Large-scale production of synthetic resins is confined principally to the United States, Germany, and Great Britain. There is small production in many other countries, of which the most important are France, Italy, Czechoslovakia, Canada, and Japan.

In 1934 the world output was estimated at 135 million pounds, of which the United States produced about 44 percent, Germany 26 percent, and Great Britain 24 percent. In 1937 world output was estimated at 360 million pounds, the United States’ share of the total being almost 50 percent, followed by 27 percent for Germany, 20 percent for Great Britain, and the remaining 3 percent scattered.

European estimates indicate that about 40 percent of the output goes into surface coatings and that 60 percent of the surface-coating resins are tar-acid and 40 percent alkyds. The Tariff Commission found that in 1937 50 percent of the United States production of all synthetic resins went into surface coatings, 27 percent into molded articles, and the remaining 23 percent into laminating and miscellaneous uses. Approximately three-fourths of the surface-coating resins were alkyds and one-fourth tar-acid resins.

GERMANY

Production.

In recent years Germany’s production of synthetic resins has increased rapidly, each succeeding year registering the attainment of a new record. In 1933 production totaled 17,500,000 pounds and by 1935 had increased to 55,000,000 pounds. A further expansion of about 30 percent to 70,000,000 pounds in 1936 and present production trends indicate a gain of about 40 percent more in 1937, to an estimated total of 100,000,000 pounds.

Although tar-acid resins comprise the bulk of the German output, considerable gains are shown for other types, notably injection molding resins of the polystyrene and vinyl types. The development of completely automatic injection molding machinery has given an impetus to these types. While technical progress, including improvement of molding equipment, has contributed to the expanded production, the use of synthetic resins in Germany has had a strong stimulus because they are made almost wholly of domestic materials. Under the “Four-Year Plan” for the greatest possible national economic independence, synthetic resins are replacing imported materials, such as the heavier nonferrous metals, iron, hardwoods, cork, and natural gums and resins in many uses. This displacement of materials has also affected such domestic products as glass and porcelain, which caused the Government to intervene and impose restrictions upon the use of resins for purposes adequately served by other materials of German origin.

Germany’s expanding production of synthetic resin has also been aided by a sharp increase in exports, which have increased well over 100 percent since 1932.

Tar-acid resins.—German output of tar-acid resins has been estimated at 35 million pounds in 1934, at 49 million pounds in 1935, and at 63 million pounds in 1936. Such resins comprise the bulk of the German production of molding resins.

There are at least seven producers of tar-acid resins in Germany and nine producers of molding powders and pellets. Tar-acid resins for surface coatings are produced by a number of these concerns. Among the important makers in Germany are The Bakelite Gesellschaft (organized in 1910 to operate under the Baekeland patents); the explosives and munitions firm of Dynamit A.G.; Dr. Kurt Albert G.m.b.H.; the I.G. Farbenindustrie; Beckacite Kunstharzfabrik G.m.b.H.; and Rohm & Haas A.G. The Beckacite firm has associates in the United States and in the United Kingdom, and Rohm & Haas, an associate in the United States.

Alkyd resins.—The manufacture of alkyd resins has developed in Germany in the past few years. Demand for these resins has been given a marked impetus by the development of a new standardized substitute for linseed-oil varnish known as El Varnish, the use of which is required by the Control Board for Industrial Fats for certain interior and exterior painting.

There are five makers of resins for paints, varnishes, and lacquers. The output of alkyd resins has increased sharply since 1934, probably reaching 10 million pounds in 1936.

Urea resins.—The output of urea resins in Germany is relatively small; two of the more important types are known as Locron and Pollopas.

Polystyrene and vinyl resins.—In 1936 Germany’s production of thermoplastic resins exceeded 1 million pounds, principally of the polystyrene and vinyl types. Among the vinyl resins are Acronal and Mowilith, both of which are manufactured by the I.G. Farbenindustrie. This combine also produces several types of polystyrene resins known as Mollit and Metastyrol. Dynamit A.G. produces a polystyrene resin known as Trolitul.

Uses of synthetic resins.

The original and most important use of synthetic resins in Germany was for electrical insulation. This use was so extensive that the industry was organized in 1924 into an association known as non-rubber insulation materials industry. Materials were standardized and classified into 14 types, of which 5 were tar-acid resins and 1 was a urea resin. Every type must meet certain specifications in order to be recognized by the Reich Testing Institute. More than 100 firms produce insulating materials meeting the institute’s specifications.

