Spinning Values Podcast - Ep. 2 - BCF Yarns and The Beekaylon Story
April 17, 2021
BCF Yarns and the story behind it:
In Conversation with Martin Van Dam,
Chief Product Officer, Beekaylon Synthetics
Martin Van Dam, from the Netherlands, is the Chief Product Officer of Beekaylon Synthetics. In this fascinating conversation, he tells the story of how he became the CPO of Beekaylon and the importance of BCF Yarns
(Bulk Continuous Filament)
to Beekaylon.
Spinning Values Podcast: Episode 2
Listen to Martin Van Dam as he tell the story of his association with Beekaylon & its BCF Yarns(Bulk Continuous Filament) operation.
What started off as a business conversation quickly transformed into a strong association with a global industry veteran and an Indian company with a strong legacy. Do subscribe to this podcast on your favourite podcast app.Transcript of the Conversation with Martin Van Dam, Chief Product Officer, Beekaylon Synthetics.
Rajeev Hello and welcome. This is Rajeev again with episode number two of Spinning Values podcast, powered by Beekaylon Synthetics. welcome to the show Martin.
Martin Van Dam
Thank you very much.
Rajeev So we have Martin Van Dam he's in Netherlands and he's the technical guru for Beekaylon shall we say? So, without further ado, I introduce technical head of things. Mr. Martin Van Dam, Martin, why don't you introduce yourself and tell the viewers what you do and your association with Beekaylon.
Martin Van Dam Right. Just to explain a little bit to about myself. I have been in the yarn and the carpet manufacturing for 30 years. So my small advantage might be that I also know the product that our customers are making from our, let's say yarns and I have been working for some global manufacturers in the past.
So I have been working for some of our co our current competitors of course. And yeah, just to explain that I'm I have been in touch with Beekaylon since let's say mid of July, 2019. So I did fly over to Mumbai and to have some talks with the family and with the people and their ideas about. How we could establish Beekaylon in the BCF market as well. Everybody already, of course, did know, Beekaylon as a Supreme supplier of B O Y D Y yarns with a 40 year history with a very good name in the market. So that was giving me already a very comforting feeling and the idea that this could be the right connection between myself and Beekaylon.
Once I visited the new factory. And when I saw the factory, it was really astonishing. it was like a being a child again in a candy store. It was like coming into a place where I could see that there was really a good thought about how to set up a factory with the state of the art machinery, of course, BCF as a technology where we can spin yarns with filaments and where we can say, okay, we can be very flexible in all the major parts of the end views of the yarn.
Yeah, just to to highlight the three biggest parts where yarn our yarns can be used to BCF yarns is contract and style applications, residential carpet, and of course, automotive industry and automotive. I mean the flooring of the automotive industry. So the molded parts and the overmatch residential, any residential carpet, you can imagine broadloom racks.
Bath mats anything you can think about. And then the contract application, of course, hospitality, hotels contract tiles, carpet tiles. That was really something where I saw that. Okay. This is the opportunity for me to be able to develop and to work with a company who is not only looking at today's hectic business, but also a company was able to.
Look at the future and to be able to see where the world is going, where our industry is going. yeah, that was really surprisingly pleasant for me to see that walking into the factory, just to see BCF machines, which is German machines. Neumag which is state of the art.
The best machines you can buy for money in principle. And just to explain what is BCF is in principle, a yarn, which you can extrude and extrude means in principle, you have a chip and the chip is melted and is pushed in principle. Very simplistically explained, pushed through a spinneret and a spinneret is a round device with all kinds of small holes. And those holes can have different shapes and the different amounts. And we can play with that, to see where we are going for the end use of this yarn, depending on the end use, we can change, let's say the number of filaments, the amount of filaments, the shape of the filaments that detects the thickness of the yarn.
We can adjust. So we have in principle already that base of machines best you can, by looking further in the company also state-of-the-art newest cabling machines, also German grounded Volkmann machines, which is also state-of-the-art perfect machines with all the devices to control the absolute quality.
