Shape

A magazine from the Sapa Group • # 2 2007

› PROFILES GIVE
GYROCOPTER A LIFT

› EXTRUDED LAMPPOSTS
SAVE LIVES

› THE SPANISH MAESTRO

OF SMALL PROFILES

BRILLIANT
ENERGY SOURCE
Solar panels are a growing market for Sapa – Page 12

›
# 2 2007 SHAPE • 
CONTENTS

Genesis shows the way

M
y first few months with Sapa have been
dominated by the fusion of Sapa’s and
Alcoa’s aluminium profile operations. That
work is still in progress, and now new challenges lie
ahead. One of them is the continuing commitment to
our Genesis business system, which is based on the
Toyota Production System.
Although most Sapa employees have received
training in the system, we are still not quite where
we want to be. The goal is that Genesis should be
a central element of all our operations and colour
Sapa’s corporate culture. The business system
12
xx
should not just be regarded as a tool, but as a
complete solution for improving the efficiency of
The sun – an inexhaustible energy supply
German solar panel manufacturer Conergy buy large numbers of aluminium profiles from Sapa.
our working routines. By decentralising tasks such
as planning, co-ordination and implementation,
Genesis lays the foundation for a more efficient and
logical way of working that will make our organisa-
tion better and more effective.
But the benefits of Genesis are not just limited to
Sapa’s own production chain. It is also about mak-
ing improvements for our customers. A better and
more effective organisation leads to reduced costs,
which in turn creates benefits for Sapa’s customers.
This is the goal of the work we call Customer Value
Management. 06 10
Sapa faces other challenges when it comes
Small profiles are made very accurately at Lampposts made from aluminium profiles
to the environment, health and safety. Our goal is
Sapa Profiles’ La Selva plant in Spain. crumple in collisions, saving lives.
clear: No employee should be injured at work. We
are planning a series of measures to improve the
situation. We will achieve our goal through regular
training initiatives, specially appointed safety repre-
sentatives at each plant and regular safety inspec-
tions. The safest working
methods are also the most
efficient; I’m convinced
of that.

18 20
Ole Enger, Indecasa in Spain designs minimalist furniture Swedish industrial brushes clear snow
President and CEO with aluminium profile frames. from runways with the help of Sapa.

Sapa is an international business group that deve- Shape is the Sapa Group’s customer magazine, and Printing: Fagerblads, Västerås, Sweden
lops, manufactures and markets value-added alu- is issued twice annually in 14 languages. Shape is Cover photo: Adam Lubroth
minium profiles, profile-based components and sys- also available at www.sapagroup.com. Changes of address: Customers should inform
tems and heat exchanger strips in aluminium. Sapa Editor-in-Chief: Eva Ekselius their contact person at Sapa, employees their
has annual sales of approximately EUR 3.8 billion Editors: Anna-Lena Ahlberg Jansen, Mats Lundström salary department and others the Communications
and roughly 15,000 employees in companies throug- Graphic design: Karin Löwencrantz Department on +46 (0)8 459 59 00.
We shape the future hout Europe, and in the United States and China. Production: OTW Publishing

 SHAPE • # 2 2007
 BRIEF NOTICES

PHOTO DANIEL CRoYDoN

Perfectly framed billboards
Prismaflex in Staffanstorp makes billboards for outdoor advertising, and Sapa
makes the profiles for these billboards, which can be seen all over the world in a
variety of designs and sizes.
Together, the two companies have now developed an entirely new illuminated
frame – or haloframe – in record time.
“we were given the task by JC Decaux at the end of June,” explains Anders
Janson, product developer at Prismaflex. “we worked with Sapa all through the
summer to get everything finished by the start of October, when eleven big bill-
boards in London were fitted with haloframes. The billboards have internal light-
ing, and these frames enhance the impact by matching the lighting to the colour
of the image; you can add blue lighting to a blue image and so on.”
Sapa created four totally new profiles for the billboards, which measure
10 x 5 metres. The whole project took just 10 weeks from start to finish, despite
the summer holidays.
“It was a really enjoyable job, and a challenge to get everything done in such a
short time. we would never have managed it without Sapa and JC Decaux,” says
Anders Janson.

Clear benefits Fireproof breakthrough

Emhart Glass in Sundsvall is a multi- in manufacturing, such as piping and
national company that develops and welding. And of course the neater In the face of stiff competition, Sapa Building System in Germany
manufactures machines for making finish is an added bonus,” says Rune recently won an order for 600 fireproof doors for a new office
glass, and is the only company of its Bergman from Emhart Glass. building in Munich.
type in Sweden. Almost the entire output of the “The order is one of our biggest ever,” says sales and marketing
This advanced machinery is designed company’s glass packaging machines manager Udo Büchel. “It marks a breakthrough for Sapa into the
to run 24 hours a day in full production, is exported. The machines are built in German market for fireproof
and a single machine can produce Sundsvall and tailored to the custom- products, which has grown
several hundred bottles per minute. To ers’ needs. The components of the rapidly since the fire at
meet these demands, every component machines are manufactured in Örebro Düsseldorf Airport in
of the machine has to satisfy exception- or sourced from a variety of suppliers, of 2004. Since then a
ally high standards of quality. which Sapa is one. growing number of pub-
An extruded hollow aluminium profile “Sapa are good at meeting our lic buildings have been
is used to build the conveyor that carries needs and wishes. we have a good designed with fireproof
bottles from the machine. Cooling air partnership when it comes to producing partitions, and emer-
and compressed air for the valves are aluminium profiles that are optimised to gency exit routes have
fed through the hollow profile. suit our customers’ requirements,” says been improved.”
“This eliminates a great deal of work Rune Bergman. Sapa has been offer-
ing fireproof products
since 2005. They are
thoroughly tested and able to
meet very strict requirements.
The Secur II door is made
from 75-millimetre anodised or
painted aluminium profiles and
7–32 millimetre-thick glass. It has
no filling, but can still resist extreme-
ly high temperatures – exceeding
800 °C for around 30 minutes.

# 2 2007 SHAPE • 3
VINJETT

›
Ole Enger.

SHAPING THE
“In Sweden we have had a close relationship
with our customers for many years, which has
enabled us to develop an understanding of our cus-

NEW SAPA
tomers’ production processes. We have found new
applications for aluminium and developed new
products and designs. This strategy has made Sapa
a world leader, and we intend to apply it through-
out the Group.”

