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SHEET EXTRUSION AND THEMOFORMING

IN CENTRAL AND EASTERN EUROPE (CEE)

ECEBD Ltd. Budapest, Hungar y

European Business

Eastern and Centra l

Development Ltd.

SHEET EXTRUSION AND THEMOFORMING IN CENTRAL AND EASTERN EUROPE (CEE)

CONTENT

1. Introduction 3

Abstract ......................................................................................................................................................................................................................................................................... 3 Geographical coverage ....................................................................................................................................................................................................................................... 3 Some words about ECEBD Ltd. ....................................................................................................................................................................................................................... 3 Methods of analysis .............................................................................................................................................................................................................................................. 3

2. Plastic processing in the CEE region 4

Plastic consumption by resin type ................................................................................................................................................................................................................ 4 Plastic consumption by country..................................................................................................................................................................................................................... 5 Plastic processing ................................................................................................................................................................................................................................................... 5 Development trends ............................................................................................................................................................................................................................................. 5 Development of plastic consumption ....................................................................................................................................................................................................... 5 Development of plastic processing ............................................................................................................................................................................................................. 6

3. Plastic sheet extrusion in the CEE region 6

Plastics used for sheet extrusion in CEE .................................................................................................................................................................................................... 6 Sheet extrusion in the individual countries ............................................................................................................................................................................................ 7 Sheet products and applications .................................................................................................................................................................................................................. 7 Sizes of companies in sheet extrusion ....................................................................................................................................................................................................... 8

4. Thermoforming in the CEE region 8

Plastics used for thermoforming in CEE .................................................................................................................................................................................................... 8 Thermoforming in the individual countries ............................................................................................................................................................................................ 9 Thermoformed products made in CEE ...................................................................................................................................................................................................... 9 Age of sheet extruding and thermoforming machinery ............................................................................................................................................................... 9 Sizes of companies in thermoforming ....................................................................................................................................................................................................10

5. Development of sheet extrusion and thermoforming in the CEE region 10

Development of thermoforming in CEE .................................................................................................................................................................................................11 Development of applications of thermoformed products in CEE ..........................................................................................................................................11

6. Conclusions 12

3 | SHEET EXTRUSION AND THEMOFORMING IN CENTRAL AND EASTERN EUROPE (CEE)

1. INTRODUCTION

It is interesting for the plastic manufacturers, converters and processing machine producers operating worldwide or in Western Europe to get a general overview of the characteristics and developments of the Central and Eastern European (CEE) plastic markets.

It should be used for re-evaluation of business and investment strategies. Reliable information regarding a special segment of plastic processing is necessary to develop marketing strategies and sales plans.

AbsTrACTThe intentions of preparing this report are:

– To show a global picture about the development of plastic converting in the Central and Eastern European countries, including the Russian Federation. CEE is a developing area having 5-10% annual growth rates.

– To give detailed information about sheet extrusion and thermoforming according to plastic materials used, end products produced and applications.

– To estimating the market development for the next five years for plastic converting in general and development trends regarding sheet extrusion and thermoforming.

GEoGrAPhICAl CovErAGEGeographical coverage of this study includes:

– Central Europe (CE): Poland, Czech Republic, Hungary, Slovakia, Baltic states, Slovenia

– South-Eastern Europe (SEE): Ex-Yugoslav states, Romania, Bulgaria

– Eastern Europe (EE): Russian Federation, Ukraine, Belorussia.

somE worDs AbouT ECEbD Eastern and Central European Business Development Ltd. (ECEBD) is a regional market research company which provides research, consulting and marketing services on the CEE plastics industry.

The company built up its own database called ChemIT which includes close to 10000 plastic converter profiles in March 2008. Geographical coverage of the database is enlarged year by year.

The content of ChemIT is based on direct phone interviews using the local languages and is renewed in every 18 months. Online access to the ChemIT database is available to subscribers.

multi client studies made regularly by ECEBD Ltd. cover different aspects of plastic converting and applications in the CEE region. These studies are based on the ChemIT database.

single client studies are made according to specific needs of individual customers. The content of the study is specified by the company giving the order. These studies are based on direct market research.

mAIn usErs of ECEbD sErvICEs– Polymer and additive manufacturers– Compounders and masterbatch producers – Manufacturers of plastic processing machines.

mEThoDs of AnAlysIsMain source of this study is the ChemIT database created and operated by ECEBD Ltd.