Radio panels of the popular sets sponsored by the Government are made of synthetic resins. Consumption in the automobile industry is increasing for such parts as instrument panels, electrical equipment, steering wheels, gear-shift knobs, and numerous others. The latest airplanes show increased use of synthetic resins, where they contribute light weight, great strength, and resistance to corrosion.

In cameras and moving-picture equipment, wood and metal have been in part replaced by synthetic resins. Other applications of resins in Germany include bearings for rolling mills, goggles and spectacles (including the lens), and perfume and medicine bottles.

Resins for surface coatings are undergoing rapid development in Germany, owing to the shortage of linseed oil. Alkyd resins in coatings are being promoted by the Government, which prohibits or limits the use of the older oil-type coatings for certain uses so as to decrease the use of linseed oil and other paint oils that must be imported and hence require outlays of foreign exchange. Penalties have been imposed for violating the regulations.[13]

Organization.

The synthetic-resin industry in Germany is a unit within the national industrial organization. It is a subdivision of the industrial chemical group, called Fachgruppe Kunststoffe, or Group 13 of the 19 trade groups in the chemical division. This subdivision controls casein and cellulose plastics as well as synthetic resins, and is further divided as follows: (1) Casein plastics, (2) cast phenolic resins, (3) molding compositions, (4) resins for lacquers, (5) celluloid and zellon, (6) transparent sheeting, (7) linoleum, and (8) miscellaneous (such as vulcanized fiber, bottle caps, and die-casting resins).

There are two cartels distinct from the national organization, which expressly excludes all functions and activities of cartels. One cartel represents the firms interested in molding compositions and the other those interested in synthetic resins for other purposes. Some of the producers are members of both cartels.

Foreign trade.

Imports of synthetic resins are negligible, although the duty of 4.6 cents per pound (25 marks per 100 kilograms) on imports into Germany is not prohibitive. Exports have increased practically every year since 1930, when they were first recorded separately.

Table 23 shows the quantity and value of exports in recent years.

Table 23.—Synthetic resins: German exports, 1930-37

German exports of synthetic resins are, for the most part, destined to European countries, most of which have increased their purchases considerably in recent years. Exports to Latin American countries have increased recently, especially to Brazil. Table 24 shows the distribution of exports in recent years.

Table 24.—Synthetic resins: German exports, by countries, 1934-37

GREAT BRITAIN[14]

As in most other countries, the history of the synthetic-resin industry in Great Britain begins with the acquisition of rights by a British concern to manufacture under the original Bakelite patents. The Damard Lacquer Co., Ltd. was probably the pioneer maker of phenolic resins in England. The principal product was a baking lacquer sold under the trade name Damarda, marketed for and used principally as a coating to prevent corrosion on brass. The outbreak of the World War created such an urgent demand for laminated materials that this firm started production of them for the British Government. In 1926 this concern was merged with Mouldesite, Ltd. and Redmanol, Ltd., under the name of Bakelite, Ltd.

Production.

Statistics of production of synthetic resins in Great Britain are available only for 1934 and 1935. They are given in table 25.

Table 25.—Synthetic resins: Production in Great Britain, 1934 and 1935

Capital invested in the British industry is reported as 15,000,000 pounds sterling and direct employment as 20,000 people.

Tar-acid resins.—Many large moldings are made in England, such as large radio cases, desk files, trays, and drain boards. Cast phenolic resin production has just been started in England.

Among the novelties recently produced in England is a toy railway molded of tar-acid resin. The trains and track spacers are of nonconducting resin; the molded rails are made conductive by a thin covering of metal which is pressed in and secured at the ends. Two trains may be run on the same set of rails at different speeds, or one can go forward and another backward, since the two outer rails are separate conductors, the third rail acting as a common return.

Molded piano parts are being tried in an attempt to solve the troubles hitherto encountered with wood, owing to variations in humidity. Resins have long been used in facing the keys, but the production of piano action parts has presented many technical difficulties. The secret of success with molded resin parts lies in molding the joints in position when the main body is molded. There are 88 sections in each piano.