ANOTHER WAY OF improving business is to invest in

Collaboration with customers must be further improved under the more expertise and make a greater commitment to
new Sapa Profiles. The company is therefore investing in more research and development. The employee training
expertise and more research and development. programme that is already in place will be extend-
ed. Sapa is also recruiting more engineers.
“our goal is to become even better at finding the best solutions in “We need to build on our know-how. This will
partnership with our customers,” says ole Enger, President and CEo. allow us to improve our own processes, and help
us work with our customers and find the best solu-
tions to their needs.”

T
he amalgamation this summer of the pro- for a long time. There was a desire throughout the Sapa is currently the global market leader in alu-
file operations of Sapa and Alcoa resulted organisation to move in this direction.” minium profiles. But Ole Enger believes that the
in the formation of the largest aluminium One of the biggest challenges associated with company has good potential for further growth,
profile company in the world. It has meant sev- the amalgamation of Sapa and Alcoa, in Ole partly by establishing Sapa’s profile operations in
eral hectic moths for Ola Enger, who took over Enger’s eyes, has been developing a system for trade markets where the company does not yet have a
in February as President and ceo of the Group. between countries where the Sapa Group operates. strong base.
But he is pleased with the results so far. “Under our decentralised organisational struc- “This applies especially to China. We’re look-
“It’s gone very well – far better than expected. ture the local marketing companies are responsible ing at possible acquisitions, but nothing has been
We have doubled in size and at the same time for sales and marketing in their own markets.” decided yet. Our goal is to have firmly established
managed to create a decentralised organisation. This also means that the companies must be ourselves in China in a couple of years.”
Everyone is very enthusiastic and there is a great equally enthusiastic about selling products from Ole explains that Sapa is continuously striving
atmosphere throughout the company,” he says. other suppliers as from their own plants. It’s been for improvements – in business efficiency and pro-
a big challenge to find a working model that will ductivity. In the long-term process of change, the
THE ALCOA ORGANISATION has experienced rather support this.” customer always comes first.
more change than Sapa as a result of the merg- “Our overriding goal is to make Sapa more
er. According to Ole Enger this is because of WITH THE NEW organisation in place, Sapa is now effective at solving our customers’ problems. If we
the more centralised administration model that concentrating on further improvements in the can’t manage to deliver better solutions to our cus-
existed in Alcoa. ways it does business, particularly from its custom- tomers, then we have failed,” says Ole Enger.
“The changes there have been more apparent. ers’ viewpoint. Ole Enger cites Swedish operations
But the reason things have gone so well is that the as an example when he describes how Sapa will TExT CARL HJELM
company’s employees have wanted these changes become an even better partner. PHOTO DANILo SCHIAvELLA

4 SHAPE • # 2 2007
 ›
FIVE SAPA MANAGERS RESPOND

Sapa Profile’s new Torbjörn Sternsjö,

Business Area President
Jack Miller,
Business Area President

organisation is divided Asia.

Reply: “In Asia we have
North America.
Reply: “Our success in

into regions with five to focus on growth, as

Sapa Profiles is still a
North America will be
determined by how well

new Business Area very small player there.

we intend to establish ourselves in this
we meet the needs of
our customers. To help us get closer to

Presidents. enormous market by actively seeking

out and taking advantage of all available
them, we have returned to a more decen-
tralised structure, with sales, manufactur-

We asked them opportunities. This is the only way we will

become a truly global company and reap
ing, and administration working together
to drive the business forward.”

where their focus lies the benefits that follow.”

in the future:

Arne Rengstedt, Paul Warton, Tor Gule,

Business Area Business Area President Business Area
President Central North Europe (Belgium, President South
Europe (Germany, United kingdom, Europe (Portugal,
Hungary, Poland, Netherlands, Sweden Spain, France and Italy).
Romania, and Slovakia). and Denmark). He also Reply: “we will
Reply: “we will have heads the key Account continue to develop
the most extensive Management and the our relationships with
offering to the German market, and we will Business Segment organisation. customers through innovative design, sup-
develop more products to introduce there. Reply: “I want to ensure that our teams port and partnerships. Our ability to supply
Our position in the 10 new European increase their focus on the Health & Safety packages and help improve customer
Union countries will be the strongest. we of our people during this significant change productivity are main priorities. The Sapa
will have a strong base to develop busi- process.” brand shall be associated with excellence
ness in this fast-growing area.” in quality and service.”

# 2 2007 SHAPE • 5
INSIGHT: SPAIN

WHEN SMALL

IS BIG
At a time when many manufacturers are investing in increas-
ingly large presses, Sapa Profiles’ La Selva in Spain has found
its own way. The company has specialised in small profiles
and is busy making something big from something small.

T
he Catalonian city of aluminium solutions. Sapa’s plant in La Selva, ances, I can claim that we do not supply profiles
Tarragona, once a large town located in a modern industrial park outside the but solutions. Our products are really specialties,
in the Roman Empire, today old town, has recently become an established increasingly often a final product that is ready for
attracts thousands of tourists, European player in the extrusion of small profiles. assembly.”
with its ancient monuments “I usually say that La Selva is a plant with
and beautiful Mediterranean its own strong personality,” explains the plant THE PLANT IN LA SELVA has two modern 1,350 and
coastline, the Costa Dorada. manager, Francesc Clos, who has 20 years’ expe- 1,500 ton six-inch presses and produced 16 mil-
More of a secret is that rience in extrusion. lion metres of aluminium profiles last year.
Tarragona also attracts an increasing number of “Seeing that our speciality is very lightweight “The day we start measuring our success in
Spanish and international purchasers of advanced profiles manufactured with extremely small toler- metres instead of tons we’re among the giants,”