The data of each plastic processing company contain:– Contact details– Resin consumption by type and volume– Processing technology and machinery– End products and applications– Trend indication

The experts of ECEBD Ltd. use not only their own data but also other technical and economical information for their evaluations. Development trends experienced by the plastics industry of Western Europe in the previous years are generally followed in the CEE region during the next years. Therefore it is used for the forecasting and estimations beside the regional general economical trends.


2. PlASTIC PROCESSING IN THE CEE REGION

Total plastic consumption of plastic converting industry of the CEE states was more than 8 million tons in 2007. It is about 20% of the Western European plastics consumption, which means that the per capita consumption of plastics is much less in the CEE.

PlAsTIC ConsumPTIon by rEsIn TyPEmass thermoplastics represent about 7.9 million tons, the distribution according to resin types is shown in the next figure:

Figure 1: CEE mass thermoplastics consumption in 2007

Polyethylene is on the first place with a share of 41%. LDPE and HDPE consumption is almost the same; LLDPE has only a small, but increasing share.

LDPE and LLDPE are mainly used for film production. HDPE is processed by extrusion, injection molding and blow molding, and pipe extrusion has a higher share than in Western Europe.

Polypropylene is on the second place representing 24%. The biggest part of PP is processed by injection molding to technical parts and consumer goods, but BOPP production is also significant in the CEE region.

PvC has a share of 16%. Rigid PVC is mainly used for extruding profiles, pipes and sheets, plasticized PVC for cable, flooring, film, coated fabrics.

Polystyrene represents 10%, injection molded and thermoformed packaging mainly for food contact applications dominate. Many injection molded technical products for the E+E industries are also made of PS.

PET has a share of 9% and mainly used for bottles.

Engineering resins represent a smaller share in the plastics consumption in the CEE than in Western Europe. The total volume was about 325 Kt in 2007.

Engineering resins are mainly used for technical products.The main processing method used for converting engineering resins is injection molding (IM) with a share of 70%. Extrusion represents 20%, and other processing methods 10% altogether.

The distribution of engineering resin consumption according to resin type is shown in the next figure:

Figure 2: Engineering resin consumption in 2007 in the CEE region

Polyamides represent more than one third of the consumption, it is processed mainly by injection molding and used for technical parts, first of all vehicle components.

ABS has a share of 29%, main converting method is injection molding. Most important applications are vehicle parts and components of appliances.

PC and its blends represent 25%. It is converted by injection molding to data storage discs and vehicle parts.

Sheet extrusion for building applications and blow molding for drinking water balloons are also made in CEE.

All other engineering resins represent 9% altogether. They are converted by IM for technical parts.

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PlAsTIC ConsumPTIon by CounTryThe volume of plastic consumption in the CEE states is shown in the next figure:

Figure 3: Plastic consumption in 2007 in the CEE states

russia is by far the biggest user of plastics representing almost one third of the total. Volume of plastic converting was more than 2.5 million tons in 2007.

Poland is on the second place with 1.6 million tons, having a share of 20%. All other CEE countries have a share of less than 10%. Hungary is on the third place with 700 Kt which is 9%, followed by Czech Republic (8%) and Ukraine (6%). The next group is Romania (5%), Serbia (5%, including Bosnia-Herzegovina, Macedonia and Montenegro), and the Baltic states (4% together)

The per capita plastic consumption is about 70 kg in Hungary and the Czech Republic, more than 50 kg in Poland, and much less in the Eastern European countries. The low per capita consumption means great possibilities for development.

PlAsTIC ProCEssInGAll plastic processing methods are used also in the CEE, and their shares are similar to Western Europe, as illustrated in the next table:

ProCEssInG mEThoDs In CEE %Film production 21Extrusion 30Injection molding 28Blow molding 12Expansion 4Thermoforming 4Others 1Total 100

Table 1: Distribution of processing methods in 2007

Film production represents somehow higher, while blow molding lower share in comparison to Western Europe. Extrusion contains pipe, profile, sheet and cable production.

