SABIC Innovative Plastics’ Resins Take Performance to New Heights in Ultra-Light Award Winning Airline Trolleys from LSG Sky Chefs & Norduyn

BERGEN OP ZOOM, The Netherlands – May 27, 2010 – SABIC Innovative Plastics’ expansive portfolio of high-performance, lightweight resins is helping airline industry customers soar. The company’s ability to provide “one-stop shopping” enabled
LSG Sky Chefs and Norduyn to create a new line of ultra-light in-flight trolleys that can help reduce aircraft fuel consumption and emissions. LSG Sky Chefs is the world's largest provider of in-flight services. Norduyn is a designer and manufacturer of innovative galley and cabin product solutions for commercial aviation. The trolleys, launched at the
Aircraft Interiors Expo and displayed at SABIC Innovative Plastics’ stand #7A48 – and also at Norduyn’s and LSG Sky Chefs’ stands – feature UV-resistant Ultem* resin for the extrusion profiles and door latch, and tough Noryl* resin for the frame and other components.

The trolleys were recently announced as a 2010 Crystal Cabin Award winner, in the Green Cabin, Health and Safety category at this year’s Aircraft Interiors Show. The Crystal Cabin Award is the only international award for excellence in aircraft interior innovation.

“SABIC Innovative Plastics is a leader in the development of innovative materials that help our aircraft industry customers grow and succeed,” said Hilmar Backer, transportation industry manager, SABIC Innovative Plastics. “This means helping them drive down fossil fuel usage through weight reduction; delivering increasingly higher performance with newer and better materials; and giving them new technologies to improve safety and open up new design possibilities to create tomorrow’s aircraft interior equipment.”`

Serving Up a New In-Flight Trolley

Jointly designed by LSG Sky Chefs and Norduyn, the new full- and half-size trolleys utilize Noryl resin in the frame and critical components to replace metal, thereby slashing weight by up to 40 percent and reducing the number of parts by a third. This high-tech engineered plastic also provides outstanding non-halogenated flame retardance and enhanced safety with industry-leading flame/smoke/toxicity (FST) performance meeting Federal Aviation Regulation (FAR) 25.853 requirements. Noryl resin was also selected for its exceptional hydrostability and low density and for its proven track record in a wide and growing range of important aircraft applications.

Ultem resin was selected for external components, including profiles that support the frame, due to its exceptional resistance to UV light and ability to be custom-colored, allowing Norduyn and LSG Sky Chefs to offer trolleys in airlines’ brand colors. This material meets FAR 25.853 requirements and OSU 65/65 heat release standards. Ultem resin also provides excellent impact and chemical resistance to withstand the demands of cabin operations, including frequent bumps and bangs and daily cleaning.

“A top-performing materials solution that specifically enabled us to achieve extreme light weight, durability, chemical and hot water resistance, regulatory compliance and parts consolidation was absolutely critical to the success of our new trolley line,” said Thomas Köhler, head of engineering, LSG Sky Chefs. “SABIC Innovative Plastics delivered exactly what we needed. Not only do Ultem and Noryl resins meet all of our quality requirements, they also helped us achieve greater manufacturing efficiencies for reduced system costs. And by using these light weight materials, we are doing our part to help the environment by cutting fuel usage resulting in lower emissions.”

In addition to its multi resin solution, SABIC Innovative Plastics provided value-added services to this project from its Global Application Technology (GapT) organization, including chemical performance testing to simulate washing cycles, equaling a minimum of 10 years of cleaning; food staining and UV stability testing; and custom color matching.`

Leaner Trolleys Help Planes Lighten Up

LSG Sky Chefs and Norduyn turned the design of standard trolleys on its head by re-engineering and using cutting edge technology. As a result the new trolleys are lighter, and better insulated with a longer useful life. The use of Ultem and Noryl resins allowed the engineers of both companies to bring their design to life, and achieve the desired reduction in weight, FST performance, colorability, resistance to cleaning cycles and part integration. According to Patrick Phillips, business development director, Norduyn, “this design enables significant savings to airlines and service integrators. The trolleys use fewer moving parts resulting in reduced maintenance hours and also less parts to stock and manage.”

The new trolleys feature a molded frame and components made with Noryl resin and extrusion profiles that support the frame as well as the door latch made with Ultem resin. The use of SABIC Innovative Plastics’ materials helped reduce trolley weight by up to
40 percent to just 16kg (37.5 lbs) for a full-size trolley and 9.9kg (23.1 lbs) for a
half-size trolley. Noryl resin has a low specific gravity of 1.1 – one of the lowest available for thermoplastics used in the aircraft industry. This weight reduction can add up to significant savings in fuel costs. For example, a Boeing 747 fully loaded with these lightweight trolleys could cut weight by approximately 750 kg (1650 lbs), equating to a savings of approximately 50,000 euros (US$ 65,000) per year in fuel costs.

Because they can be extruded as well as injection molded, Noryl and Ultem resins provide new options for an array of interior applications such as rub strips, seat track covers, switch panels, cable guides, conduit, wall/ceiling mounted electronics, and parts machined from slab stock.

For additional information on SABIC Innovative Plastics’ Noryl and Ultem resins, please go to www.sabic-ip.com.

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About SABIC Innovative Plastics

SABIC Innovative Plastics is a leading, global supplier of engineering thermoplastics with a
75-year history of breakthrough solutions that solve its customers’ most pressing challenges. Today, SABIC Innovative Plastics is a multi-billion-dollar company with operations in more than 35 countries and approximately 9,000 employees worldwide. The company continues to lead the plastics industry with customer collaboration and continued investments in new polymer technologies, global application development, process technologies, and environmentally responsible solutions that serve diverse markets such as automotive, electronics, building & construction, transportation, and healthcare. The company’s extensive product portfolio includes thermoplastic resins, coatings, specialty compounds, film, and sheet. SABIC Innovative Plastics (www.sabic-ip.com) is a wholly owned subsidiary of Saudi Basic Industries Corporation (SABIC), one of the world’s top six petrochemicals manufacturers.

* Trademarks of SABIC Innovative Plastics IP BV.


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