Document mpxL7Jz1953L562rVaKpz2k1k

I INTRA-COMPANY CORRESPONDENCE Mr. B, E. Boyd, Toledo R F Shannon, Granville FEASIBILITY STU2T - ALTERNATE PROCESSES FCR MANUFACTURE OF -H-T--C---H---T-S--M--?-:--?----.-7-"---I---I-N--S-U--L--A-T--I-O--N---- / e*. March 15. 1968 -- Mr. E. Gay, Toledo Mr. R. S. Grant, Tolads Mr. M. Hardwick, Berlin Mr. R. J. McEvoy, anrilla Mr. C, G. Staalin, Tolads Mr. R. P. Vitacben, Tolads , Cantral Filaa Last January you askad aa to taka a good hard look at tha various prseassas undar considaration for tha nav Southwaat "Kayls" facility. Attaehad is a copy of ay rapsrt, which sumaritas our study of ovary known proeass. Aa you will nota, I raducod tha list to Just thraa prseassas, which merit further considaration for installation.at tha now facility. Thay include; pan pouring, filter presaingjand bonded aggregate. Tha Boat important question whleh Bust be resolved before any final selection of process is Bade relates to the use of asbestos (Silihoff). Because of this problem, I also included an evaluation of Multi-Temp in ay report. After all, it la the only asbestos free produet available. Unfortunately, I had to compare the various processes strictly on a technical basis. I an not in the position at the aonent to aake a recommendation as to the process or combination of processes we should select for the new facility, because of the laek of cost data. As soon as east projections are completed by Gay and Brooks on all of the processes still under considera tion, wa will be able to at least flake a recommendation as to which process ve feel offers OCF the best produet and gross Margins in the years to cone. I as sura you are already aware of the advantages and disadvantages of Berlin's pan pouring process. Filter pressing has a lot ef Barit. It produces a stronger, better looking produet, the produet is precisian added and the process itself is highly automated. Bonded aggregate produets as they now aid at on the Market have serious shortcomings. They break easily in transit and when handled. Why then would wo still want to consider this process? The reason is if Philip Carey ever solves their breakage problem, they will have the best produet on the Market. Zt is precision aided, lends Itself to automation, is water repellent, higher temperature resistant and la a non-autoelaved product.' Last, but not least, is the fact it has the best ehanee of being made asbestos free. The only reasons for considering Multi-Temp sre the facility is already available, the product ia free of asbestos fibers and it could relieve sosm of the current overload at Berlin, especially in the block market. Zt is ay hope this report gives you a better insight as to the advantages and disadvantages of eaeh process. Once we get eost data we will be in a mueh better position of making a recommendation as to which process is beat for the new facility and for the 1970* market. 42 002 0147 . >.!_-* PLAINTIFFS1* EXHIBIT U/tf-0>/655 PLAINTIFFS EXHIBIT 05/2$-60 -1- IKTSCTXTIOS 'The expanding market far Kaylo pip and block has Rada it naeaesary for OCR not only to expand tha Berlin operation again in 1966, but also to consider building a new facility in tha Southwest. Tha problem facing Management today is defining tha type of process to be installed at tha new {facility. Should it be Berlin's pan pouring process, one of the aore automated processes developed by our competitors or a combination of processes. Also, to be considered by Management is whether Multi-Temp has a place in the high tempera ture market of the future. t To help Management decide which process or cosibination of processes is most suitable for installation at the new Southwest facility, Kaylo RAD carried out an intensive evaluation of all known processes for the manufacture of high temperature Insulation products. A lack of eost data on competitive processes side it necessary for us to limit this study to strictly a technical comparison rather than a aore preferred economic-technical evaluation. The Kaylo RAD study confirmed the fact no other product can compete with Kaylo block made by the pan pouring process. It is by far the best on the marxet. Block aade by the filter press process tends to delaminate, bonded aggregate block crumbles. It should also be noted that neither the filter press process nor the bonded aggregate process can be used to produce structural 1-17 type core for the UL fire rated door market. To maintain our position in the block and core markets, we must continue to produce such products by the pan pouring process. Management must deeide whether block and core products are to be produced at the new Southwest facility. If the answer is yes, a pan pouring flatware line will then have to be installed. The second decision Management must make elates to the type of process or combination of processes to be installed . t the Southwest facility for this production of pipe insulation. If the decision is made to go to a process other than pan pouring, technology will have to be purchased. There is not sufficient time to develop from scratch an alternate process and still meet the timing for construction of the Southwest facility. Management has a number of process options to chose from for the production of pipe insulation at the new Southwest facility. They include; (1) a filter press or bonded aggregate process to produce all sites of pipe up to and Including 30 inch CD, (2) a pan pouring process to produce the smaller pipe sizes and a filter press or bonded aggregate process for the production of lerge size sectional pipe and (3) a pan pouring process to produce the smaller pipe sizes and a Multi-Temp facility (located anywhere) for the production of large size sectional pipe. With our current level of technology, the pan pouring process should not be considered for pouring large else sectional pipe at the new facility. 