 SHAPE • # 2 2007
› # 2 2007 SHAPE • 
“ The day we start
measuring our
success in metres
instead of tons we’re
among the giants ”
says Clos with a smile,
referring to La Selva’s
really lightweight
products.
The smallest
profile in the range
weighs only 30 grams.
The diameter varies
between 5 and 170
millimetres.
“We have stuck to a
Francesc Clos.
market segment that
many other producers
have abandoned in their ambition for increased
production in terms of number of tons per hour.
By using our working methods and our organisa-
tion, we have gained competitiveness in a segment
that is both labour intensive and very technically to the surface finish. La Selva can supply products “In our industry, proximity to the customer
demanding,” he says. with a finish equivalent to a surface roughness of is crucial and we’ve made great efforts to opti-
less than six microns. One example of a seemingly mise our service and logistics. We can therefore
SUCCESS IS ALSO SEEN in the shift in markets. Sales simple but perfect product is the roof bars on some offer a customer in Germany, for example, the
to the construction sector are falling, while sales Audi models. The narrow profile with a perfectly same lead time as our German competitors,”
of more advanced industrial applications to, for smooth surface joins the car’s roof and sides and What the Romans did with Tarragona dur-
example, the automotive and energy sectors are provides a means of attaching any roof accessories. ing the Roman Empire, Sapa La Selva seems to
increasing. “There is a clear trend for our customers to have succeeded in doing with its plant: creating
Exports are growing and now account for 60 per design in more and more functionality in the a modern and international centre on the beau-
cent of sales. The Benelux countries, France, the profiles through more sophisticated design. In tiful Mediterranean coast.
UK and Germany are the largest foreign markets. order to meet the demands for advanced solutions,
The biggest challenge in the manufacture of we’re increasing our machine and after-treatment
small profiles is precision. Tolerance for variances is capability to satisfy higher quality and performance Text Erico Oller Westerberg
almost non-existent, and these demands also apply requirements,” says Clos. PHoto David Levin

Small products – high precision

One of La Selva’s customers orders but the tolerance on the diameter was
large volumes of aluminium pipes for only a tenth of a millimetre. Only La
the manufacture of cooling systems for Selva succeeded in getting the per-
artificial ice rinks. centage of rejected pipes to remain
“It’s actually a very simple design, below the stipulated percentage.”

 SHAPE • # 2 2007
 BRIEF NOTICES

Reducing noise
with glass and aluminium
To reduce noise levels along motorways the Danish with Sapa. “It consists of one large and one small
company Milewide makes acoustic screens from profile that are clipped together. No special tools
aluminium and acrylic glass, a combination that is are needed for assembly, just a standard rubber
both effective and good-looking. mallet.”
The screens are assembled on site, and the The customer saves the cost of drilling and
original version consisted of several aluminium threading, assembly is much quicker and the install-
profiles that were joined using numerous bolts. This ers get a better working environment.
was time-consuming and expensive, so a year ago “The new design was used for the first time along
Milewide and Sapa began a development project. a motorway in Herning. Over a 600-metre stretch it
“we’ve now found a solution that everyone is eliminated 20,000 bolts. That’s a really big improve-

Eliminating happy with,” says Gustav Lundkvist, an engineer ment,” says Ole Refshauge from Milewide.

bus fires
Fire can often spread rapidly on a bus, and there
is little time to escape. Under Swedish fire regu-
lations all buses weighing over 10 tonnes must
therefore be fitted with a permanent extinguisher.
A few years ago the Swedish company Dafo
Brand developed an aluminium fire extinguisher
container for heavy vehicles such as buses,
trucks and forestry machines, in collaboration
with Sapa.
In contrast to normal handheld fire extinguish-
ers, the container, which is filled with a liquid
extinguisher medium, can be laid flat. It takes up
little space and is easy to service and install. The
large aluminium profile for the container was
complex and has to meet strict dimensional
requirements.
“Sapa contacted us and said they would like
to develop it,” says kaj Dahlström, technical
designer with Dafo Brand. “we worked very well
together and it has resulted in a simpler internal
profile and an outer profile that just clips in place.”

Greener blue lights

“If all the police cars in Sweden switched to our ‘“green”’ blue emergency technology that we are the first to use, and
lights it would cut fuel costs by up to EUR 2 million each year,” says Anders it carries away surplus heat so that the LEDs
wiqvist, CEO of Standby AB, which manufactures alarm and warning can be powered to produce more light,” says
equipment for emergency vehicles and working vehicles. Anders wiqvist.
The secret behind the saving lies in aerodynamics and new technology. “we will be doing climate testing this winter and
The low-energy emergency lights – with six specially made aluminium expect to start supplying the new emergency
profiles from Sapa, light fittings and plastic covers – have been redesigned lights in spring 2008.”
with a new aerodynamic shape. Compared to previous models, the air
resistance is reduced by a full 75 per cent.
“The light units have been tested in a wind tunnel in Stuttgart, so
their performance has been verified. The reduced air resistance is good
for the environment and gives lower fuel consumption, as well as less
The aluminium substrate is a type of circuit board
noise inside the car. The standard bulbs have been replaced with low-
that uses an aluminium sheet with several layers of
energy LEDs.
insulation and conducting tracks for electronics.
“The LEDs are mounted on an aluminium substrate. This is new

# 2 2007 SHAPE • 9
ON THE ROAD

Hinged lampposts
mean safer roads
Aluminium lampposts have many advantages:
long life span, no maintenance, and they give
way in a collision, reducing the risk of human
injury.
Some models can also be easily taken down
by one person when it’s time to replace a bulb or

T
he Sapa Pole Products plant in Drunen in the install something on the lamp. The most important
Netherlands has been making aluminium lamp- argument, however, is traffic safety. The lampposts can
posts since the 1960s. be chosen to suit the type of road, traffic situation and
The Netherlands is one of the first countries to realise environment. The lampposts all meet eu safety norms (en
the big advantages of aluminium over steel in street 12767 and en 40) and come in three classes depending
lighting – 40 per cent of Dutch street lamps are made on how much energy they absorb in a crash (high, low and
of aluminium, in contrast to just three per cent in the zero absorption).
rest of Europe.
“We have a lot of convincing to do. We need to ON A MOTORWAY surrounded by open fields, the ideal lamp-
market our products more, especially to the roads post doesn’t absorb any energy, but just snaps in two
authorities in each country. Their choice of materi- at ground level, while traffic on a bridge or in the city
als is largely a matter of culture and tradition,” says requires lampposts that absorb more energy.
Sales Director Leopold Moormann. Last year the Drunen plant made some 70,000 lamp-
Other advantages include the ease with which posts. An expansion is planned for the future – as more
the lampposts can be assembled, transported, countries discover the advantages of aluminium.
decorated and shaped, the fact that they have no
welded joints and are fully recyclable. Text THOMAS ÖSTBERG

The hinged design

also simplifies
maintenance.