DEvEloPmEnT TrEnDsCEE is still a developing area. The Central European and Baltic states are already members of the EU, have relatively developed market economy and moderate growth rates are forecasted for the next 5 years. Eastern and Southern European states, first of all Russia, have less developed market economy, but big resources. Fast economical development is forecasted for the coming years in this sub-region. Increase of plastic consumption is generally higher than the growth of GDP. Main driving factors in CEE:

– General economical development– Consumerism –demand on mass products– Increasing income –demand on cars, appliances– Developing private sector– Foreign direct investments– Building activities –business and residential

These factors are generating increasing demand on plastic products, first of all packaging. Plastic manufacturing is developing fast in the region, creating good local supply for plastic converting.

DEvEloPmEnT of PlAsTIC ConsumPTIonPlastic consumption of CEE will increase at least by 6% yearly during the next 5 years. More than 10.5 million tons of plastics will be converted to end products in the region in 2011. The consumption of each resin increases, but with different rates. Our forecast is summarized in the next table:

rEsIn TyPE AnnuAl GrowTh rATE ConsumPTIon2007-2011 in 2011

% KtLD+LLDPE 6 2100HDPE 7 2050PP 7 2500PVC 5 1500PS 5 950PET 9 1000Engineering resins

9 450

Total 6 10550

Table 2: Development of resin consumption in CEE

PET, HDPE and PP increase faster than the average, while PVC and PS will have slower AGR. The distribution of resins will not change significantly: PE will hold its first place, followed by PP and PVC. During this period PET will pass PS.

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The use of engineering resins will increase by about 9% yearly, and their share will increase from 4,0 to 4,3%.

PA represents the average increase rate and keeps the first place with 38%. PC converting will develop faster and will have a share of 26%. The growth of ABS is slower than the average and its share decreases to 27%. The use of all other engineering and specialty resins will increase by at least 10% yearly, but their total share will not pass 10% of total engineering resin consumption.

DEvEloPmEnT of PlAsTIC ProCEssInGEvery processing method will develop well during the coming years both in volume and technical level. Multilayer films, sheets and pipes or sophisticated injection molded technical parts will be as common in 2011 as they were in 2005 in Western Europe.

Forecast for the development of processing is summarized in the next table:

ProCEssInG mEThoD AnnuAl GrowTh rATE shArE In2007-2011 2011

% %Film (blown + cast) 5 20Injection molding 7 27Extrusion 6 30Blow molding 9 15Thermoforming 7,5 4Others 5 4Total 6 100

Table 3: Development of processing methods in CEE

Blow molding shows the highest growth rate, but its share will be less even in 2011 than it was in Western Europe in 2005. Injection molding is developing well and will increase its share to 22%, at the expense of film blowing.

Sheet extrusion and thermoforming will develop faster than the average, but thermoforming will have a share of about 4% in 2011, too.

3. SHEET EXTRUSION IN THE CEE REGION

In the CEE region about 550 Kt plastic sheets were extruded in 2007, two thirds of it is made of PS and PP. One third of this volume is used as sheets, and two thirds are converted by thermoforming (THF) to end products. Main applications are food packaging, building industry, manufacturing of vehicles and appliances. Russia and Poland represents almost 70% of the total volume produced in the CEE region.

PlAsTICs usED for shEET ExTrusIon In CEEMost of the mass thermoplastics are used for extruding sheets, but 2 resins, PS and PP dominate in the CEE region, representing two thirds of the total volume. It is so because the main application is packaging.

Distribution of polymer types used for sheet extrusion is shown in the next table:

rEsIn volumE shArE Kt %

PS 220 40

PP 150 27

PVC 90 16

HDPE 35 6

LDPE 15 3

PET 15 3

Others 25 4

Total 550 100

Table 4: Polymers used for sheet extrusion in CEE in 2007

About 40% of the plastic sheets are made of PS (including HIPS and EPS). Most of them are used for food packaging made by thermoforming.

PP sheets have a share of 27%, and half of it is processed to different end products by THF and used also for food packaging.

PVC sheets (which includes rigid and plasticized sheets, but excludes flooring) is on the third place with 16%. PVC sheets are used mainly in the building and construction industry.

PE sheets (including HDPE, LDPE and LLDPE) represent 9% altogether and are used for different applications.