42 002 0148 J/7 -2 g'JWttSY fCont. ) The Kaylo RAD study indicates that from technical standpoint no on* process has s distinct advantage over other known processes for the Manufacture of high temperature pip* insulation. Each has its advantages, each jslso has a number of disadvantages. Only after a comprehensive cost analysis is Bade on each process will vc be able to decide which process or combination of processes is most suitable for the new Southwest facility. Our intensive technical evaluation of all knsVn processes for the manufacture of high temperature insulation products indicates there are only three processes worthy of further consideration for possible installation at the Southwest facility. They include the Berlin pan pouring process, Johns-ManviTl*'s filter press process and Fnilip Carey* s bonded aggregate process. AH of the other processes considered during this study, with the possible exception of MultiTemp, were rejected, because (1) the process would not yield a product suitable for OCF's needs or (2) the process was not sufficiently developed to meet the time schedule for installation in the new Southwest facility. The Crosfield filter press, non-autoclaved process /ailed on both accounts. Multi-Temp should only be considered for the production of large site sectional pip* and possibly as an additional facility for the production of high temperature bloc* whan Berlin becomes overloaded. Before a final decision is made by Management as to the process they will adopt for installation at the Southwest facility and the produet they will market in the 1970's and 19&0's, they must consider a number of basic questions relating to rising labor costs, need for automation, need for a produet of a higher quality level and the asbestos fiber health threat. This report will attempt to outline the questions which must be considered and aeted on before the final decision as to process is reached. This report will also provide for Manage* ent's consideration a list of the advantages and disadvantages for each of the processes still under consideration for the new Southwest facility. c, u: :trz&:s A visit to Johns-Manville*s Research Center has already been Bade to appraise the filter press process. This visit aust be followed-up by an OCF prepared cost projection and a plant visit. A visit should also be aade to Philip Carey to appraise their banded aggregate process. Zt too should be followedup by a cost projection and. if possible, a plant visit. Cost projections must be aade or updated on the filter press, bonded aggregate, pan pouring and Multi-Temp processes. To achieve a fair ccaparison, east projections for the pan pouring process should be aade on a more automated process than now exists at Berlin. The latter is a reasonable request, since a major R A D/plant program is currently underway to reduce labor and batch costs and to achieve a higher degree of automation of the pan pouring process. Cost projections on the filter press and bonded aggregate processes must be prepared at two levels of activity. One cost projection should be based on the assumption the filter press or bonded aggregate process will be used to Prd the. tire line of pipe up tp end inciting 24" x 3". The second eost 4 -42 002 0149 -3- --rr::~rATiONS (cart.) projection should be based on the assumption the filter press or bonded aggregate process will be limited to the production of large site sectional pipe only. Under these conditions it must be tied in with the eost projection covering par. pouring of the smaller sizes of pipe. The Hilti-Tesp eost projection should be limited to large size sectional pipe only. It too must be tied in with the eost projection covering the pan jjpuring of the smaller sizes of pipe. To get a good economic picture of the various options available to us. eost projections should be prepared on the following process ocmbinstions. Block Zl21 2. Pan poured. Filter pressed. 2. Par. poured. Banded aggregate. 3- Par. poured. Small sizes, pan poured; large sizes, filter pressed. 