existing exterior alu- corrosive chemicals. But a improvement, Shaw says: “Standard alumin- minium car components, the new coating ium oxide films are usually stable between offers vehicle manufacturers the ability to use new anodising process a pH range of 4 to 8. The coating that we this lightweight and recyclable material more can boost the metal’s resist- intend to offer is in excess of 12.5 pH.” As widely. Cutting the overall weight of a vehicle the pH scale is logarithmic with a maximum ance by a factor of 10,000. saves fuel consumption and reduces carbon value of 14 for the strongest alkalis, the dioxide emissions. In addition, the resistant actual increase from 8.5 to 12.5 represents an aluminium coating also offers the attractive tough world for cars. improvement of a factor of 10,000. finish that is used increasingly in trim com- IT’S AN INCREASINGLY Even at the car wash, more aggressive clean- Details of the process are a closely guarded ponents. ing fluids are taking the shine off aluminium secret, says Tony Wall, sales director at Sapa The new coating has been tested on a components faster than ever before. To Components. “We had to overcome consid- number of automotive components such counter this attack, Sapa Components Ltd in erable technical hurdles,” he says “to achieve as roof rails, window surrounds and grilles Gloucester, United Kingdom, has developed a coating with the right physical characteris- with major car companies including General an enhanced anodising process that offers tics to deal with increasingly corrosive alkali Motors, Ford, Jaguar and Aston Martin. And a much-improved resistance to corrosive exposure. The two-year development project following the success of these trials, the com- chemicals on the market. adds an extra step to the anodising process, pany had its first volume product order with Anodising is a widely used surface treat- and Sapa has worked with its main chemical a major original-equipment manufacturer for ment for aluminium alloys that provides a suppliers to develop the new coating. “The finishing of a new exterior trim, Wall says. protective coating by oxidising the metal by make-up of the chemicals is key to the proc- Sapa has also set its sights on exploring the electrolysis in sulphuric acid. The benefits are ess,” Wall says. wider application potential of its new coating increased resistance to corrosion and wear, which it believes has great potential within all invested around £500,000 and anodising provides better adhesion for aspects of aluminium anodising sectors. One ThE COMPANY hAS in the development of the new process and paint primers and adhesives than bare metal. promising area is in the architectural market associated equipment and production facili- “The new anodising process consists of a for window frames. In the United States, one ties that have given Sapa “a two- to three-year new type of corrosive-resistant coating that aluminium window manufacturer is inter- lead over key competitors in the market- has the ability to inhibit the attack of alkalis ested in the extra protection the coating can place,” Wall says. Though a small number on the surface of the anodised aluminium,” give to products installed in coastal regions of companies across Europe claim to offer says Richard Shaw, anodising manager at where sea salt is a corrosion issue. a higher level of resistance, Wall says, “We Sapa Components (Pressweld). The kitchen appliance market is another believe we are the only company capable of sector where the new anodising process could has been developed in offering 12.5 pH resistance anodised finishes be of benefit for products such as dishwashers, ThE NEW PROCESS response to the automotive industry’s need in a variety of colours.” In addition, the com- cookers and washing machines where alkaline for more corrosion-resistant car components, pany’s development activities are aimed at cleaning products are commonly used, Wall particularly as aggressive alkali chemicals pushing this pH resistance towards the magic says. are used increasingly in high-pressure car figure of 13.5, which has been requested by TEXT ELAINE MCCLARENCE # 1 2009 SHAPE • 19