PET has a share of 3%, and is used in different fields.Among the engineering resins PC and ABS has to be mentioned as raw materials for extruded sheets.


shEET ExTrusIon In ThE InDIvIDuAl CounTrIEsThe market size for packaging consumer goods and appliances depends on the number of population and level of GDP. Production is driven by consumption. International trade has a great influence on the local production especially in the case of smaller countries. Transport costs caused by big distances limit the export and import of goods. In the case of sheet production the share of the individual CEE countries is shown in the next table:

shEET ExTrusIon KT %Russia 285 52

Poland 95 17

Czech Rep. 40 7

Hungary 28 5

Belorussia 25 5

Ukraine 20 4

Romania 13 2

Bulgaria 12 2

Serbia BH M M 12 2

Baltic states 9 <1

Slovakia 4 <1

Croatia 4 <1

Slovenia 3 <1

Total 550

Table 5: Sheet extrusion in the CEE countries in 2007

It is not a surprise that Russia has by far the largest share representing more than half of the total CEE sheet production.The second biggest country of the region is Poland, having a share of 17%. Czech Republic represents 7%, Hungary 5% and Slovakia 1%, the markets of this 3 countries are closely related to each other Belarus has a share of 5%, Ukraine represents 4%.

In the smaller Central and Eastern European countries the volume of sheet extrusion is not very significant, not all of the main sheet types are produced in each country.

shEET ProDuCTs AnD APPlICATIons

shEET ProDuCTs KTSheet for THF 350

Geomembranes 45

Technical 35

Foamed sheet 30

Tapes and labels 25

Furniture 15

Other sheet 50

Total 550

Table 6: Types of plastic sheets produced in CEE in 2007

Thermoforming is by far the biggest application of plastic sheets, representing 64% . Thermoforming is discussed in the next chapter.

Geomembranes, waterproofing sheets, and other sheets used in the building industry have a share of 8%.

Extruded foamed PS sheets used for heat insulation in building industry (EPS heat insulating panels are not considered as sheets, so are not included).

Tapes and labels are mainly produced from films, but some thin sheets are also used in this application. Technical sheets are used in the manufacturing industries. Other sheets represent about 10%, many different types and applications belong to that category.


sIzEs of ComPAnIEs In shEET ExTrusIon Small and medium size companies dominate also in sheet extrusion, the average plant size is much smaller than in Western Europe. Western European professional investors are present for 10 years in Central Europe, and are moving to Eastern Europe nowadays.

Distribution of sheet extruder companies by size is illustrated in the next figure:

shEET

ComPAny sIzE numbEr of ComPAnIEs volumE ProDuCED

Kt/year Kt

<100 149 4

100-500 67 16

500-1000 25 17

1-2000 28 35

2-5000 25 66

5-10000 4 27

>10000 4 54

Total 302 219

Table 7: Distribution of companies by size in sheet extrusion

It is evident, that the small companies dominate in number, but are not significant in the output: 80% of the companies produce less than 1000 tons in a year. Their share in the produced volume is only 18%.

Big companies having a production volume of over 5000 tons in a year represent only 3% in number but 36% in the volume.

Concentration of companies and improvement of technical conditions are going on.

4. THERMOFORMING IN THE CEE REGION

About 350 Kt plastic sheets were thermoformed in the CEE region in 2007, almost all of them were made of mass thermoplastics.

Main uses are food packaging and disposable service ware, but technical parts also represent significant volume.

PlAsTICs usED for ThErmoformInG In CEEMost of the thermoplastics are processed also by thermoforming, but 3 resin types, PS, PP and PVC dominate in this region. It is so because the main application is packaging.

The distribution of thermoforming according to polymer type used is given in the next table:

rEsIn volumE shArE Kt %

PS 185 52

PP 70 20

PVC 45 13

PE 30 9

PET 10 3

Others 10 3

Total 350 100

Table 8: Polymers used for thermoforming in the CEE region in 2007

About half of the thermoformed products are made of PS (including HIPS and EPS). More than 80% of thermoformed PS products are used for food packaging and as a disposable service ware.

PP thermoformed products have a share of 20%, and it is mainly used as food packaging Technical parts are also produced from PP sheet by thermoforming.

PVC is on the third place with 13%, these are mainly rigid PVC sheets, used mainly in the building and construction industry.

PE sheets (including HDPE, LDPE and LLDPE) represent 9% altogether and are used for different applications.

PET has a share of 3% in sheet production, and among the engineering resins PC and ABS has to be mentioned.