4. Par. poured. Small sizes, pen poured; large sizes. bonded aggregate 5- Pan poured. Small sizes, pan poured; large sizes. Kulti-Tsap. It is possible the new Southwest facility will be limited to the production of pipe. Kaylo block would all be produced at Berlin and stockpiled st various distribution centers in the Southwest snd West. Sinee this is a possible Management option, eost projections should also be made on the five pipe process combinations listed above, minus the pan pouring facility for block. In deciding the type of process to be installed in the new Southwest facility, .'Management will have to give serioua consideration to the Silikoff-asbestos fiber-health threat. What effeet, if any, will it have on the future growth of the overall high temperature insulation market and our share of the marxet ir. particular? It could be the most important decision we face in deciding which process to install in the Southwest facility. The only asbestos free product on the market during the pest 5*10 ysars was Multi-Temp. All three processes, pan pouring, filter press snd bonded aggregate now under consideration for the new facility contain asbestos. The probability of removing asbestos from the non-autoelaved bonded aggregate product is far greater than it is from products made by eithsr the Johns-MsnviUe filter press or OCF* s pan pouring process, both of vhieh require autoclaving and are based on highly alXaline batch compositions. In the event Management decides to install the Berlin pan pouring process for both pipe snd block st the new Southwest facility, Kaylo BAD still recommends that an alternate process, either the filter press or bonded eggregste, also be installed on a limited basis either et Berlin or et the new facility. This should be further supported by an K A D program on the ehesen alternate process st Gnr.villa. These recommendations are being made because it is our opinion the company should net have to again face the 'choice-of-process' dilemma we are now facing. If future market conditions demand e product made by a process other than pan pouring, we will have, the technology, knowhow snd experience to convert our manufacturing facilit1ies over to the new process without delay. Regardless ef the decision as to the process to be installed et the new South west facility, the major R A D/plant program currently wderway to automate the ,*n pouring process st Berlin should proceed full speed ahead, especially for tpe processing ef Kaylo block. y 42 002 0150 J/f -Au * F.Zrr.TZT^ATI^S Cart.) During this planning period, many have suggested two processes be installed in the new Southwest facility, the psn pouring process for block snd smaller sizes of pipe snd s filter press for the asnufseture of larger sixes of sectionil pipe. The first question which must be resolved is will our customers snd the 1 sr.d C Marketing Division sccept two types of pipe products. If the snswer is yes, the second question is would the asrket slso accept Multi-Temp if it were limited to the lsrger sizes of sections^pipe. If the only res son for purchasing s filter press or bonded sggregste process from one of our competitors is for the asnufseture of large size sectional pipe, i.e., sizes in the 13 to 2U inch ID range, then we aust ask whether it would be better to direct a major effort toward producing largo size sectional pipe by the psn pouring process (at acceptable gross aargin levels) rather than direct such a major effort and expense toward a new process and technology for such a snail portion of the overall market. Actually, there has been little, if any, technical effort directed toward learning how to pan pour large size sectional pipe with adequate gross margins. To achieve sueh a result, changes in mold cesign, as well as new techniques of pouring, prehardening and handling, must be developed. If liilti-Terep pipe is acceptable to the market and gross margins are projected as being adequate when limited to large size sectionals only, then OCF already has a product, a process and a facility available to service the large size sectional pipe market. Asbestos The firit question whieh must be resolved is the use of asbestos as the rein forcing fiber. Today, all high temperature insulations contain asbestos reinforcement. In fact,, during the past 10 years, the only known asbestos free high temperature Insulation on the market was Multi-Temp, a product sold for a brief period of time by OCF. To emphasise hew important is the problem of asbestos as a fiber reinforcement, I would like to eall to your attention D. V. Ladd's letter dated October 9. 196? to D. M. Barthold concern ing asbestos and Xaylo expansion. Quoting from Mr. Ladd's memo, "I think there is no other consideration whieh is of paramount importance to this whole subject. As you are well aware, the government will probably blow the whistle relative to the use of asbestos in the not too distant future and before we embark upon a substantial expansion program at Berlin and/or consider putting a new facility in the Southwest, we had better be damn sure that we have an answer to the asbestos threat. Work has been done on this in the past and to date there has been no successful answer." The probability of replacing asbestos fibers in ealeiua silioate products is rated at best at 50/50. He solution to this problem has been found by OCF. Johna-Manville told us recently they too have had no success in getting glass fibers to survive the autoclave procees. If the decision is to install the Berlin pan pouring process or the Johns-Kanville filter press process