MINERAL SOLUTIONS FOR A CHANGING WORLD IN BRIEF 2014
THE WORLD LEADER IN MINERAL-BASED SPECIALTY SOLUTIONS FOR INDUSTRY
Imerys transforms a unique range of minerals to deliver functional specialty solutions (heat resistance, mechanical strength, conductivity, coverage, barrier effect, etc.) essential for its customers’ products and manufacturing processes.
Whether mineral components, functional additives, process enablers or finished products, Imerys’ solutions contribute to the quality of a great many applications in consumer goods, industrial equipment and construction.
Combining expertise, creativity and attentiveness to their customers, the Group’s teams constantly identify new applications and develop high value-added solutions, in line with a determined approach to responsible development.
04 Presence in a great number of markets
05 Our business: world leader of specialty minerals for industry
06 A leading position in its four business groups
08 OUR COMMITMENTS
10 Guaranteeing the group’s growth is preparing for the future
12 Developping know-how is preparing for the future
14 Acting with a responsible approach is preparing for the future
€3,688M revenue
€495M current operating income
234industrial sites
14,900 employees
50countries
CONTENTS
3
FILTRATION & PERFORMANCE ADDITIVES
Filtration &
Performance Additives
ENERGY SOLUTIONS & SPECIALTIES
Oilfield Solutions
Graphite & Carbon
Monolithic Refractories
Carbonates
CERAMIC MATERIALS
Clay Roof Tiles
Minerals for Ceramics
Kaolin
HIGH RESISTANCE MINERALS
Refractory Minerals
Fused Minerals
I N B R I E F 2 0 1 4
S O L U T I O N S F O R A C H A N G I N G W O R L D
4
Imerys serves a wide range of industries, guaranteeing
balanced exposure to different economic cycles.
The Group’s sales are spread across over 20 markets.
PRESENCE IN A GREAT NUMBER OF MARKETS
DECORATIVE MATERIALS AND FITTINGS
Sanitaryware, tableware, flooring, paint, floor tiles, etc.
STEELMAKING AND METALLURGY
Refractory linings for furnaces, etc.
AUTOMOTIVE, INDUSTRIAL EQUIPMENT
AND CONSUMER DURABLES
Plastics, batteries, paint bodywork,
tooling, etc.
HEALTH, BEAUTY AND CARE
Deodorant, skin creams, toothpaste,
hygiene products, etc.
AGRI-FOOD
Filtration of beer, wine, drinking water
and fruit juice, etc.
PAPER
Catalogues, advertising materials, brochures,
magazines, specialty papers, etc.
PACKAGING
Plastic film, specific packaging, etc.
CONSTRUCTION
Roof tiles, cement making, window profiles,
etc.
ENERGY
Batteries, photovoltaic cells and panels, oil and gas drilling, etc.
HORTICULTURE, PROTECTION OF FLORA
Hydroponics, UV production, repellents, etc.
ELECTRONICS
Device structure, processors,
semi-conductors, etc.
I N B R I E F 2 0 1 4
5
OUR BUSINESS: WORLD LEADER OF SPECIALTY MINERALS FOR INDUSTRY
Imerys dedicates 1.7% of its revenue to Research & Development.
This amount represents quite a significant share for the industrial
minerals industry and reflects the Group’s determination
to make innovation the driver of its internal growth.
By selecting relevant techniques for the characteristics of every deposit, Imerys can extract minerals with an economically efficient, yet environmentally-friendly approach.
Sites at the end of their industrial lives are restored in the best possible environmental conditions. The Group has established common responsible management processes, including for restoration plans that are studied from the outset of mine opening projects.
THE ART OF MINING
SPECIALTIES FOR WIDE-RANGING APPLICATIONS
Imerys’ mineral-based specialty solutions can be used in four different ways in the industrial chain:
- mineral components- functional additives- amanufacturing
process enablers- finished products
BENEFICIATION KNOW-HOW
To obtain the required properties and so add value, minerals are processed using various technologies, many of which are specific to Imerys, e.g. grinding, grading, drying, calcination, sintering, melting, bleaching, surface chemistry, magnetic purification and flotation, but also shaping processes such as pressing, extrusion, granulation and casting.
