Materials manufacturer Bayer MaterialScience has brought on line a world-scale plant for the production of the chemical toluene diisocyanate (TDI), a main component in high-quality foams, at its site in Dormagen, located in the state of North Rhine-Westphalia. Valued at some EUR250 million, the high-tech plant was inaugurated at a ceremony attended by representatives from politics, industry, public administration authorities and the local community. Including infrastructure and supplier costs, total capital expenditure at Chempark Dormagen amounts to more than EUR400 million.

The site is to become the German firm’s European centre for TDI production. Under construction for 30 months, the new plant replaces a smaller production unit for TDI. The chemical is used in the production of flexible polyurethane foams, used to produce many everyday articles including mattresses, car seats and upholstered furniture. Demand for TDI is expected to continue growing steadily worldwide in the years ahead.

"This investment is also a commitment to Germany as an industrial location - and to the state of North Rhine-Westphalia," said Bayer CEO Marijn Dekkers. In North Rhine-Westphalia alone, Bayer has invested more than EUR1 billion over the past ten years in the maintenance and expansion of MaterialScience production facilities. We want to continue investing in both NRW and Germany," Dekkers said while also pointing out the need for the appropriate boundary conditions.

Patrick Thomas, CEO of Bayer MaterialScience, presented the capital expenditure project within the context of the planned separation of the company from the Bayer Group. "MaterialScience is superbly positioned worldwide and optimally prepared to operate independently. Our products are in demand, our customers value our innovative power, and we are leaders in our markets," he said.

Thomas cited the gas-phase technology developed at Bayer as an example of the company’s innovations. This technology makes TDI production in Dormagen particularly energy and resource efficient. "Compared with a conventional plant with the same capacity, the new facility will reduce energy consumption by up to 60% and require as much as 80% less solvent," Thomas explained.

Some 20 new employees were hired as a result of the project. The project also safeguards existing upstream and logistics jobs at the site. The same applies to thousands of additional jobs associated with TDI production in the value-added chain both in the state of North Rhine-Westphalia and throughout Germany.

With 2013 sales of EUR11.2 billion, Bayer MaterialScience, a Bayer Group company, is among the world’s largest polymer companies. It has 30 production sites and employs approximately 14,300 people around the globe.