ThErmoformInG In ThE InDIvIDuAl CounTrIEsThe distribution of THF in the CEE region is shown in the next table:

Thf KT %Russia 170 49

Poland 70 20

Hungary 21 6

Czech Rep. 19 5

Belorussia 15 4

Ukraine 15 4

Bulgaria 9 3

Serbia BH MM 9 3

Romania 8 2

Baltic states 6 <1

Slovakia 3 <1

Croatia 3 <1

Slovenia 2 <1

Total 350 100

Table 9: Distribution of THF in CEE countries

It is seen that Russia represents by far the largest share, producing almost half of the thermoformed items. The second place is occupied by Poland with 20%. Hungary has a good share of 6%, but the market is saturated already. The Czech Republic represents only 5%, but the rate of technical parts is the highest in this country.

In the other Central and Eastern European countries the volume of thermoforming is not very significant yet, therefore high growth rates are forecasted.

ThErmoformED ProDuCTs mADE In CEEPackaging items dominate by far among the end products made by thermoforming. Tubs, cups, small containers, lids and closures, trays, small boxes are used mainly for food packaging and disposable service packaging. The volumes of the main end product groups produced in 2007 are shown in the next table:

EnD ProDuCTs KTDisposable wares 135

Tub, cup, container 105

Lid, cap, closure 30

Vehicle parts 25

Appliances 15

Furniture parts 10

Other THF items 30

Total 350

Table 10: End products made by thermoforming in CEE

It is seen that technical products do not represent high share in the total volume, but there are some companies specialized for it in each CEE country.

AGE of shEET ExTruDInG AnD ThErmoformInG mAChInEryThe new, small and medium size companies are generally equipped by older, less developed extruder lines having smaller production capacity.

These equipments operate with moderate efficiency (work force and energy demand). The quality and reproducibility of products are on medium level, but good enough for most of the local applications.

Some of bigger local companies and the sister companies of international plastic converters have new extruders with high capacity and good operating efficiency.

During this evaluation only the THF companies having their own sheet extrusion, (which is common also in CEE), were taken into account.

The distribution of 361 companies according to the average age of machinery shows: About 34% of the companies have practically new (1-5 years old) machinery, but producing 53% of the total output. The advantage of well equipped companies is clearly seen. The next group, 42% of the companies have good (5-10 years old) equipments, and have a share of 39% in the output. The remaining 25% of companies uses more than 10 year old machines, and produces only 8% of the output.

About 200 companies did not give information regarding age of machinery, we suppose, that at least half of them uses old extruders and thermoforming machines.


sIzEs of ComPAnIEs In ThErmoformInG Most THF companies belong to the “small” category according to Western European standards. Concentration of companies and improvement of technical conditions are started and going on fast. Western European professional investors are present since 10 years in Central Europe, and are moving fast to Eastern Europe.

Distribution of thermoforming companies by size is illustrated in the next figure:

ThfComPAny sIzE numbEr of ComPAnIEs volumE

ProDuCEDKt/year Kt

<100 173 6

100-500 108 26

500-1000 57 40

1-2000 36 47

2-5000 36 102

5-10000 10 68

>10000 5 80

Total 425 369

Table 11: Size distribution of thermoforming companies in CEE

It is evident, that the small enterprises dominate in number: 80% of the companies produce less than 1000 tons in a year. Their share in the produced volume is only 20%. The Pareto principle is true for THF companies, too. Big companies having a production volume of over 5000 tons in a year represent only 3% in number but 40% in the total volume.

5. DEvElOPMENT OF SHEET EXTRUSION AND THERMOFORMING IN THE CEE REGION

Plastic consumption of CEE will increase at least by 6% yearly during the next 5 years, and more than 10 million tons of plastics will be converted in the region in 2011. The consumption of every resins will increase but with different rates.

All the processing methods will develop, injection molding and blow molding faster than the average.

The annual growth rates are different in each country, in the Central European sub-region smaller, in Eastern Europe bigger AGR is anticipated.

The main applications of plastics in the region are packaging, building industry and technical parts for the vehicle and E+E industries, they are increasing nearly the same rate.

Sheet extrusion and thermoforming will develop faster than the plastic converting in general: We estimate 8,5% average annual growth rate (AGR) for the CEE region.