HIGH-QUALITY MINERALS
The Group develops specialty solutions by transforming and formulating a range of around 30 minerals. Thanks to its mining sites, where it holds on average 20 years’ high-quality mineral reserves and with teams dedicated to exploring additional resources, Imerys guarantees its customers a lasting supply.
• Graphite to meet the specifications of mobile energy and precision engineering industries (lithium-ion batteries, etc.)
• Monolithic refractories for high-temperature industries (steelmaking, foundry, etc.)
• Diatomite and perlite to filter edible beverages
• Electrofused magnesia for domestic appliances (dishwashers, etc.)
A WIDE VARIETY OF USES
The Group calls substantial resources into play to innovate in line with its customers’ needs: 300 scientists based in market-focused Research & Development centers across the world, and collaboration with renowned institutes.
The Group has developed many exclusive processes, technologies and products that it strives to protect.
INDUSTRIAL AND TECHNOLOGICAL SKILLS
S O L U T I O N S F O R A C H A N G I N G W O R L D
6
WORLD #1 in talc for plastics, paints, paper,
ceramics, health & beauty
WORLD #1 in mica
WORLD #1 in mica for engineered plastics and high-performance coatings
WORLD #1 in diatomite-based and
perlite-based products for filtration
WORLD #1 in minerals for breathable
polymer films
WORLD #2 in carbonates for paper
WORLD #1 in alumino-silicate monolithic refractories
WORLD #1 in graphite for alkaline batteries
WORLD #1 in conductive additives for Li-ion batteries
The Filtration & Performance Additives business group is a supplier to a great number of industries
(agri-food, plastics, paint, rubber, catalysts, paper, pharma, personal care & beauty, etc.).
Its activity is driven by trends in consumer goods (beverages, food, packaging, etc.), capital goods
(particularly automotive) and construction (new buildings and renovation).
The Energy Solutions & Specialties business group manufactures and sells
high-performance mineral solutions for various demanding industries: the consumer goods and paper sectors with Carbonates, high-temperature industries served by Monolithic Refractories, Graphite & Carbon
applications linked to mobile energy, and oil and gas exploration served by the
Oilfield Solutions activity.
A LEADING POSITION IN ITS FOUR BUSINESS GROUPS
ENERGY SOLUTIONS
& SPECIALTIES
Carbonates
€ 1,279 million revenue (35% of Group total)
28 countries
76 industrial sites
4,958 employees
Monolithic Refractories
Graphite & CarbonOilfield Solutions
FILTRATION & PERFORMANCE
ADDITIVES
Filtration & Performance Additives
€ 658 million revenue (18% of Group total)
16 countries
45 industrial sites
2,518 employees
9%
7% 43%
41%
100%
I N B R I E F 2 0 1 4
7
WORLD #1 in raw materials & ceramic bodies
for sanitaryware
WORLD #1 in kiln furniture for roof tiles
WORLD #1 in kaolin for paper
EUROPEAN #1 in raw materials and ceramic bodies
for porcelain tableware
FRENCH #1 for clay roof tiles and accessories
WORLD #1 in alumino-silicate minerals
for refractories
WORLD #1 in fused minerals
for abrasives
WORLD #1 in fused zirconia
The Ceramic Materials business group is organized around Clay Roof Tiles (France’s largest producer of clay
roof tiles and roof accessories), Minerals for Ceramics and Kaolin activities. The Minerals for Ceramics activity
mainly addresses the ceramic industries (tableware, tiles, technical ceramics), but also other markets such as
fiberglass. Imerys kaolins are a key component of many products including consumer goods (paper, packaging,
paints, plastics and polymers).
The High Resistance Minerals business group is positioned upstream of the industrial equipment chain
(steel production, industrial and automotive sectors). The business group leverages on sophisticated manufacturing processes for high-temperature operations, to offer mineral-based specialties
with key functionalities: refractoriness, abrasiveness, mechanical resistance, purity and conductivity.
CERAMIC MATERIALS
Kaolin
€ 1,157 million revenue (31% of Group total)
21 countries
84 industrial sites
4,269 employees
Minerals for Ceramics
Clay Roof Tiles
HIGH RESISTANCE MINERALS
€ 642 million revenue (16% of Group total)
14 countries
29 industrial sites
2,841 employees
Fused Minerals
Refractory Minerals
33%
27% 40% 41% 59%
The composition of Imerys’ business groups was changed in 2014 as a result
of the acquisition project of S&B. The Kaolin activity was integrated into the Ceramic Materials
business group and S&B’s activities were integrated into the Filtration & Performance Additives
business group on March 1st, 2015. All 2014 financial data are therefore presented
under the new organization.