10 SHAPE • # 2 2007
 “ This is a building
that you can show
your children and

Cubic
grandchildren and
feel proud of ”

ART
The New Museum on the Bowery, Lower Manhattan is one of this
year’s most talked about buildings. Designed by the Japanese
architect duo SANAA, the Museum marks the start of a major
regeneration of the whole district. The facade is constructed using
Sapa’s decor profiles.

T
he Bowery is located just east of Little Although New York is one of the world’s
Italy and is not one of Manhattan’s trend- leading art cities, it has not previously had a
ier districts – yet. The New Museum of museum devoted exclusively to contemporary
Contemporary Art opens on the Bowery in art. The New Museum is set to fill this gap.
December and marks the start of a revitalisation The cladding contractor is McGrath
project for the district that is being financed by Architectural Sheet Metal in Minnesota. The
both private and federal funds. firm specialises in architect-designed build-
The New Museum is the first art museum
A new art museum in Manhattan automati- ings and has previously supplied exciting
that has been built from scratch in Lower
cally arouses considerable interest, but this time metal facades for art museums in Denver and Manhattan in New York.
it is the building itself that has been the focus Delaware, and for Walker Art Museum in
of attention. The New Museum has been Minnesota. This is the first time they have cho-
designed by the architectural world’s hottest sen to work in extruded aluminum.
duo, the Tokyo-based Kazuyo Sejima and Ryue “It gave us the best opportunities to design a was then shipped to a firm in Ohio for surface
Nishizawa of sanaa. The practice is well known facade that was both flexible and strong. This is finishing. In order to create a consistent design,
for its elegant, pure style and cubic forms. a special building and its design was particularly the project architects also chose to use the same
demanding in terms of quality and precision. solution for the exteriors of the lifts.
THE NEW MUSEUM has been designed as a tower of There are not many firms in the usa that could “The logistics surrounding such a major con-
stacked semi-transparent boxes. Sapa’s profiles manage this,” says Mark LaSalle of McGrath. struction project in Manhattan are tricky. You
form the grid behind the transparent mesh of can’t store the materials on site, and deliveries
expanded brushed aluminum that clads the facade. MARK LASALLE DEVELOPED a new type of fixing that have to be made just in time. Collaboration
“We’ve never been involved in such a prestigious is manufactured by Sapa and accommodates the with Sapa has gone exactly as we had hoped and
construction project before. This is a building that movement of the building and thermal expan- we’re now bidding for a new project in Florida,
you can show your children and grandchildren sion of the extruded wall panels so that they fit using the same type of solution from Sapa,” says
and feel proud of,” says Tim Fox, Midwest regional the irregular building. The decor facade was Mark LaSalle.
sales manager for Sapa in North America. extruded in Sapa’s plant in South Dakota, but Text THOMAS ARNROTH

# 2 2007 SHAPE • 11
 Photo ADAM LUBROTH
CUTTING EDGE

Schüco’s installation
at a solar farm in
Corral de Almaguer
(Toledo - Spain).

12 SHAPE • # 2 2007
SUNNY
OUTLOOK
It is difficult to imagine a company more in tune with the
times than Conergy. This fast-growing company is involved
in renewable energy and is a global leader in several
areas. Conergy has become one of the most important
customers for the German division of Sapa/Alcoa.

he Hamburg-based nies, are entering the market,” says Nikolaus orchestrated investment by central govern-
company Conergy Krane, who is a senior executive with respon- ment and the business world to build a new
specialises in renew- sibility for the subsidiary Epurion and for sector in what is perhaps the most environ-
able energy through Conergy Service. mentally aware industrial nation in Europe.
several subsidiaries, Nikolaus Krane sits in a soberly designed Homeowners who install solar panels on their
ranging from solar meeting room at head office with a view of one roofs receive a central government grant and
panel production to of Hamburg’s many canals. Shape has arranged the electricity companies have to accept and
wind turbines, bioen- a meeting with one of the leading people pay a market price for the power produced by
ergy and heat pumps. behind Conergy’s phenomenal growth. these solar panels. In this way, the German solar
But Conergy is also involved in the financing, “I was the fifth person hired by the company. energy market has developed in just a few years
servicing and maintenance of major installa- That was in 1998. Now we have more than and the country has the world’s largest domestic
tions for collecting solar energy. 2,000 employees,” he says. market for solar panels.
This listed growth company has risen to be To date, these investments have been fur-
one of Germany’s brightest stars in the corpo- THE OBVIOUS QUESTION is how a company can be ther fuelled by the stabilisation of oil prices at
rate world. Conergy has grown from almost so in tune with developments. a sustained high level, while carbon dioxide
nothing to a turnover of more than eur 1 bil- “Good timing of course, but also a strategic emissions have become a serious issue. Some 40
lion in less than ten years, and its future pros- approach and a capacity for value creation with other countries have introduced similar regula-
pects are extremely bright. the aid of competent staff and new technology. tions to Germany and have started incentive
“Even so, we’re still only in the first stage of And last but not least: we dared to take risks in programmes to facilitate investments in renew-
growth. We’re seeing an enormous increase in order to win. We had both a fighting spirit and ably energy. Global growth in the sector is
interest, particularly as the really big companies luck,” says Nikolaus Krane. estimated at 20 per cent annually. The amount
in the energy sector, such as Siemens, General
Electric, Eon, Vattenfall as well as oil compa-
The alternative energy sector is, on the
whole, a German success story. It is a cleverly
of energy from renewable sources has already
overtaken that produced by nuclear power. ›
# 2 2007 SHAPE • 13
 Production of solar panels is fully automated at the new plant in Frankfurt an der Oder.