TODAy’S TECHNOLOGy A SUITABLE ALLOY excess metal shaving and increased speed and Furia. “Of course it’s not quite like lead, but When the EU banned lead accuracy. But two European Union regula- it is rather satisfactory and much healthier.” as an additive in aluminium tions passed by the European Parliament in Once Sapa had an alloy mix it thought 2002 and 2003, coming into effect in 2006 might work, it began testing the mix with a alloys, a plant in Italy set out to and this year, essentially prohibited lead as German client in the automotive industry to find a substitute. an additive in aluminium alloys. (Up to 0.4 see how it actually performed. The client was percent lead is still acceptable, but only if it’s so pleased that he has ordered 600 tonnes already present in recycled aluminium.) of the new alloy for 2009, notes Sannicolo. mix is like tailoring a “These edicts created significant problems “We would say that we have reached the 80 “CREATING AN ALLOY suit,” says Sergio Sannicolo, location manag- for our industry,” Sannicolo recalls. Sapa percent mark in terms of a solution to the er for Sapa Profili s.r.l. in Bolzano, Italy. Just would have preferred that the eu specifies a lead-free issue.” as custom suits are designed for the wearer, substitute alloy, but Brussels left it up to the the hard alloys used in the aluminium pro- NEVERThELESS, SAPA CONTINUES to work on market. So for the past several years Sapa files produced by the Bolzano plant have to the alloy to refine it. Research is ongoing at has focused on developing a lead-free alloy be suited to specific client needs. Since the the company’s research centre in Sweden to that would retain lead’s desirable properties. Bolzano plant specialises in profiles for auto- reduce the waste from metal shavings, as well After many months of research, the company motive and industrial applications (largely as improve quality control. Automotive proc- developed an alloy of aluminium mixed with hard alloy screw machine stock for mechani- esses are high speed and highly automated. If magnesium, silicon, copper, tin and bismuth. cal, electrical and electronic equipment), the a metal is of inferior quality, it threatens both The additives, notably the tin and bismuth, alloys it uses need to fit the requirements of the speed of output and the quality of the mimic lead in that they enhance the charac- those industries. final product. teristics of the alloy. Until recently, Sapa had used lead in its “We should always be striving for perfec- “The initial results were very good, just alloy mixes, because the addition of up to tion, no?” says Sannicolo. about as good as alloys with a lead additive, two percent lead helped enhance productivity and the shaving problem was handled well,” in the manufacturing process. Lead reduced says Sapa marketing analyst Claudio Del TEXT CLAUDIA B. FLISI 20 SHAPE • # 1 2009

BRIEF NOTICES One-stop supplier provides better terms > “Thirteen years ago, Hällde had three suppliers of aluminium profiles, but now we have just one: Sapa,” says Rami Riihimäki, purchasing manager for Hällde. Hällde is a Swedish manufacturer of catering appliances. With a number of key patents, the company has achieved a global lead in the development and manufacture of vegetable slicers and other food processors. Its products are sold in over 80 countries around the world. These professional appliances are in a class apart from everyday household appliances. Hällde appliances have a reputation for efficiency, safety, ergonomics and performance. “The Hällde range of appliances is built around housings made from aluminium profiles supplied entirely by Sapa, and thanks to the high volumes, Sapa have been able to offer us a com- plete, cost-effective solution,” reports Rami Riihimäki. Two at the top > Two important commercial projects in Portland, Oregon, have won third place in the 2008 “Daily Journal of Commerce” Top Projects Awards. The Atwater Place condominium in Portland boasts a custom glass railing system and aluminium privacy screens by Sapa, which provided in-house paint, engineering, draft- ing and project management. The Casey, another award-winning Portland condominium, has a highly customised Sapa railing system combining three types of infill (glass, panels and interior panels) and a three-coat commercial-grade charcoal paint. All designs, drawings, die creations, extrusions, etcetera were done in- house. Solar solutions at Sapa > Aluminium is a material of choice for the solar industry offering total solutions, whether for solar industry. Its strength, ductility, corrosion solar panel frames or installation systems. Over resistance and low weight make it ideal for this kind the years, the company has built a huge bank of of application. Aluminium profiles can integrate knowledge covering almost all industrial fields, and functionality, are highly durable and practically every day it sees examples of ideas and solutions maintenance-free and can be finished according to feeding into each other. All this experience is now customer needs. And – a must for green applica- at the disposal of the solar industry. tions – they are 100 percent recyclable. For more information, see www.sapagroup.com/solar Sapa has launched a new organisation for the # 1 2009 SHAPE • 21

WORLD’S SMARTEST BILLBOARD It can cope with any weather. It does not require a mains supply for illumination. And a single person can change a poster in less than five minutes. Bannergear in Finland has developed the billboard of the future – in aluminium of course. TRADITIONAL BILLBOARDS hAVE been around for a long time, and normally have a frame of wood or steel and a poster that is pasted on. This often takes more than one person and requires very careful positioning, since the posters are pasted up in sec- tions. The approach that Bannergear takes is different. The poster is hooked to a frame made from aluminium profiles and then simply winched into place. “It means that one person can replace a poster measuring several square metres in the space of just five minutes. The posters can be supplied in a variety of materials – paper, polythene, airtex or pvc – depending on the customer’s wishes,” says Kari Karesola, product manager at Bannergear. The size of the billboard can also be tailored to the customer’s requirements, along with a choice of lighting, by Replacing billboard posters is now both quicker and easier. spotlights above the billboard or led lighting behind semi- transparent posters. They quickly understood what we were looking occasionally. We’re also looking at a variant that is Kari Karesola The frame profiles for the for and can supply profiles in different lengths.” wind-powered, which will be ideal for windy loca- billboards are always made from the same mate- The billboards can also be made even more tions,” says Kari Karesola. rial, however, and Kari Karesola explains his com- environmentally friendly by attaching solar cells to Current customers include the German food pany’s choice. the frame. This allows the lighting to be powered giant Lidl, and the building company K-Rauta. “The profiles have an extremely long life, they without a mains supply. “There is a lot of interest, so there is a good are easy to machine and a variety of features can “This means the customer can effectively place likelihood that Bannergear will grow over the next be built into the profiles themselves. The fact that the billboard anywhere that receives daylight. All few years.” aluminium is an attractive material is obviously an the customer needs to do is change the poster TEXT DAG ENANDER added benefit. Sapa are very good to work with. 22 SHAPE • # 1 2009