I N B R I E F 2 0 1 4
9
For Imerys, preparing for the future consists of three
commitments: to ensure the Group’s growth, develop
its know-how and be a responsible actor. To ensure
its growth, the Group is implementing a strategy based
simultaneously on innovation, geographic expansion, entry
into new growing markets and carefully targeted acquisitions.
Regarding know-how development, Imerys leads
a Human Resources policy promoting the evolution of
its employees and the recruitment of new talents. The Group
also seeks to develop and share, within the company, good
practices in operational excellence to improve and sustain
its industrial success.
To meet its growth targets while ensuring its social and
environmental responsibility, the Group is engaged
in performance improvement plans that encourages each
of its entities to implement concrete local initiatives whose
progress is assessed using performance indicators.
PREPARING FOR THE FUTURE TODAY
S O L U T I O N S F O R A C H A N G I N G W O R L D
1 0
Imerys has developed rapidly since the early 2000s thanks to a strategy based on innovation, expanding its geographic footprint and
activity portfolio, and stepping up its presence on profitable markets.
STAYING ONE INNOVATION AHEADImerys innovates with and for its customers. Three hundred researchers and technicians are mobilized at all times worldwide to meet customers’ expectations while the marketing teams try and anticipate their needs. In 2014 Imerys launched 75 new products: innovations stemming from improvements to existing ranges, or disruptive innovations based on
the development of new concepts. For 2014 alone, the new products introduced over the last five years have generated €449 million, i.e. 12% sales revenue. The vast range of applications offers many possibilities for our teams’ creativity.
FOCUS ON GROWING MARKETSImerys focuses its research efforts in the areas with the strongest growth potential. The projects launched in 2014 notably reflect the dynamism of the plastics markets, recycling, lithium-ion batteries and organic agriculture.
PRODUCTION CAPACITY DEVELOPMENTImerys has developed new production capacities to continue
its development on growing markets identified as having the highest potential. In Brazil, the Group unveiled a new blending
S&B ACQUISITION
With the integration of S&B’s activities into the
Filtration & Performance Additives (F&PA) business
group, Imerys counts on a number of synergies: business’ exposure on existing and growing
markets, increased geographic presence
and innovation potential development.
GROW
TH
RESPONSIBILITY
KNOW-HOW GUARANTEEING
THE GROUP’S GROWTH IS PREPARING FOR
THE FUTURE
IMERYS
S O L U T I O N S F O R A C H A N G I N G W O R L D
1 1
€242 million
industrial investments in 2014
Imerys’ innovative solutions are appreciated on every continent. In Europe, the C-NERGYTM materials for electrodes have become a benchmark for high-performance battery manufacturing; Steagreen™ talcs are used to restore mechanical properties to plastics compounds; the ImerCare™ Scrub range, based on engineered perlite, was developed in response to growing demand in the cosmetics industry for natural ingredients. In North America, the JetWhite® references, functional additives for polymer compounds, are used in color-sensitive automotive and appliance end uses. In Asia customers benefit from CerafluxTM, a new range of fluxes for glazes developed to lower sintering temperatures, thus reducing tile production costs and subsequent environmental impacts.
75new products
marketed in 2014
INNOVATIONAnticipating our customers’ needs
_
platform for the Minerals for Ceramics activity. The High Resistance Minerals business group launched a new production line in Austria for ultrafine alumina. The Energy Solutions & Specialties business group opened a new natural graphite quarry in Canada and commissioned a third production line for monolithic refractories in India. The new production line in Willebroek (Belgium) enabled Imerys Graphite & Carbon to double its capacity for carbon black.
