Borden Chemical, Inc. Increases Formaldehyde Capacity

15-Jul-2004

Borden Chemical, Inc. announced it has completed startup of its new formaldehyde plant at its manufacturing complex in Edmonton, Alberta, Canada.

In addition, the company announced the start of a new Six Sigma process improvement initiative designed to increase yields and improve throughputs in its network of formaldehyde plants, with a goal of creating "virtual plants" through anticipated capacity improvements.

"Our new Edmonton plant, as well as our initiative to create additional capacity through process improvements, reinforces our commitment to be the world leader in formaldehyde production and technology," said Reggie Jenkins, Business Director, Formaldehyde and Derivatives.

New Edmonton Plant Adds 200 Million Pounds Of Capacity

The new formaldehyde plant in Edmonton adds 200 million pounds of capacity to the site manufacturing complex, bringing annual production capacity to 460 million pounds of 50 percent formaldehyde solution. Formaldehyde made at the facility is used by Borden Chemical to make resins for oriented strandboard and other engineered wood product applications, and also is sold to industrial users in the region. The new $10 million plant uses silver catalyst technology and state of the art process controls and environmental systems. It is the latest addition to the company's Edmonton complex. In 2002, the company expanded the site's resin production to meet growing demand in western Canada. Built in 1957, the Edmonton complex has undergone a number of significant expansions and improvements over the years and now is one of the largest manufacturing operations in Borden Chemical's plant network.

Six Sigma Productivity Initiative To Generate Additional Network Capacity

The Edmonton plant is one of 17 Borden Chemical facilities in North America producing formaldehyde to serve the wood products sector and industrial markets. Globally, the company has a total network of 25 locations that produce formaldehyde for these markets. Through a joint venture affiliate, it also is constructing a formaldehyde plant in China.

Through a Six Sigma initiative focused on increasing formaldehyde yields and throughput, the company believes it can further expand production without building additional facilities in North America. The goal of the initiative is to create 400 millions pounds of additional capacity in the next three years, the equivalent of two "virtual plants," according to Executive Vice President Joseph Bevilaqua. Six Sigma is a widely recognized methodology to drive process improvement by eliminating waste and inefficiency.

Bevilaqua said the company's Six Sigma "blackbelts" will lead the initiative, using analytical tools and working in project teams with operations, manufacturing and engineering, and commercial associates. Work will start immediately with a focus on North American operations. Methods that create improvements in the North American plant network will be shared globally throughout Borden Chemical's organization.

The company's Six Sigma program includes "voice of the customer" input to ensure critical customer focus and quality aspects are designed into all process enhancements, helping to create competitively advantaged supplier-customer partnerships, Bevilaqua said.

https://www.chemeurope.com/en/news/38511/borden-chemical-inc-increases-formaldehyde-capacity.html