Location: Aiken, SC
Sales: $191 Million
Description: Key Personnel
North & South America: Boudewijn Morelissen—General Manager; Europe & Asia-Pacific: Steven Vermeulen—General Manager
Plants
Aiken, SC; Ft. Smith, AR; Danville, IL (JV); Apeldoorn, Netherlands; Liversedge, U.K.
Processes
Wetlaid, drylaid
ISO Status
All locations, except Danville, IL (JV) are ISO 9001, 14001 & 18001 certified
Major Markets
Ceiling systems, roofing systems, flooring systems, battery separators, insulation facers, gypsum facers, wall coverings, electrical laminates, automotive applications, paving mats, fire-resistant fabrics for mattresses and upholstered furniture
While best known for its building materials business, including PINK insulation, roofing materials and vinyl siding, Owens-Corning also operates a global composites solutions business that contains a glass nonwovens business with myriad applications. Reported at $191 million last year, sales of these nonwovens target ceiling tiles, flooring systems (carpet tiles and vinyl flooring), wall coverings, insulation facings, roofing systems, paving systems and automotive applications, among others, and executives are considering nonwovens one of the company’s best growth prospects.
“While a number of OC’s businesses are incredibly strong, the nonwovens segment is one of our fastest growth opportunities,” said Todd Williams, nonwovens market manager. “We are growing this business globally by managing it as a true nonwovens business, leveraging our global presence and expertise in fibers, composites and building material systems.”
Owens-Corning began making dry-laid glass nonwovens in the 1950’s, then led the roofing industry’s conversion to fiberglass mat-based asphalt shingles in the late 1970s. In the 1980’s, Owens-Corning acquired two European operations, one from Pilkington in the U.K. and another in The Netherlands. The company currently operates five nonwovens production facilities in Apeldoorn, Netherlands; Liversedge, U.K.; Aiken, SC; Ft. Smith, AR; and Danville, IL (JV). While the bulk of its output is made using a wetlaid process, the company also manufactures drylaid nonwovens. Also, as the nonwovens business continues to expand, the company is diversifying beyond glass veils and mats into input fibers such as polypropylene, PVC and polyester, among others.
The company most recently showed its commitment to nonwovens through the announcement of a nearly $25 million investment at its Aiken, SC site. The expansion will increase output of a glass mat facer for gypsum wallboard, more specifically, Georgia-Pacific’s next generation of DensArmor, which features a glass mat facing that finishes like paper-faced wallboard, resulting in the first completely paperless interior wallboard that offers mold and moisture resistance and finishes easily.
Another recent product introduction is Owens-Corning’s Fire Resistant (FR) Filler Cloth, which is fast transforming the mattress industry’s ability to comply with open flame fire resistance standard TB603 without making any manufacturing process changes. Comprised of fire-resistant and self-extinguishing fibers, Owens-Corning’s (FR) Filler Cloth is seamlessly bonded to standard non-FR filler cloth, which then looks, feels and installs just like traditional materials that are applied to the bottom of no-flip mattresses. Together the materials are inherently fire-resistant without additional chemical treatment, effectively shielding foam and other flammable comfort materials within the mattress and foundation.
Beyond these recent product introductions, Owens-Corning envisions growth in areas where its fibers and technologies can provide practical solutions to needs. “What we are doing is continually examining opportunities where our nonwovens expertise can provide improved performance attributes to meet specific market needs both nationally and internationally,” Mr. Williams said.
The company currently relies on its strong global network to serve nonwovens customers in such emerging regions as Latin America and Asia-Pacific.
Location: Aiken, SC
Sales: $202 Million
Description: Key Personnel
North & South America: Boudewijn Morelissen – General Manager, Europe & Asia-Pacific: Steven Vermeulen – General Manager
Plants
Aiken, SC; Ft. Smith, AR; Danville, IL (JV); Apeldoorn, Netherlands; Liversedge, U.K.
Processes
Wetlaid, drylaid
Major Markets
Ceiling systems, roofing systems, flooring systems, battery separators, insulation facers, gypsum facers, wall coverings, electrical laminates, automotive applications, paving mats, fire-resistant fabrics for mattresses and upholstered furniture
With nonwovens sales estimated at $200 million, Owens-Corning’s glass nonwovens operation continues to target ceiling tiles, flooring systems, wall coverings, insulation facings, roofing systems, paving systems and automotive applications, among others. And, while the multinational conglomerate and maker of PINK insulation, roofing materials and vinyl siding has been beleaguered by asbestos-related litigation, which were partially blamed on the company’s filing for bankruptcy protection late last year, nonwovens remains on of the company’s best growth prospects.
Owens-Corning has been making drylaid glass nonwovens since the 1950s and led the roofing industry’s conversion to glass mat-based asphalt shingles in the late 1970s. In the 1980s, Owens-Corning acquired two European operations, one from Pilkington in the U.K. and another in the Netherlands. The company currently operates five nonwovens production facilities in Apeldoorn, The Netherlands, Liversedge, U.K., Aiken, SC, Ft. Smith, AR and Danville, IL. While the bulk of its output is made using a wetlaid process, the company also manufactures drylaid nonwovens. Also, as the nonwovens business continues to expand, the company is diversifying beyond glass veils and mats into input fibers such as polypropylene, PVC and polyester, among others.
The company has also proven its commitment to its nonwovens operation with the announcement of a $25 million investment at its Aiken, SC site. The expansion will increase output of a glass mat facer for gypsum wallboard, more specifically, Georgia-Pacific’s next generation of DensArmor, which features a glass mat facing that finishes like paper-faced wallboard, resulting in the first completely paperless interior wallboard that offers mold and moisture resistance and finishes easily.
On the new product front is Owens-Corning’s Fire Resistant (FR) Filler Cloth, which boosts the mattress industry’s ability to comply with open flame fire resistance legislation, set to come up next year. Comprised of fire-resistant and self-extinguishing fibers, Owens-Corning's (FR) Filler Cloth is seamlessly bonded to standard non-FR filler cloth, which then looks, feels and installs just like traditional materials that are applied to the bottom of no-flip mattresses.
On the corporate front, in June Owens-Corning announced it would merge its Reinforcements Business with with St. Gobain’s Reinforcements business (formerly known as Vetrotex). The anticipated transaction would be structured as a joint venture, with Owens-Corning owning a 60% equity interest and Saint-Gobain owning the remaining 40%. After a minimum of four years, the joint venture provisions would give an option to Saint-Gobain to sell its 40% stake to Owens-Corning, and Owens-Corning to buy the same.
The new company would have approximately $1.8 billion in annual revenues. The Owens-Corning-Saint-Gobain joint venture would present significant opportunities for synergies. These are expected to come primarily from scale benefits in purchasing and procurement; operational and technological plant improvements; improved distribution costs; reduced administrative costs and asset management optimization.