TARGETED EXPANSION In the regions identified as high potential development sources, the Group is expanding
extensively through organic growth projects, acquisitions or partnerships. The Group has completed the acquisition of Termorak, a Finnish refractory material producer, and Kinta Powdertec Sdn Bhd, a Malaysian producer of ground calcium carbonates. Imerys also set up its first industrial facility in the Middle East with a fused alumina plant in Bahrain, built under a joint venture with the Al Zayani Investments group, extending its geographic footprint in a strategic area for the Group. With the S&B acquisition, I m e r y s a c c e l e ra t e s i t s development and increases its offer in mineral-based specialty solutions for industry.
I N B R I E F 2 0 1 4
S O L U T I O N S F O R A C H A N G I N G W O R L D
1 21 2
GROW
TH
RESPONSIBILITY
KNOW-HOW
Driven by entrepreneurship and focused on sound values, the Group imple-ments a Human Resources policy that is consistent
with the changes in today’s world.
TRAINING TO ENHANCE EXPERTISE To accompany its strategy implementation, the Group has designed training programs through Imerys Learning Center (the Group’s training center), and its business groups, on security, industrial performance, etc. Imerys Learning Center provides training on all continents to allow employees to develop their skills, broaden their internal network and share the Group’s culture. In total,
over 10,200 employees, e.g. 66% of the average annual workforce, were trained during 2014.
ALL ONLINEIn 2014, the Group decided to extend the scope of its training through IM-Pulse, a new e-learning solution. The aims of this online training platform are to reach as many employees as possible, especially in the most remote regions, and to offer personalized training. More than 4,000 employees will eventually benefit from this new ongoing training offering from 2017.
A SHARED CORPORATE CULTURE All over the world, the Group’s
men and women add to its value, build its success and forge its reputation. Many in-house initiatives are taken to strengthen this company spirit. Cross-division seminars are organized by function to share best practices. External and internal communication support information sharing (electronic newsletters, social networks and videos published online via YouTube on Imerys Replay channel).
WELCOMING NEW EMPLOYEESTo facilitate new employees integration, a welcome program cal led “Onboarding” was launched in 2014. This program, based in part on the best
S O L U T I O N S F O R A C H A N G I N G W O R L D
DEVELOPING KNOW-HOW
IS PREPARING FOR THE FUTURE
IMERYS
1 3
221, 000 training hours
were allocated to 10,200 employees
75%of employees
are covered by a collective agreement
A Group-wide analysis of industrial assets showed performance levels that varied from site to site. To reach a common standard of operating excellence, Imerys implemented in 2014 a program to improve its industrial processes called Imerys Industrial Improvement (I-Cube). The implementation of the program follows a three-phase roadmap expected to conclude in 2018. The program is a new guarantee from Imerys on its commitment to supply increasingly high-performance products that meet strict quality criteria.
OPERATIONAL EXCELLENCEDeveloping and sharing
best practices_
practices of the Group’s entities, includes a practical presentation kit on Imerys, its businesses and its sustainable development policy, as well as essential i n fo rmat ion fo r smooth integration. “Welcome Sessions” for new employees are organized several times a year in Europe, North America and Asia. In 2014, a session was organized in Brazil for the first time.
SOCIAL MODEL, ETHICS AND BUSINESS CONDUCTWi t h b a s e s i n a l m o s t 50 countries, Imerys also has to take account of specific social legislation and practices that can vary widely. Considering that its
employee benefits had to be harmonized if not identical, the Group set down the principle of gradually aligning its subsidiaries’ compensation and benefits. In 2014, Imerys updated its Code of Ethics and Business Conduct to st rengthen po l ic ies and procedures against fraud and corruption.
I N B R I E F 2 0 1 4
1 41 4
To reconcile its growth ambitions with its social and env i ronme nta l responsibilities over the long term, the Group has
centered its Sustainable Development strategy on three main areas: social, environment and governance.
CONSERVING THE ENVIRONMENTAll of Imerys’ facilities worldwide have set up an Environmental Management System (EMS) and 81 of them are ISO 14001 or Eco Management and Audit Scheme (EMAS) certified. An EMS enables each operation to manage and control the risks and issues relating to the protection of the
environment. The systems are fully integrated into the Group’s environment, health & safety (EHS) audit program. Every site has to measure its water, ensure waste water is recycled and check the quality of discharged water. These actions have achieved tangible results as the Group’s total water withdrawals have been cut by 13.2% since 2013 and by almost a third over the past five years. As far as biodiversity is concerned, Imerys pledges to respect the ecosystems around its facilities and conserve their value. In-depth studies are conducted on fauna and flora before any operations start on a
site. In addition, a restoration program is systematically set up for the site’s entire lifespan. On a Group scale, the measures taken since 2009 in favor of
TAKE 5
In 2014, Imerys rolled out “Take 5” in all its
operations worldwide. Each employee without
exception is asked to acquire the habit of taking
five safety steps before starting any task. This initiative was the focus of a broad awareness
campaign.