› This means new markets for Conergy, and in

2006 foreign sales rose by 268 per cent, consid-
erably above expectations.
means that we can accompany
Conergy in its global expansion. In
our conversations with the customer,
brand. Sales to dealers and consum-
ers take place through its subsidiary,
SunTechnics.
“It was a surprise that solar panels grew so we’ve mentioned our interest in joint The other subsidiary, Epuron, is
much. We’re the biggest supplier in the German projects, such as a new mounting sys- not involved in product sales but in
market for panels, but the domestic market is tem and a new tracker system,” says the financing and planning of very
maturing with an ever-increasing number of Lothar Konawski. large renewable energy projects.
manufacturers. The major potential is abroad, In order to cope with the rush of “Module production will be the
mainly in southern Europe. We’re already customers, Conergy has invested core of Conergy’s operations in the
Nikolaus Krane, senior
the second biggest supplier in Europe,” says in a new plant in Frankfurt an der executive for Conergy,
foreseeable future, but it’s important
Nikolaus Krane. Oder in eastern Germany, near the believes that solar that we diversify operations, since
Polish border, where production has panel arrays in areas new technologies and new opportu-
FOR SAPA, this of course means increased sales of recently begun. such as North Africa nities in renewable energy are being
profiles, which are used both as frames and mount- “The new plant means that we could supply Europe created all the time. We are constant-
ing systems for solar panels. can keep more in step with demand, with much of its elec- ly looking for new ways of adding
“Sales of aluminium profiles to Conergy have but by the start of next year we run tricity needs. value,” says Nikolaus Krane.
increased steadily from 500 tons in 2003 to almost the risk of hitting the production
2,000 tons last year,” says Lothar Konawski, who is ceiling again,” says Nikolaus Krane, who is pleased ONE SUCH OPPORTUNITY is concentrating solar col-
customer account manager for Conergy at Sapa. that the plant also gives Conergy an opportunity lectors, an area that Nikolaus Krane thinks will
Collaboration began with Sapa modifying the to handle more aspects of the production proc- become very big.
design of the frame profiles for Conergy’s solar ess, from wafer production and cell production “Large amounts of energy can be produced by
panels and thereby reducing their weight, making to module production. But operations are mainly reflecting the sun’s rays to a point. If this technolo-
the handling cheaper. focussed on the development of inverters for heat gy is developed properly through the construction
Lothar Konawski hopes to be able to increase recovery and mounting systems and monitoring of really large plants in North Africa, for example,
this collaboration and provide Conergy with better systems for larger panel installations. it could provide a real alternative for the energy
service, increasing customer value. The finished solar panels are then sold through needs of European countries.”
“Our large network of plants in all markets its own wholesale business under the Conergy TEXT MATS LUNDSTRÖM

Solar energy in brief

In just four hours, the earth

receives as much solar energy as
the whole of mankind consumes
› A solar collector consists of linked parallel
pipes filled with a circulating glycol mixture
that is warmed by the sun’s rays. The assembly sits
during a full year. But consider- in an insulated box covered with a sheet of glass.
able expertise and research are One problem with solar collectors is that it is dif-
required to convert the sun’s rays ficult to store surplus energy during the warmest
into usable energy. time of the year.

14 SHAPE • # 2 2007
 CUTTING EDGE

“We’re the only compa-

ny in the sector that is not
owned by nor has interests
in the oil industry or the
conventional energy sector.
We focus exclusively on
solar energy and the sus-
tainable supply of energy,”
says Bellido.
Isofotón develops and Julián Bellido, deputy
purchasing manager of
manufactures technical
Isofotón.
solutions for exploiting
solar energy using photovoltaic cells. As early as
the year 2000 the company also began developing
optical solutions for capturing and focusing solar
radiation into small storage areas.

THE MODULAR CONSTRUCTION of the cells means they

can be used on roofs or to build pv plants. The

A SPANISH
use of new materials as well as their technologi-
cal advances, such as silicon, have contributed
substantially to the increased efficiency of the cells.
Isofotón can supply small systems for rural areas in

sunshine story
developing countries, such as the 35,000 systems
sold to an electricity company in Morocco, or
build complex solar power stations with panels
that track the movement of the sun. The company
IIsofotón was established in Malaga by a group of university is behind the solar power station in Carmona in
researchers in solar cell technology in 1981. Twenty-six years later southern Spain, which is Europe’s largest, produc-
ing six megawatts.
the company achieved technological leadership and sales of Regardless of the design and purpose, the panels
EUR 77 million. are generally framed with aluminium profiles, and
Isofotón buys around 1,500 tons of aluminium

R
enewable energy is the future, particu- protect the environment and contribute to the products per year.
larly solar energy,” according to Julián development of isolated communities. Sapa in Spain entered into a partnership with
Bellido, Isofotón’s deputy purchasing An important part of the company’s efforts is Isofotón a few years ago to supply anodised alu-
manager. still targeted at energy projects in rural areas of minium frames for the solar panels.
“It’s not only a question of replacing fossil South America, the Caribbean and Africa. “We’re so dependent on aluminium products
fuel, but also of offering an electricity supply Isofotón has succeeded in growing, develop- that we’ve chosen to have three suppliers: one local
to the two billion people who are not currently ing new products and making a profit, while eu supplier and two global suppliers. We want to
connected to the electricity grid at all.” protecting the environment and creating prosper- safeguard deliveries to our plant and we are sure
Isofotón was established as a result of a ity in developing and remote areas of the world. that Sapa will continue to be one of our key suppli-
university project aimed at developing lead- According to Bellido, part of the explanation is ers,” says Bellido.
ing-edge technology in solar energy, in order to that they do not compete with themselves. TEXT ERICO OLLER WESTERBERG

› The most important application for solar

energy is electricity generation. When silicon
is exposed to light it reacts by generating a cur-
› The efficiency of solar panels is still relatively
low at around 20 per cent. This means that a
great deal of sunlight is required to produce large
rent. A single photocell produces a relatively low amounts of energy. One way of increasing energy
voltage, so solar cells are usually linked in series to production is to mount the solar panels on a mov-
create larger solar panels. ing structure that can track the sun’s movement
across the sky, maximising electricity production.

# 2 2007 SHAPE • 15
BRIEF NOTICES

10,000
times cleaner air
Aluminium scaffold Demand for mobile smoking cubicles is growing rapidly
as smoking restrictions are introduced around the world.

gains ground
The cubicles capture tobacco smoke effectively and mean that
smokers are no longer banished to dreary smoking rooms.
The smoking cubicles made by Swedish company Smoke
Because weight is an important factor when erecting scaf- Free Systems have frames built from aluminium profiles. Various
folding, more and more customers are choosing lightweight filters in the walls remove particles and gases from the air, mak-
aluminium scaffolding, reports wilhelm Layher, a German ing it 10,000 times cleaner than air elsewhere in the room.
company that is Europe’s leading manufacturer of scaffold- A new series of cubicles has now been developed for the
ing systems. French market, in partnership with Sapa.
The company’s product range includes the traditional, mod- “we recommend open or semi-open cubicles, but under
ular scaffolding that is versatile and quick to erect, frame French law they have to be closed. Now that our new mod-
scaffolding for fast and easy facade erection, as well as lad- els – the SF 6000 and smaller SF 4000 – are complete,
ders, mobile scaffolding, stages and platforms. we can see that they’ve made a big difference,” says Bo
wilhelm Layher aims to make scaffolding components that Dolk-Petersson, project manager at Smoke Free Systems.
are as light as possible without compromising on stability. Sapa was closely involved in the development work,
For many years the company has therefore used aluminium which took very little time. The SF 6000 went from sketch
profiles from Sapa, which are pressed, cut, punched, riveted to prototype in just four months and is now being manufac-
and welded at its plant in Eibensbach. tured by Sapa.
“This demonstrates Sapa’s strength. You can get alu-
minium profiles anywhere, but not in combination with devel-
opment, prototype building, specification and consultancy,”
says Bo Dolk-Petersson.