BRIEF NOTICES Urban enlightenment Riverside pearls > Many cities in the world may soon benefit from a modern touch of “la belle époque,” as changing styles of urban > architecture transform the shape of aluminium lighting columns, Picture a neighbourhood with miles of riverfront for walking, running or influenced by fashion, design and technical developments. cycling. Think of a district featuring art galleries, bookshops, new res- Today modern extrusion techniques allow Sapa Pole Products taurants and cafés. Then put the two together. to supply affordable and innovative aluminium columns, such Downtown culture and the great outdoors are the backdrop for the as the square columns that fit the Philips Urban Line lanterns Waterfront Pearl, two 10-storey towers on the banks of the Willamette River shining in Düsseldorf, Tilburg, Eindhoven and Amsterdam. The in Portland, Oregon. The architects behind the project contacted Sapa one-stop-shop Sapa plant in Drunen, the Netherlands, can deliver Railing Systems to provide residents with an unobstructed view. not only round and square aluminium lighting columns but a large The final design used Sapa’s series 200 flat top aluminum railing variety of different shapes. Through a combination of an extensive with 1/4\" tempered glass infill and decorative horizontal midrails. knowledge of aluminium, extrusion technology, procedure, design The residents of the Waterfront Pearl can maximise their pano- and fabrication, Sapa Pole Products are able to fulfil the needs of ramic views while feeling safe and secure on their balconies. customers. Good suspension takes the lead > Motorsport enthusiasts are used to seeing Öhlins’ service vans at racetracks around the world. But it is not just competition motorbikes, cars, snowmobiles and ATVs that use suspension components from Öhlins Racing. A growing number of private users are ordering Öhlins dampers made in Sweden for their two-wheel, four-wheel or tracked vehicles. Sapa, which has been a supplier to Öhlins for 25 years, has followed the company all the way, from local manufacturer to world contender in the highest division. Continuous research and product development lie behind Öhlins’ success, and have been key elements in the partnership with Sapa as a supplier of increasingly complex and refined components. “We set high standards of quality, performance, function and appearance,” says Lars Macklin, purchasing manager at Öhlins Racing. “Picture a newly washed motorcycle standing in the sun … the owner is obviously not going to be satis- fied with a shock absorber that is simply the best – it has to look like the best as well.” # 1 2009 SHAPE • 23

DANCING IN ALUMINIUM S Most of us use aluminium foil ince its premiere in Israel in 2003 the show He received assistance with the technical details has toured the world and drawn capacity from Yuval Keden, a special effects designer, who for wrapping a packed lunch or audiences. Accompanied by modern dance made the most of all the crazy ideas the choreo- covering leftovers in the fridge. music, audiences have seen aluminium in the form grapher had. The performance can be interpreted of gigantic cushions that hover over their heads, as questioning whether man controls technology, But Israeli choreographer ilan giants controlled by the dancers, an opera-singing or technology controls man, but can also be seen Azriel saw a slightly different ball gown, and in the form of enormous Slinkys, purely as light entertainment. those spiral toys that were able to walk down stairs. For the dancers, however, this is no light task, as application for this material The performance is a mix of dance, music and they frequently have to dance wearing outfits made than you would normally expect, special effects, topped with a generous serving of from aluminium. imagination and creativity. “Rehearsing for the performance wasn’t easy,” and turned it into the key element At the press conference prior to the European reports Ilan Azriel. in his dance performance: the tour in 2008, Ilan Azriel explained how he hit “Dancers like to show themselves off, but here Aluminum Show. upon the idea: they are mostly hidden inside a variety of alumin- “I was looking for inspiration for my next show ium shapes. It takes time getting used to dancing and happened to find a piece of aluminium duct in aluminium, but because they are all profession- from an air conditioning system. I stuck my hand als it eventually becomes as natural as any other in the duct and realised how flexible it was, and costume.” my imagination took over from there. Once I’d And yes, of course, all the aluminium that is decided to use aluminium I discovered that you used in the performance is recycled. can do almost anything with this material.” TEXT HENRIK EMILSON 24 SHAPE • # 1 2009

Sapa Group - Shape Magazine 2009 #1

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