at the Southwest facility, we are accepting the fact the reinforcement used will probably be asbestos (taless a breakthrough is made by X 4 D during the next year or so in modifying glass fibers to survive the alkali and the autoclaving process). " j 42 002 0131 -5 Asbestos (Cent.) If Management decides the asbestos threat is still vith us, then careful consideration should be given to the bonded aggregate process. It does not involve the highly alkaline ealelun silicate batch (which attacksTglats) and does not require as part of the process the use of expensive autoclaves (which dissolve glass). Although Careytemp, Philip Carey's bonded aggregate high te.rperafure insulation, contains some asbestos the probability of develop ing a bonded aggregate product reinforced wit 100 percent glass fibers remains quite hugri. Johns-Mar.ville told us during our recent meeting in Manville, New Jersey, they were surprised we never followed-up on our high temperature glass fiber insulation product line (Multi-Temp). By the tone of the conversation, they seemed to be concerned about this product. If it were to be placed back on tha markat, it would ba tha only asbastos frae product available. If the esbestos threat is raal and is a serious threat to OCF's participation in tha high tamperaiure insulation market of tha future, thenrwe should consider directing a major ?. * 1 affort toward product and/or process modifications to rsisa gross margins to adequate levels. Alternate Process Licensing If s decision is made to install a proeass other than pan pouring at tha nav Southwest facility, technology will have to be purchased. There is not sufficient time to develop from scratch an altamata process and still meet the timing for construction of the new facility. Since the purchase of technology will probably mean taking out a license from a competitor, the cost of the license and its adverse effect on gross margins and competitive position in the market must all ba carafully considered. OIF already has 20 yaers or more of technology on pan pouring and several yaars plus a patant position on Kulti-Tanp. Major strides have been made in recant months ir. mechanizing the pen pouring process at Berlin. No costs for licensing will be involved if the pan pouring process is choson for producing both pipe and block at the new facility. The same is true if large site sectional pipe ara produced by the Multi-Temp process. Competitive Processes Before tabulating tha major advantages and disadvantages for oaeh of the Ihree processes still under consideration for installation in tha new facility and for Multi-Temp, I would like to compare briefly each process against the others. The major problems with produets made by the pan pouring proeass include: (1) they are not as strong as products mad# by the filter press proeass, (2) they have a visual appearance Inferior to both filter press and bonded aggregate products, (3) not being precision molded, dimensional and nesting problems result in customer complaints and (4) products mads by pan pouring involve considerable hand labor to produce, labor costs for the production of pan poured pipe constitutes nearly 40 pareont of the total manufacturing eost. Vith l.bor costa rising rapidly, pipe made by the pan pouring process could be /, 42 002 0132 Uf Cc-r^-.itire Processes 'Cent. ) / -6- *l placed at a cappetitive disadvantage in the future with pipe Bade by one of the r.are automated processes, such as filter press or bonded aggregate. It is quite unfortunate OCF did nat place the sane emphasis during the past 5 ta 10 years an automating our pan pouring -process as our competitors have on theirs. If ve had, it is quite possible ve would not be today in the position of having ta take a license from one of our competitors. Kayla made by the pan pouring process does have a number of advantages aver all other products on the narket.today. They include; (1) the ability to produce by one process both light density heat Insulation and heavy density str-ctur&l core material, (2) the tremendous flexibility of the daily nix of goads, coupled with the ability ta expedite desired various sizes and thick nesses of bath pipe and block, (3) the best service shipping cycle in the industry, (4) the versatility of batch composition to achieve lower costs of batch on a cubic foot basis, (3) production of the best block products on the marxen ana (c) production of light density heat insulation and structural care with maximum temperature resistance of 1800 F. As ta competitive processes, the filter press developed by Johns-Xanville has drawn the most Interest from OCF personnel. There is ns doubt it has a number of advantages over both the pan pouring and bonded aggregate processes. Prad-cts made by this process have considerably higher flexural, eompressive and impact strengths. It has a better visual appearance than Kaylo and like the banded aggregate process, produces pipe and block products vhieh are precision maided. The filter press process also lends itself to the production of large size sectional pipe up to and Including 30 inches CD. Field breakage of filter pressed products is extremely