Urea resins.—British Cyanides, Ltd., well-known makers of synthetic resins in England, acquired the Pollopas patents for the manufacture of urea resins in the United Kingdom, in certain continental European countries, and in the British Empire except Canada. The agreement called for a full exchange of patents and other information with the other licensees of the Pollopas patents. These arrangements were made for the purpose of consolidating the patent position and for the pooling of technical data already existing on manufacture, with the object of improving quality.

Acrylate resins.—An outstanding development in Great Britain has been the production of the thermoplastic resins known as Diakon and Perspex. These are made from methyl methacrylate and are developments of the Imperial Chemical Industries, Ltd. Diakon is for molding powders and Perspex is in the form of cast sheets, rods, tubes, and optical forms.

These new commercial resins are considered the best combination thus far obtained of strength, transparency, and light weight. Applications in England include fittings for aircraft, transparent inspection covers for machinery, medical equipment, instrument windows, lenses and prisms in optical systems, and aircraft windscreens. They are used in subways for lenses for deflecting and diffusing light and in battery cases and coil forms.

The general properties of the acrylate resins include transparency to both visible and ultraviolet light, almost unlimited color range, resistance to acids and alkalies, and superior electrical properties.

Aniline resin.—Panilax is an aniline-formaldehyde condensation product made in England. It has high electrical and thermal insulating properties, great mechanical strength, is odorless and odor repelling, and practically unaffected by water, oil, and alkalies.

Organization.

Most of the British producers of synthetic resins are members of the British Plastics Federation, Ltd.

Several years ago a 10-year contract was made between the Imperial Chemical Industries, Ltd. and the Toledo Synthetic Products Co. (now Plaskon Co.) of Toledo, Ohio. This agreement provides for an exchange of all technical and commercial information on urea-resin products and processes and the granting of free licenses under present or future patents.

Agreements probably also exist between the British Bakelite Co. and the American firm on tar-acid resins; between Nobel Chemical Finishes, Ltd. and E. I. du Pont de Nemours & Co. on alkyd resins; between British Thompson Houston Co., Ltd., and the General Electric Co. on alkyd resins; between Imperial Chemical Industries, Ltd. and du Pont on acrylate resins; and between Beetle Products Co. and American Cyanamid Co. on urea resins.

Foreign trade in resins.

British imports of synthetic resins, by principal sources, are shown in table 26.

Table 26.—Synthetic resins: Imports into the United Kingdom, in selected years, 1930-36

British exports of synthetic resins to principal countries are shown in table 27.

Table 27.—Synthetic resins: Exports from the United Kingdom, in selected years, 1930-36

FRANCE[15]

Producers.

Statistics of French production and sales of synthetic resin are not available. Larousse Commercial Illustré describes the French synthetic resin industry as not important and estimates the output in

1930 at 2,000,000 pounds. The Revue Général des Matières Plastiques, most important technical review in France, estimates the production in 1931 as about 3,500,000 pounds.

The comparatively few French companies producing synthetic resins are, for the most part, under British or German control. The types of synthetic resin made in France, the trade names, and the names of the manufacturers, follow:

Bakelite.—Tar-acid molding compounds and laminating materials; cast phenolic resins; Cie La Bakelite, Bezous, Seine.

Plastose and Ferodo.—Tar-acid molding compounds; Société Ferodo-Plastose, Saint Ouen, Seine.

Pollopas.—Urea molding compounds and laminating materials; Établissements Kuhlmann, Paris.

Foreign trade.

French imports of synthetic resins are classified under tariff item No. 0376 bis: Synthetic resins (solid or resinous products of the Bakelite, Albertol, Plastose types, etc.) derived from the condensation of aldehydes with phenols, amines, and amides. Several subclassifications are shown: (a) Soluble in oil and not polymerizable, (b) which may be rendered insoluble and infusible, and (c) infusible. Imports in recent years, from principal sources, are shown in table 28.

Table 28.—Synthetic resins: French imports, by types and by countries, 1931 and 1933-37

Exports of synthetic resins from France, by principal markets, are shown in table 29.

Table 29.—Synthetic resins: French exports 1931 and 1933-37

CZECHOSLOVAKIA

Production of phenolic resins in Czechoslovakia has increased rapidly in recent years and is ample to supply domestic requirements. Most of the raw materials are imported from Germany, Great Britain, and France, but formaldehyde is produced locally in sufficient quantities.