Enjoying the spa

experience at home
The new Felicity steam shower from sauna man- The supporting structure is made from anodised
ufacturer Tylö gives consumers the chance to aluminium with walls and doors of toughened safety
enjoy the spa experience at home. The shower glass. Plumbing and electronics are concealed behind
is the result of close collaboration on develop- the aluminium profiles. The design places very strict
ment between Tylö and Sapa. demands on dimensional tolerances and finish. Sapa
Felicity takes up no more space than a show- has worked closely with Tylö for many years and
er enclosure and comes in three versions. Each Patrik karlsson from Technical Service was involved
has a steam generator, thermostatic mixer, hand throughout the development process.
shower, ceiling with shower head, control panel, “we were able to bounce ideas off each other
seat and shower tray. and our partnership worked well financially, as well
The more exclusive models feature massage as speeding up the project,” says Jan Bjärnhag,
nozzles, rain function, built-in lighting and cascade. product manager for Tylö.

 SHAPE • # 2 2007
THE PEARL of Qatar
The Pearl is one of the world’s most extraordinary construction projects. A 400-hectare
man-made island that will provide luxury accommodation, five-star hotels, marinas and luxury
shopping. Sapa is supplying the building system for two of the first towers being built.

A
lthough Qatar is the richest country per constantly updated. Everything backs the advertis-
capita in the Arabian Peninsula, it has not ers’ message that The Pearl will one day be opulent,
kept up with the growth of tourism as well luxurious and secure.
as neighbouring countries such as Dubai.
This is all set to change. SAPA IS SUPPLYING the aluminium profiles for two of
The Pearl has already attracted massive publicity, the first tower blocks being built around one of the
and the nearer the project approaches completion, marinas.
the more attention it will get. It is an entirely new, “We’ve only worked on a few exclusive projects
man-made island shaped to provide the longest in the Middle East before, but we now have local
possible coastline, with several marinas designed to production through a firm that we’ve certified.
provide natural harbours. This means we can produce our building systems
in compliance with all us and European require-
THE PEARL IS TARGETED at international investors as ments, locally in the Middle East, which gives us a products, but also the support we provide to con-
well as visitors and, in the future, at residents from strong competitive advantage with lead times,” says tractors who engage us. We’re involved throughout
all over the world. This multi-billion dollar project export director Bernard de Bruyckere. the project right up to completion, through our
is scheduled for completion in five years’ time, pro- The tempo is high on The Pearl project, which local project teams in Qatar and Abu Dhabi. This
viding Qatar with its very own Riviera, on which is scheduled for completion in 2009. Sapa has great gives the client the security that is especially impor-
the development has been modelled. hopes of supplying solutions for more of the towers tant on such a big and prestigious project as The
Progress on The Pearl can be followed online, via to be built on the island. Pearl,” says de Bruyckere.
satellite images, a live webcam and images that are “The strength of our solution is not only our Text Thomas Arnroth

The Pearl of Qatar is

modelled on the French
and Italian Riviera.

The Pearl in brief

• 400-hectare man-made island located

20 km north of Qatar’s capital Doha.
• 40-kilometre coastline of which half will
be beaches.
• 11,000 luxury villas are being built and the
island will have 40,000 residents.
• 700 marina berths and three five-star hotels.
• 15,000 square metres of luxury retail
space are under construction.

# 2 2007 SHAPE • 17
DESIGN

A PASSION
FOR ALUMINIUM
Furniture from Indecasa can be described as minimalist, stylistically pure, futuristic and,
not least, comfortable. The Spanish company has been making aluminium furniture for
several decades, sometimes combined with other materials, but always with winning designs.

I
ndecasa mostly makes furniture for public ness with a true passion when Francisco López
spaces, specialising in chairs, benches, outdoor de Vega describes the process from concept to
furniture and lounge furniture. The furniture finished product. He is personally involved in
always has an aluminium frame, combined with almost every aspect of the process, and although
other materials such as leather, plastics and textiles. he has no design training himself, he has firm
The company has made furniture for airports, opinions on what he believes will work, prefer-
offices, restaurants, bars and cafes, and exports to ring a pared-down, ‘less is more’ style.
countries worldwide. “I either like something or I don’t,” is his
Indecasa was established in 1963 and began by explanation of his attitude to design.
manufacturing garden and camping furniture,
hence the choice of this SINCE INDECASA made its first garden furniture in
durable and weather- the 1960s, the market has changed and so has
resistant material. Francisco López de Vega, CEO of Indecasa. the company. The importance of functional-
ity has increased, environmental awareness has
“If a piece of our furniture doesn’t contain risen and interest in furnishing and design has
aluminium, then it’s not an Indecasa product,” taken off. Good design is a strong feature of
says Francisco López de Vega, ceo of Indecasa Indecasa furniture. It is furniture that brings to
and son of the founder. mind terms such as futuristic, hi-tech and mini-
malist, and one of the company’s chairs indeed
WHEN FRANCISCO’S FATHER started up the company, featured in the science fiction film The Matrix.
aluminium was a very exotic material; it was The company has a creative partnership with
a totally new and innovative choice for mak- a number of independent designers and often
ing furniture. Indecasa was relatively unique looks outside Spain to find the right individual.
to the market and it was not until much later Nico Smeenk, Kurt Thut and Sapiens Design
that aluminium furniture became trendy. The are some of the furniture designers the com-
choice of material and the focus on good pany has worked with. The recently retired
design have proved to be a winning concept. designer Joan Casa has been of great impor-
The company, which is now based in the tance to the company and has had a major
small town of Manresa, outside Barcelona, influence on its design language.
employs 60 people. The plant has a For Francisco López de Vega, it is important that
number of specially made machines that the partnership between the firm and the designer
are used to cut, bend, polish and treat the is based on a good understanding and that tech-
The Barcino chair was selected by furniture components. nology and aesthetics go hand in hand. He believes
the design magazine MD as one of You can tell that Indecasa is a family busi- that many designers focus on how stylish the final
the 200 Best Products of the Century.