AGR of the individual countries and estimated volumes for 2011 is shown in the next table:

ToTAl shEET ExTrusIon AGr volumE 2011Country % Kt

Russia 10 410

Poland 6 120

Czech Rep. 5 50

Hungary 3 31

Belorussia 8 33

Ukraine 15 35

Romania 12 22

Bulgaria 9 17

Serbia BH M M 9 17

Baltic states 7 12

Slovakia 10 7

Croatia 8 6

Slovenia 7 5

Total 8,5 765

Table 12: Total sheet extrusion in CEE

Russia will develop fast and will increase of its share to 54% till 2011.


Poland will have 16%, developing slower than the average of the region.

Ukraine and Romania will show exceptional growth rates, and Slovakia is also better than the average of the region.

Ukraine will pass Hungary and will occupy the fourth place in the region.

DEvEloPmEnT of ThErmoformInG In CEE Consumption of packaging and technical parts increases rapidly, so thermoforming has good chances to grow fast.

The total volume of thermoforming will increase by 44% according to our moderate (not optimistic) forecasts in 5 years and will be about 410 Kt in 2011.Estimated development of thermoforming is summarized according to country and resin type in the next tables:

CounTry AGr 2007-2011 volumE of Thf In 2011

% KtRussia 7,5 175Poland 6,5 82Hungary 5 26Ex-Yugoslavia 8,5 27Czech Rep.+ Slovakia 8 25Belarus 8 22Ukraine 10 16Romania 10 10Baltic states 8 12Bulgaria 12 9Total 7,5 410

Table 13: Development of thermoforming in the CEE countries

Russia is on the first place and will affirm its position experiencing significant increase. Poland keeps the second place even with slower than average growth rate.

Fast developing countries: Ukraine, Romania, Slovakia, Bulgaria, Serbia.

Hungarian market is becoming saturated, the 2 biggest thermoforming firms already established production plants in Romania, Ukraine and Serbia to approach the developing markets.

rEsIn AGr 2007-2011 ConsumPTIon In 2011

% KtPS 6,5 205PP 9 77PVC 5,5 42EPS 7 25HDPE 6 16PET 10 13LDPE 5 9Engineering resins 10 13Total 7,5 410

Table 14: Development of resin consumption for thermoforming in CEE

The share of PS in thermoforming will decrease to 50% till 2011, while PP will increase to almost 20%.

PVC remains an important raw material for thermoforming with a share of 10%.

Fast increase is forecasted for PET, but its share remains insignificant.

DEvEloPmEnT of APPlICATIons of ThErmoformED ProDuCTs In CEEMain application is and will be packaging, first of all food packaging. Our forecasts for the development of the different segments are shown in the next table:

APPlICATIon AGr 2007-2011 volumE of Thf In 2011

% KtFood packaging 8,5 143Mass products 6 121Other packaging 8 44Manufacturing ind. 7 28Vehicle industry 10 32Others 7 42Total 7,5 410

Table 15: Development of applications of thermoformed products

in the CEE region


Packaging (Packing of dairy products and other foodstuffs, and secondary packaging of food products and other goods) will show above the average growth rate and will represent two thirds of thermoforming in 2011.

Mass products (mainly disposable goods) will increase slower than the average, but remain on the second place.

The fastest development is forecasted in the vehicle industry, but its share will be only 8%.

6. CONClUSIONS

Central and Eastern Europe is a well developing area experiencing much higher growth rates than Western Europe. Because of the increasing demand on plastic goods the consumption of every plastic is growing.

Plastic manufacturing and converting in the CEE region is increasing, total plastic consumption will be over 10 million tons in 2011.

Central Europe is on a higher level already, therefore the further development is slower, estimated annual growth rates are 3-6%. Poland is the dominating country.

In the Eastern and Southern European countries plastic consumption is on a lower level, but 6-10% annual growth rates are anticipated.

Russia dominates in the CEE region.

Sheet extrusion and thermoforming is developing well.

Thermoforming represents by far the highest use of extruded sheets. Fast increasing applications of thermoforming are packaging, technical parts, consumer goods.Building and technical applications of sheets are developing even faster than thermoforming.

Eastern and Central European Business Development Tel.: +36-1-391-6577 Fax: +36-1-391-6578 E-mail: [email protected] URL: www.ecebd.com Hungarian office: Erzsébet királyné útja 125, 1142 Budapest, Hungary

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