JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 46

USERS’ PLATFORM Application MFG: boosting the growth of the wind energy market In 2007, MFG opened a new manufacturing facility to support GE Energy’s growing wind business. (That year, the industry grew by 45%; in 2008, installed generating capacity in the United States doubled.) The plant manufactures turbine blades for 1.5megawatt machines, and is designed to support an annual production of 2,000 blades. n November 2007, Molded Fiber Glass Companies (MFG) broke ground for a new wind-turbine manufacturing plant in Aberdeen, South Dakota, to help their customer GE Energy meet the robust worldwide demand for wind turbines. The plant manufactures blades for GE’s 1.5-megawatt machine, one of the most widely used wind turbines in the world. I facility in Aberdeen will significantly increase the manufacturing capacity of our supply chain, as we continue to face strong demand for wind turbines in the US and worldwide,” said Victor Abate, GE Energy’s Vice President, Renewables. According to MFG CEO Richard Morrison, “the new plant represents a new milestone in the commercial relationship between MFG and GE Richard Morrison, Energy, and we are CEO, MFG pleased to continue supporting GE’s efforts in the wind energy industry, which is experiencing strong growth around the world.” These are no trifling words, given that wind energy accounts for about 35% of MFG’s business. This dynamic market has tempted any number of companies, but the return on investment is not rapid. It takes time to harness technology. Besides the Aberdeen plant, MFG has five other units working in the wind energy sector. Two units produce blades, two produce nacelles, and one unit produces spinners. There is also the Wind Energy Services Company, which provides field service for blades and nacelles. teammates. The original crew of 17 grew to 100 by the end of June, and to well over 200 by year’s end. MFG Aberdeen now employs 250, and will continue to expand its workforce as soon as the situation allows it. Ramping up a blade factory is challenging, due to the training that is necessary. Producing each blade requires a high amount of labour. MFG facilitated its successful start by attracting good talents and dedicating sufficient time to train its teammates in production. Under the direction of General Manager Blake Seas, the blade production rate is accelerating. The plant specializes in blades 37-40 metres long, each weighing 6-7 tons. These are produced using infusion moulding technology, which requires a good command of the process when applied to parts this large and complex. Plant equipment consists mainly of 8 extra-large moulds, three post-curing chambers more than 40 metres long, a fully automated machining centre, and a paint booth (also fully automated) with four robots. The plant is specialized in blades 37-40 m long. The new plant in Aberdeen, South Dakota. A business with prospects The new 30,000-m² facility is owned by the Aberdeen Development Corporation (ADC), and leased and operated by MFG. It represents a $40 million investment. The facility enables MFG to increase the volume of wind turbine blade sets being supplied to GE Energy. Over the past three years, GE has supplied wind turbines to meet more than 50% of new wind capacity across the US. “GE currently has over 6,500 1.5-MW wind turbines in operation worldwide. By the end of 2008, we expect that number to exceed 10,000 units. The new MFG Smooth production In 2008, the first teammates were hired and sent to train in MFG’s sister plant in Texas. They returned in June to begin initial blade production and train new 46 jec composites magazine / No50 July-August 2009
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009