18 SHAPE • # 2 2007
 TRIAL
The minimalist Trial chair, with its alumin-
ium feet and base, and its black leather
seat, featured in the film The Matrix.

product will be and not on the technical process.

Although aluminium is a material with
which the company’s technicians and design-
ers have long experience, there are always some
details that can cause glitches in production.
“Aluminium is not always an easy material
to work with. We have to choose the alloy and
grain structure carefully when we make small or
fragile parts,” explains Francisco López de Vega,
adding that several pieces of furniture are made
with aluminium profiles from Sapa.
›

THE PLANT IN MANRESA now has its own complex

quality control process, and invests a great deal OYYO
The Dutch industrial designer Nico
in material analysis and research and develop-
OYYO Smeenk created the Oyyo chair.
ment, as well as quality and the environment.
The technical process of creat-
Aluminium is of course a recyclable material
ing the chair was complicated. But
and the company’s furniture meets the market’s
once the prototype was finished
growing eco-labelling requirements. But it is a
– the frame in aluminium and the
material that also presents challenges and set-
seat in rigid plastic with cutout
backs, says Francisco López.
holes – it was very easy to pro-
“Complications can arise along the way, but I
duce.
believe that everything is possible – if you make
ndå inte helt isolerad.
compromises.”
Text Jessica Johansson
photos Indecasa

# 2 2007 SHAPE • 19
 WHAT A TA
SAFE LANDINGS WHATEVER THE WEATHER
Clearing snow effectively is critical for safety at many airports.
Lycksele Airport uses a unique system from Svenska Industriborstar
that was developed in close collaboration with Sapa.
“It’s very simple and easy to use,” says airport worker Rune
Hedman.

H
igh quality runways for takeoff and land- time on the landing runway. It also makes the has been developed by Svenska Industriborstar
ing are essential if airports are to guarantee plane more susceptible to side winds,” says airport (sib) uses brushes housed in cassettes that can be
the safety of passengers. In some parts of worker Rune Hedman. replaced without dismantling the brush shaft.
the world the weather conditions place special To ensure that takeoff and landing runways Rune Hedman explains that this is a big improve-
demands on maintenance – particularly in areas always have sufficiently high braking values, ment over other systems, which require removal of
that get frequent snow. sweeper and blower machines are usually towed the brush shaft during replacement.
Staff at Lycksele Airport know this only too well. behind the snow ploughs. After the runway has “You remove a ring, pull out the old cassette
Its geographic location in northern Sweden means been ploughed clear, these machines sweep away from its slot and fit a new one. It’s a very simple
that the airport gets heavy snow in winter. Because the remaining snow and blow the runway clear. system that is easy to use and saves us a lot of time,”
even the lightest snow covering affects plane take- “In winter we basically run the machines every he says.
offs and landings, snow-clearing operations must day, and if we get snow it can be several times a
be highly efficient at all times. Snow reduces the day,” says Rune. The sweeper and blower machines can also be
braking value of the runway, which is measured The brushes on the machines have a big impact used in summer when the snow has gone. In
regularly using special equipment. on the effectiveness of snow clearing. Because the 2004 the airport at Lycksele was extended.
“A low braking value reduces the braking per- machines at Lycksele Airport are used frequently, Before every takeoff and landing the machines
formance of the plane. Among other things that the worn brushes generally need to be replaced were sent out to clear building sand and gravel
increases the risk that the plane will not stop in several times each season. The brush system that from the runways.

20 SHAPE • # 2 2007
SK!
The brushes are
mainly used for
snow, but can also
be used to clear
sand and gravel
from runways.

The brush
cassettes fit
into slots in the
profiles, making
them easy to
replace.

Rune Hedman is
an old hand at
clearing snow from
Lycksele Airport.

The machines can also be used to remove tailored to the customer’s requirements. minium. That know-how is one of main reasons
rubber deposits from the runway surface. “Because it was difficult and expensive to get we have chosen Sapa as a partner,” she says.
sib was founded in 1955 and the company hold of steel tube for production we chose to Sapa now supplies almost five times as many
employs 15 people, based in Västerås. At the make the shafts from aluminium profiles instead. aluminium profiles to sib as it did five years ago.
end of the 1970s the company introduced the Aluminium is cheaper and lighter. Aluminium Patrick Massana, a sales representative with Sapa,
unique, patented brush system that now forms also permits more variations in the design,” says explains that Sapa and sib keep in touch regularly,
the core of its business. Markets for the brush Caroline Droeser, ceo of sib. usually a couple of times a month. Sapa also makes
system include Scandinavia, Russia, Greenland, regular visits to sib, up to five times each year.
Canada and the usa. SAPA HAS BEEN SUPPLYING SIB for around 20 years and “It can be more often when we’re developing new
The sib system consists of a shaft with slots into helped to develop the system. products. I believe that collaboration of this type is
which the brush cassettes slide. Previously the shaft Caroline Droeser explains that Sapa’s expertise is best for both partners. For us at Sapa it is important
was made of a steel tube to which aluminium pro- one of the key reasons why sib chose to work more that the product we develop gives the best perform-
files were attached. Now the shaft is manufactured closely with the company. ance for our customers. We work hard to improve
entirely from aluminium profiles that are made by “We’re always discussing how we can improve our products continuously, and to come up with
Sapa. The shaft consists of five parts, or profiles, the product. We try to find new solutions together ideas and suggestions,” he says.
that are joined to create a cylinder. sib makes the all the time. Thanks to Sapa we are kept updated Text Carl Hjelm
shafts in two different diameters and the length is on new techniques and ways of working with alu- photo SAMUEL ARNFJELL

# 2 2007 SHAPE • 21
 Focusing
on the wall
When Danish company BANG & OLUFSEN needed profiles
for a new store presentation stand they contacted Sapa.
The result was not just a stand that was discreet and easy
to use, but also the start of a deeper collaboration.