The principal makers of synthetic resins in Czechoslovakia are:

Resin products are widely used by the electrical industries for wall plates, plugs, switches, fuse boxes, etc. Other articles made of synthetic resins are: handles and knobs for furniture and kitchen equipment, bottle caps, fountain pens and pencils, clock and radio housings, tableware, cutlery handles, trays, buttons, toilet ware and toys.

Imports of synthetic resins in 1934 totaled 1,270,500 pounds; Germany supplied 46 percent and Great Britain 22 percent of this total. Exports of synthetic resins during the same year amounted to 166,540 pounds and went principally to Poland, Yugoslavia, Germany, and Argentina.

ITALY

The Societa Italiana Resine, an affiliate of the important chemical firm, Chimiche Forestali, is a leading maker of tar-acid resins in Italy. A new and modern plant is located at Milan in close proximity to the electrical and textile industries, both important markets for resins.

In 1936 the Ministry of Corporations granted Montecatini Societe Generale per l’Industria Mineraria, Milan, a permit to develop a factory for alkyd resins; and also Societe Italiana Ebonite and Sostituti, Milan, one to produce tar-acid resins. In 1937 a permit was granted to Montecatini S.A. for a plant to manufacture acrylic acid resins at the Villadossola works of the Soc. Elletrochimica del Toce.

JAPAN[16]

The history of the synthetic resin industry in Japan goes back to 1913 when Dr. Jokichi Takamine, discoverer of adrenalin and takadiastase, acquired the right to manufacture and sell tar-acid resin Products in Japan. The business was financed by the Sankyo Co., Ltd., and a factory was built at Shinagawa, near Tokyo. In 1923 a subsidiary company known as the Japan Bakelite Co., Ltd., was formed with a paid-in capital of 1,200,000 yen. This firm considers itself an affiliate of the Bakelite Corporation of the United States and, according to an existing agreement, cannot export to the United States. Its territory includes the Japanese Empire and Manchukuo. China is considered an open market.

The original plant at Shinagawa was partially destroyed by fire in 1919, and the following year was moved to Mukojima, Tokyo. The firm makes tar-acid resins, and a full line of products covered by the patents of the American concern. Included are laminated sheets, molding compounds, molded articles, surface coating resins, laminated resin gears and spindles for rayon mills. An interesting development is the adaption of tar-acid resin lacquers to the production of Japanese lacquer ware such as bowls, vases, etc.

Since the establishment of the Japan Bakelite Co., several other firms have started the production of synthetic resins. The Tokyo Electric Co., an affiliate of the General Electric Co., makes tar-acid resins under the trade name Tecolite. Products are used principally for insulation, although molding compositions and molded articles such as are used by the electrical trade are commercially produced.

The Matsushita Electrical Works at Osaka are producers of tar-acid resins and articles made therefrom. The output is used largely for radio and electrical equipment. The Nissholite Manufacturing Co., Ltd., with a factory at Yasui-cho, Uzumasa, Kyoto specializes in decorative laminated material sold under the trade name Nissholite. The Japan Nitrogenous Fertilizer Co. (Nippon Chisso Hirijo Kabushiki Kaisha) is an important maker of tar-acid resins, marketing them under the trade names Chissolite, Safeloid, and Minaloid. The Yokahama Resin Co., a relatively small company, produces tar-acid resins and markets them in the form of molding powders. The firms listed account for practically all of the Japanese production of synthetic resins and for about 50 percent of the molded articles made from them. The remaining 50 percent of the output of molded articles is made by a large number of small firms, the majority being household industries. It is reported that there are about 2,000 of these so-called plants already engaged in this relatively new industry.

Production.

The Japanese production of manufactures of tar-acid resin reported by the Department of Commerce and Industry is shown in table 30. These data include the output of plants employing more than five operators and apparently account for only half of the total.

Table 30.—Manufactures of tar-acid resins: Production in Japan, 1929-35

Estimates from other sources of Japanese productions of tar-acid resins indicate an output of 2,600,000 pounds of resin and 3,600,000 pounds of molded resin articles in 1933, and of 4,900,000 pounds of resin and 7,500,000 pounds of resin articles in 1935.

It was recently announced that the Gosei Chemical Co. will manufacture vinyl resins in Japan. This firm’s principal interest is in acetate fiber and rayon manufacture. Later in 1936 the Showa Fertilizer Co. announced the successful development of a process for making urea. Urea resins are in commercial production by the Toyo Gosei Kagaku Kogyo K.K., an affiliate of Chugoku Toyo K.K.