low. Finally, the process as now developed by Johns-Manville is highly automated. When compared ta products made by the bonded aggregate process, filter pressed produets have two distinct advantages, higher physical strengths and lower breakage characteristics. The filter press process has a number of disadvantages when compared directly with the par. pouring process. They include; (1) shipping delivery cycles are considerably longer, (2) flejdbility in the daily mix of goods is poor, (3) batch easts are higher, (4) does not lend Itself to the fabrication of fittings, (3) product densities are higher, (6) has a tendency to delaminate when moisture is absorbed, (7) will not produce structural eore, (8) produces block products less acceptable to the market and (9) operating efficiencies due to a 5 to 6 hour period for mold ehange over are still very lew compared to operating efficiencies for the pan pouring process. The bonded aggregate proeess as developed by ftilip Carey has many advantages over bath the pan pouring and filter press processes. If and when Philip Carey solves their handleabillty and breakage problems, they will have by far the best product on the market. Some of the major advantages of the bonded aggregate process include; (1) a very low manufacturing eost, (2) a very low investment east, (3) a non-autoelaved product, (4) ability to nee glass fiber as reinforcement, (3) ability to produce a precision molded produet, (6) a proress which lends Itself to high production rates at low investment costs, (7) a 1303 to 1600 F temperature resistant product and (8) water repellency. 42 002 0153 7- 9 Cc-roetitive Processes (Cant.) When compared directly with filter pressing, the banded Aggregate process has tvs major disadvantages. It produces a product vith lover strengths and sr.e that is susceptible to breakage vhen roughly handled. On the other hand, it has a number of advantages over filter pressed products. Overall process costs are lover, batch costs are substantially lover, the product ean be Marketed for higher temperature application/ (1500 vs 12003 F), it is water repellent, fittings can be fabricated from the product, investment costs are such lover (no autoclaves) and it probably ean be nade fhee of asbestos. The ability to use glass fibers as reinforcement in this product, vhen combined with the tremendous glass fiber knovhov available to OCF personnel, makes it mandatory our Management give careful consideration to the bonded aggregate process before rejecting it in favor of a process which requires asbestos as the reinforcing fiber. Where does the Multi-Temp product and process fit in the overall picture? The product as ve currently know it does not yield adequate gross margins to compete across the board with pan poured, filter pressed or bonded aggregate products. Kovever, one must remember it is a glass fiber product, one that is a natural for OCF to market and one that could be produced at any of our G? plants. If it were to be placed back on the market, it would be the only asbestos free produet on the marxet today. Should ve go ahead and install the pan pouring process at the new Southwest facility rather than the filter press or bonded aggregate process? This is a decision which Management must make. If the filter press or bonded aggregate process is chosen to produce the complete range of products at the new facility then there is no need to reconsider Multi-Temp at this time. If and only if the asbestos threat reaches the 'danger point' would ve then want to reconsider an asbestos free product, such as Multi-Temp for the high temperature Insulation market. If for some reason such m high eost 1' vnsing, Management decides to install the pan pouring process in the new facility, ve will again be feeing the problem of deciding how to produce large size sectional pipe. Under such circumstances Multi-Temp could be the answer. Even if Management decides to go vith the pan pouring process for all production except large sise sectional and choses to license the filter press or banded aggregate process to produce these produets, we must raise the question whether it is worth all the problems and costs to license another process from one of our competitors for such a small percentage of the market. Ve must market large size seetional pipe to remain competitive. If we ehose not to license another process, we would have three choices; (1) fabricate large size seetional pipe as we do now at Berlin, (2) start up a crash program to learn how to pour large size sectional pipe at adequate groas margins by the pan pouring process or (3) we.could market a line of large site seetional Multi* Temp pipe. Only under those conditions where all production except large size sectional pipe is to be made by the'pan pouring process at the new Southwest facility would I recommend we reconsider Multi-Teqp. United to the production of large site seetional pipe (and.to block when Berlin block producing facilities y 42 002 0154 i 0 Cometitlve Processes (Cor.t. ) -e- beepne aver taxed a* they ir today), Multi-Temp may have a placa in today's market. It may b chaapar ta praduca large aita factional pipa byftha MultiTemp pracass than by tha currant, fabrication technique used at Berlin. It vauld increase aur share af tha to^al narkat immediately. Pan Pouring (Kavla) r*. u > * tares 1. The highest nix af goods flexibility. This flexibility results in tha lavest varkabla.finished goods inventory for any of tha processes r.ov in use for tha aar.ufactura af high tanparatura insulation products. 