T
he Focus Wall presentation stand is an “This work presented a challenge to optimise
important element in bang & olufsen our own processes,” says Johnny Christensen,
stores that is designed to show off the latest an engineer, and Thomas Behrndtz, key
products and promotional messages. Because of account manager with Sapa Profiler a/s.
this it has to be updated regularly. Automation and a combination of new
“It’s important that our in-store fur- techniques give Sapa the opportunity to make
nishings are discreet and elegant. We improvements in pricing and quality.
want our products to take centre stage. “A central part of Sapa’s philosophy is to be
Aluminium frames fit this requirement a partner in collaboration. Together with the
very well,” says Juval Friis Philosof, customer we create a ‘win-win’ situation. The
in-house store designer with bang & Focus Wall project has meant more than finan-
olufsen. cial benefits alone for bang & olufsen and for
In August 2006 Sapa in Denmark received an Sapa,” says Thomas Behrndtz.
enquiry from bang & olufsen. Discussions fol-
lowed and a series of improvements were made text Jesper Elm Larsen
to the specification of requirements. Sapa’s com- PHOTO MAGNUS GLANS
plete solution entails providing everything from
aluminium frames to screws and fittings, in the
form of a complete “ikea kit” that is delivered
direct bang & olufsen’s central warehouse.

BY REPLACING STEEL with aluminium the weight Focus Wall in brief

of the entire package has been reduced from 25
to 16 kilograms. Handling costs have also been • The presentation stand consists of a sheet
reduced by using simpler packaging. of MDF that provides a mounting surface,
“Sapa’s expertise was a great help to us. We’ve an aluminium frame made from profiles and
continuously raised the bar and arrived at new horizontal profiles for shelves. The horizontal
solutions together,” says Thomas Svendsgaard, profiles are threaded internally so that they can
buyer with bang & olufsen. easily be attached to the MDF sheet using
There is big demand for Focus Wall version specially developed heavy-duty screws.
2.0. The stands are needed in a large number of
new stores and for updating existing stores. • The Focus Wall comes in two sizes: 120 and
In order to meet bang & olufsen’s pricing and 180 centimetres wide. A silicone strip makes
capacity requirements Sapa took a fresh approach it easy to attach textile banners to the aluminium
to production, including investing in a robot sys- frame.
tem to simplify machining of the profiles.

22 SHAPE • # 2 2007
 PROFILE

IN THE HANDS oF

DAVID MARSHALL At the start of his tions, but the end result is
David Marshall is an artist who career David Marshall always unique and unusual;
combines aluminium with used a lot of scrap every piece is different.”
materials such as glass, leather material – why not David Marshall does not like
convert waste into minimalism and feels we have
and wood. The results are something beautiful? too many pared-down designs
fantastic works of art. Scrap, old cars and around us today. He believes
gearboxes, were trans- that too few people make
formed into art in his things with their own hands,

M
ultitalented Scottish polymath David hands. “It’s a sort of so he travels widely around the
Marshall has been practising his art for creative recycling,” he world learning from other art-
many years in his adopted homeland of explains. ists and craftsmen. He has, for
Spain, more precisely Ronda in Andalusia. He has instance, worked with smiths
a colourful background and has worked among ALUMINIUM IS NOT an in Rajasthan, drum makers in
other things as a copywriter, welder, architect and easy material to work Ghana and leather craftsmen
jewellery designer (for clients that have included with, according to David Marshall works in Spain, but his art in Indonesia – a mixture of
Christian Dior). David Marshall. He also sells in the Nordic region, Ireland and tradition and inspiration that
However, David Marshall is still best known has had to experiment Saudi Arabia. clearly influences his art in
for his sculptures and design work, which include a great deal to get the the form of fantastic organic
furniture and lamps. He first took an interest in results he wanted. It shapes.
aluminium during a trip to Colombia over thirty is a brittle and delicate material, but he sees it He likes to combine his favourite material with
years ago. David took a job as a welder and was as a challenge and loves working with old craft others, such as pigskin, glass, wood and wool, and
able to try working with aluminium, learning techniques. often brings home unusual materials from his trav-
about its properties, good and bad. David uses the material as it is, or melts it to els. He recently began collaborating with local glass
“You can do things with aluminium that you make castings and sculptures. craftsmen in Thailand, for example.
can’t do with other materials. I can make the mate- “It takes discipline to work with aluminium,
rial move, I can bend it and cast it,” he comments but because I get bored easily it is the perfect
on his fascination for this metal. challenge for me. I have some technical limita- TExT JESSICA JoHANSSoN

# 2 2007 SHAPE • 23
AND FINALLY

PRoFILES GIvE
GYROCOPTER A LIFT
It’s not a plane and it’s not a
L
ike an aeroplane, an autogyro is powered but very strong,
by a propeller; but the autogyro has no and able to han-
helicopter. The gyrocopter, or wings. Instead, it is fitted with a rotor dle high vertical
autogyro, is sort of a mix of blade that is turned by the headwind and stresses without
updraughts, giving good lift even at low speeds. twisting.
both – only much cheaper. You Some differences between a gyrocopter and “They also Rotor blade made from profiles.
can park the popular AutoGyro a helicopter are that the gyro doesn’t need a tail have a very asym-
rotor (which keeps the helicopter from spin- metrical profile. But we worked with the Sapa
MT-03 on your own driveway for ning round) and that the gyrocopter can’t do a in Belgium and succeeded in creating a geo-
“just” 50,000 euro. vertical takeoff – although in a headwind it only metric shape that met all the requirements,”
needs a takeoff run of ten metres. A “prerotator” says Michael Brodam, who is responsible for
is used to pick up the rotor speed to 250 rpM. application & design engineering at Sapa in
Düsseldorf.
THE VITAL ROTORon the AutoGyro MT-03 is The MT-03 is described as safe and relatively
manufactured by HTc/AutoGyro in Hildesheim easy to learn to fly. The standard version costs just
in Germany, and this is where Sapa comes into over 50,000 euro. Add to that the cost of obtain-
the picture. The rotor blade is made of two alu- ing a ul-b flight certificate, about 5,000 euro. The
minium sections, each four metres long. little flying machine is easy to load on a trailer and
Designing the sections was a technical chal- park in a regular garage.
lenge. Their walls are just 1.1 millimetres thick, TExT THoMAS ÖSTBERG

24 SHAPE • # 2 2007