The resin industry in Japan is expected to undergo considerable development in the near future. Raw materials are available in sufficient quantities and the art of molding is fairly well developed.

CANADA

The producers of synthetic resins in Canada are:

The Bakelite Corporation of Canada, Ltd., an affiliate of the firm of the same name in the United States, was formed in 1925. This plant makes molding materials, laminating materials, and an extensive line of technical varnishes. Molded parts were made at this factory until 1932.

Shawinigan Chemicals, Ltd. is the pioneer organic chemical maker in Canada. A modern plant at Shawinigan Falls, Quebec, produces synthetic acetic acid, acetaldehyde, vinyl acetate, vinyl resins, and other chemicals. The vinyl resins manufactured by this firm have already been described (see p. 44). Appreciable quantities of these resins have been exported to the United States in the past but the construction of a factory (jointly owned by Shawinigan Chemicals, Ltd., and the Fiberloid Corporation) at Indian Orchard, Mass., for the manufacture of vinyl resins will probably result in a decrease of exports from Canada to the United States.

The Canadian General Electric Co. makes alkyd resins for use in surface coatings. Phthalic anhydride and other raw materials are imported from the United States. Canadian Industries, Ltd., produces alkyd resins at a plant in Toronto, Ontario.

There are about 14 molders of synthetic resins in Canada, of which all but 3 are in Ontario. These firms make a general line of molded articles including electrical articles, closures, costume jewelry, and smokers’ accessories. Appreciable quantities of molded articles are imported from the United States and smaller quantities from Germany.

UNION OF SOVIET SOCIALIST REPUBLICS

The synthetic resin industry in the Union of Soviet Socialist Republics is concentrated in two public departments, known as Public Commissariates: (a) Public Department for Heavy Industry and (b) Public Department for Light Industry.

The Department for Heavy Industry, known as Soyuzchemplastmass, controls the following plants:

1. Karbolit-pawod in Ljubatschani, producing tar-acid resin laminated fabric known as Textolite.

2. Karbolit-stroj in Ljubatschani, making cast phenolic resins.

3. Karbolitni-pawer in Dubrowka, making tar-acid resin molding compounds. This plant has at least 350 molding presses producing electrical parts and automotive parts. The number of presses was to have been increased to 1,000 in 1937.

4. Komsomolskaja prawda in Leningrad manufactures articles, including phone sets, from cast phenolic resins.

5. Ochtenski Chimkombinat in Ochta. This plant makes nitrocellulose plastics. No information could be obtained by our Chargé d’Affaires at Moscow concerning its production of synthetic resins, although it is believed to be considerable.

The Department for Light Industry has a resin section known as Mosplastmass producing casein plastics only.

THE NETHERLANDS

There has been no production of synthetic resins in the Netherlands; but a plant is under construction (October 1937) at Groningen for the manufacture of alkyd resins. The manufacture of surface coating and electrical parts from imported resins is carried on, chiefly by N. V. Philips’ Gloeilampenfabrieken, Afdeeling Inkoop, Eindhaven, manufacturers of radios, filament lamps, and electrical appliances. Efforts are being made to employ resins for other purposes, such as the bonding of plywood and the manufacture of closures and novelties, but little has been accomplished thus far. The relatively high cost of the resins is the principal difficulty. Molding compounds and laminated sheets, rods, and tubes are imported from Germany, Great Britain, Austria, and the United States.

The paint, varnish, and lacquer industry in the Netherlands has been experimenting with synthetic resins for several years. Alkyd resins of the glycerol phthalate type are being used by Dutch paint makers, imported principally from Germany and Austria. In spite of high cost, they have been found to have many advantages, especially better and more uniform quality. The prices of gums and resins in the Netherlands during the latter part of 1936 are shown in table 31.

Table 31.—Prices of gums and resins in the Netherlands, 1936

The Dutch aviation industry is using tar-acid resins to bond plywood for wing surfacing on Fokker-type wooden planes. The advantages obtained are excellent adhesiveness and resistance to moisture and temperature changes. In this application they have replaced casein.

Germany supplies more than 85 percent of the Netherland imports of synthetic resins, as shown in table 32.

Table 32.—Synthetic resins: Netherland imports by countries, 1931 and 1933-37