GROW
TH
RESPONSIBILITY
KNOW-HOW ACTING WITH
A RESPONSIBLE APPROACH
IS PREPARING FOR THE FUTURE
IMERYS
S O L U T I O N S F O R A C H A N G I N G W O R L D
1 5
-61% in five years
for the frequency rate of lost-time accidents
(including subcontractors).
ENVIRONMENTEnvironmentally-friendly
cement _
With Andalusite quarries close to the Pretoria Portland Cement (PPC), Imerys was able to offer a more efficient and environmentally-friendly product than fly ash from thermal power plants transported over long distances before going into cement production.
COMMUNITYFine perlite for local population activity
_
Used as a clay replacement to manufacture bricks, fine perlite, transformed in our factories, is a sustainable and economical solution, which helps to develop local activity but also to stop degradation and protect flora and fauna.
renewable or low-carbon energies have already led to a decrease in atmospheric CO2
emissions.
SPREADING SAFETY AWARENESS The Imerys Safety System is a program based on compliance, continuous improvement, and communication/training. The purpose of this integrated approach is to communicate the Group’s safety culture and ensure compliance with the same safety standards and rules at all of its activities worldwide. It presents t h e m a i n c o n t i n u o u s improvement levers for safety. The disciplined rollout of the Imerys Safety System has helped
to cut the lost-time accident rate (including subcontractors) by 61% in five years. Prevention efforts have been stepped up since 2013, leading to a 27% reduction in frequency.
BEING AN INTEGRATED PARTNERBuilding and sustaining the best possible relations with the communities near its sites is an essential condition for Imerys’ successful growth. The Group integrates social responsibilities into its sustainable development policy based on respect for its neighbors, leading to tangible actions on education, culture or health. A specific protocol on community relations has been
published, translated into seven languages and has been implemented at all Imerys sites.
75new products
launched in 2014 are of benefit to the environment.
More than one-third of the
I N B R I E F 2 0 1 4
S O L U T I O N S F O R A C H A N G I N G W O R L D
154, rue de l’Université – 75007 ParisTelephone: + 33 (0) 1 49 55 63 00Fax: + 33 (0) 1 49 55 63 01
TRANSFORM TO PERFORM
To find out more?
To find out more,visit the websites of the Group www.imerys.com and its activities
ENERGY SOLUTIONS & SPECIALTIES
Carbonates:www.imerys-carbonates.com
Monolithic Refractories:www.calderys.fr
Graphite & Carbon:www.imerys-graphite-and-carbon.com
Oilfield Solutions:www.imerys-oilfieldsolutions.com
FILTRATION & PERFORMANCE ADDITIVES
Filtration & Performance Additiveswww.imerys-perfmins.com www.imerystalc.com www.imerys-filtration.com www.celitecynergy.com www.advancedminerals.com www.insulation.imerys.com www.imerplast.com www.imerys-specialitiesjapan.com www.imerysvermiculite.com
CERAMIC MATERIALS
Clay Roof Tiles:www.imerys-toiture.com www.imerys-solaire.com
Minerals for Ceramics:www.imerys-ceramics.com www.imerys-aurora.com www.thequartzcorp.com www.ikf-solutions.com
Kaolin:www.imerys-kaolin.com www.imerys-perfmins.com www.imerysnopara.com.br
HIGH RESISTANCE MINERALS
Refractory Minerals:www.imerys-refractoryminerals.com
Fused Minerals:www.imerys-fusedminerals.com www.ifme.eu
Design and production:
Photo credits: G. Carillo • Fotolia • Imerys • Kwestion • N. de La Falaise • D. Lecuivre • Thinkstock • P. Wiangnont
Print: TI Médian impressions. This report is printed on paper produced from sustainably managed forests. The paper is FSC certified and contains Imerys pigments.