2. The bast shipping cycle in tha high tanparatura insulation industry with normal inventories. J .3 Block produced by tha pan pouring process is tha acknowledged leader of all flatware high tanparatura insulations on tha market today. 4. Pan pouring is an established process at OCF. Plant personnel are wall trained as to process. Va have a 20* year working background with this process. 5. Process permits considerable versatility as to bateh composition. Various additives and extenders can be added to reduce costs. 6. Ksylo contains an extremely low percentage of soluble ehloride. Meets AIC and military spee requirements. 7. Higher daily production of pieces are procurable in the same sizes and thicknesses for both pipe and block when needed for crediting shipments than in any of tha co^etitiv# manufacturing processes. 6. The 1968 expansion at Berlin will further improve the service cycle. It is already better than tbs service cycle of any of cur competitors. 9. Ksylo has high acceptance icthe high tei^erature insulation market among owners, distributors and applicators* 10. Pan pouring is the only process whieh lends Itself to the production of structural eore. Only one with UL fire ratings. H. K-20 pipe and block products produced by the pan pouring process are in a class by themselves. K-20 products can be used st temperatures up to 1800 F. / 12. Batch miring for pan pouring is the least complicated. Be gelling of bateh required. 42 002 0155 Si'f f l L L E r L [ E t [ r r '9- w' F<-. r.r (Kayla) (Cent. ) Advantages (Cent. ) 13. Drying carts are currently lover for pan poured products thir. far products produced by any other process. This advantage vlll soar, be lost since the SID cylinder patent expired in January 1968. 11. Densities of pan paured' products are lover than densities of filter pressed products. 1 15. In general, thernal conductivities of pan poured products are lover than for competitive products. 16. Pan pouring operating efficiencies are considerably higher than they are for filter pressing. 17. Fittings can be cut and fabricated from pan poured products. Filter press products delaminate whan attempts are Bade to fabricate them into fittings. 18. No license vould be involved if the decision is to install a pan pouring process at the nev Southwest facility. Disadvantages 1. Physical strengths of pan poured products are lover than those obtained from filter pressed products. | 2'.' Visual appearance of surface is inferior to both filter press and bonded aggregate products. 3. Fan pouring is not a precision process. Problems of dimensional stability and nesting of ware show up from time to time in the field. U. With currant level of technology, large size seetional pipe cannot be poured with adequate gross margins by the pan pouring process. 5 Like filter pressed products, pan poured products are reinforced with asbestos fibers. With current level of technology, glass fibers cannot be used in either process. 6. Fan pouring requires the use of expensive autoclaves (SH)' s) and Dovtherm units. 7. Fan poured X-10 products have a masdmun temperature application of 1200 F vs 1500 to 16300 F for bonded aggregate products. 6. Pan poured products have higher breakage losses while in transit and vbar. handled at tba job sita than filtar pressed products. 42 002 0156 -10- Ft- Fouri--:? fKavls) (Cart.) Pi sidya-.tares (Car.t. ) 9. Par. pouring involves considerable hand labor. Labor costs to produce pipe are currently averaging 40 percent of total manufacturing costs. Level of autoration at Berlin is still very low. - 10. Process job efficiencies^for the pan pouring process are lower than those for competitive processes, because of the high degree of mar-handling in the plant. 11. Pan poured products are not water repellent. Only bonded aggregated products and Kulti-Temp are water repellent today. Filter Press (Johrs-Manville and Ruberoid) dr s-.tares / 1. Filter pressed products have higher physical strengths in all three categories; K/?., compressive end impact strengths. 2. 03 end ID surfaces are smooth and free of air hales. Has an excellent visual appearance. 3. Filter pressing es developed by Jahr.s-Xanvilie is a highly automated process. Labor costs as a percentage of total manufacturing east are quite law. 4. The filter press process lends itself to the molding of large size sectional pipe up to and including 24" x 3"* 5. The Johns-Manville product contains no aaasite asbestos, only 7 percent ehrysotile. 6. Filter pressed produets suffer very little in transit and job site breakage. 7. Process jab efficiencies are extremely high (98-99*pereent) for the filter press process as developed by Johns-Menville. 8. Cylinder capacity for induration of green ware is greater for filter pressed products than for pan poured products. This is because filter pressed ware ean be stripped from the mold prior to autoelaving. 9. Filter pressed products have fewer broken corner problems during processing. 10. Very little weste material in the Jafans-HenriHe process. Only legs of pipe are trimmed. ,/ 42 002 0157 2* -11v/- *r Press 'Car-..) Pi sairsntscvs 1. Shipping cycles are considerably longer than those for pen poured products. * 2. Poor flexibility in the daily mix of goods. 3. Products contain asbestos fibers. With current level of technology, glass fibers cannot be used as reinforeenent. 1. Filter pressed products are not water repellent. Tend to delaminate when wet. 5. Johns-Manville probably do not aeet Mil Specs, because of high chloride content. .6 Process involves the use of ^expensive autoclaves. .7 Filter pressed products have majamun temperature applications of 1200 F vs 1500-1600 F for bonded aggregate produets. e. Block produced by the Lter press process is substantially inferior to pan poured block and has a tendency to delaminate. 9. Structural core produets cannot be made by the filter press process. No U1 fire rated products. 10. Filter press products have a tendency to delaminate trher. moisture is absorbed. 11. Operating efficiencies still remain low (65 percent) due to 5 to 6 hours required for mold change over. 12. Bateh easts are considerably higher than those far the pan pouring process. Not flejdble concerning use of additives to lower batch costs. 13* Densities of filter pressed products are higher than densities of pan poured products. li*. A very large inventory of finished goads must be maintained, because of the limited range of the mix of goods. 15 Production rates of same sites of ware is usually less per hour for filter press than for pan pouring. 16. Skilled craftsmen are required to change the precision meld equipment. 17. Fittings cannot be fabricated from filter pressed ware -- problem is one of delaaination. 42 002 0158 sn i .12- Ho-.=*d A-rr-aie (Philip Ctrev) Acvar.ta res rt 1. Xa autoclave required to produce bonded aggregate product*.\ 2. Lav investment costs. ^ 3. Precision molded product - good dimensional rUbility - nests veil. 4. Smooth surface - no air boles. 5. Car. be reinforced with glass. 6. Product is water repellent. 7. Temperature limitations for bonded aggregate (Careytsmp) products are 15TC to lo33a F (330 to 4039 F higher than for pan poured and filter pressed products). . 3onded aggregate offers potential of being a highly automated process ~ potential low labor cost process. $. 3atch costs are lower than those for the filter press process. 10. The bonded aggregate process is capable of producing large size sectional pipe. 11. Pipe fittings can be fabricated from bonded aggregate produets. disadvantages 1. Bonded aggregate products arc quite fragile, break easily when bandied. 2. Has lower physical properties than ealeiua silicate type products. 3. Flejdbility in the daily six of goods is rsther poor. 4. Like filter press products, shipping cycles would be much longer than those for the pen pouring process. 5. Bonded aggregate block is inferior to Kaylo block. Crumbles when handled. 6. Bonded aggregate process will not yield structural cere. The tendency for the product to crumble makes it unsuitable for use la UL fire rated door applications. 7. Large iuventoriea of finished goods must be maintained, because of the limited range of the mix of goods. B. Bonded aggregate products do not fabricate as well as pen poured ; products due to breakage f^oa sawing and cutting. ' 1 42 002 0159 St* c i l /'V r i ( v f i i Multi-Tere yCCF_) Arfys-tsces 1,, Multi-Temp is a product aide from Fiberglas, the bade product of the Corporation. It is free of asbestos fibers. ( 2. It lends itself to decentralized operations, adaptable to any General Products plant capable of Baking Fiberglas pipe Insulation. 3. The product is rain and snov resistant and water repellent in that capacity. 4. The saturation process is not a complicated one to operate efficiently. 5. Multi-Temp pipe has an acceptable "K" value. 6. Multi-Temp pipe can be applied to 1930 F surfaces. 7. Large size sectional pipe can be produced by the Multi-Temp process. . Breakage due to rough handling would be nominal. 9. Easy to cut, good fabrication characteristics. 10. Excellent gross aargins (33 percent) projected for block. Disadvantages 1. The maximum temperature resistance of the product was 1000 F rather than 1200 F far K-10 Kayla. 2. The ends and edges were susceptible to in transit and handling damage. 3. Jfcjlti-Tsmp products were acre dusty than competitive materials. 4. Projected gross margins for Multi-Tamp pipe vers lower then those projected for Kaylo pipe. 5* In the Newark pilot plant facility, job efficiencies wars very low due to excessive offware. Major causes of offware were excessive end rough handling, improper operetion of proeoss and burr, ware in the oven. 6. Distributors objsetsd to carrying invsntoriss of two diffsrent types of high temperature insulation, which called for additional warehouse space. 7* Softer produet than the calcium sllieeto end bonded aggregate type products. 42 002 0160 Jif