What is a cabling machine do in BCF. You can use the yarn as a single yarn for certain applications to make the yarn suitable for residential carpet tiles automotive. You can also twist them or air entangled them. And heatset them. heat setting again. Superba machines, which is the best money can buy with the best stable process in the world.
So my heart was beating like, Oh, this is absolutely fantastic. Then walking through the factory, I came upstairs and even there, it was more exciting for me because there are small sampling machines for almost all the steps in the process. So we have a development center upstairs, which allows us to not only wait for customers to tell us what they need, but also to be able to be proactive.
And to make samples and even make small carpets by using a KB or an MTF machine, which is a one needle machine, which is trying to replicate industrial machines on small scale. So instead of sending a customer only a piece of yarn, we are already able to send them a small piece of carpet where the customer can see how its end product will look like.
And that was absolutely fantastic. That was step number one for me, went in the Beekaylon story. So we very quickly agreed that I would be their global let's say, product development manager. So being responsible for the technical aspects and for, let's say the developments having worked all over the world in principle for 30 years, I did know all the major.
Let's say carpet manufacturers globally in Europe, Australia, New Zealand, Asia Pacific. ASEA, USA. Having worked for companies in the U S companies in Europe, companies in Asia, Pacific, knowing a little bit the differences in the demands for the different areas, because the carpets you have in New Zealand, or I have in Europe are different.
And there's just let's say a matter of of the market and about what customers think about it, how they use it, what is taste. Colours are of course always a matter of taste as well. And you see differences globally. So there was, that was step number one. Then of course, I also needed to be able to create the teams in the factory.
Right. Because you can have the best car in the world. If you don't have a driver with a license, it's not going to work. So the good thing is that also within Beekaylon, we were able to create teams with a lot of experience with a lot of knowledge about textile, but also about BCF already. And then working with the global sales teams.
it was very satisfying to set up, let's say a model where we could guarantee quality better than in any other company I've ever worked for. So we created as much as possible SOP with the knowledge which everybody put in, where are the bottlenecks in processes. So where are the risks of quality in the process?
Where are our opportunities compared with other companies? Just to explain, let's say the three most used polymers are polypropylene, polyester, and polyamide nylon. And those, all those three products have their differences in applications. If you look at the PP, it's mainly used for residential and for relatively commodity products in let's say carpet towels, our machines are very suitable for all the three polymers.
So we have multi polymet BCF, extrusion lines. BCF. If you look at it, It is a continuous filament bulk continuous filament. That means that in principle, you can make carpets with a different weight and with a different application. So if you are looking at the highest end of the market, we would recommend polyamide six.
We would recommend for resilience to use that because the resilience of polyamide is higher than the resilience of polyester or PP polypropylene. We had the advantage that we did know, of course the market, we did know the customers and we were able to talk with customers to give us the opportunity to sample and looking at that. Then the advantage of knowing what the customer is making is helping us.
And what we thought was very important is that we have people in every region who are representing us in the proper way. So building the team to manufacturer was one thing building a team to develop was the second part. But having a team, which is also corresponding with customers on weekly basis or on a monthly basis to really understand the needs of customers was really one of the major parts of the success we are having. Of course, for me, it was quite easy in the beginning to say, okay, I think we will be able to fill up our total capacity within a certain timeframe. And before. We really work together. I already asked her, I said, listen, I will, I'm willing to invest in, let's say in growing the company, but I need to know if we are expanding if it's necessary.
And the answer was very clear. Yes. Because the area which the company did buy has the opportunity to put additional buildings to put additional factories warehouses. So the setup was already there. And I can tell you that due to the success we had, even with the Corona situation globally, we were able to let's say, fill up the capacity of our plant quite fast.
So even some things got delayed due to the COVID restrictions due to the fact that we could have the zoom meetings. We had agents on the right places. We could do the sampling in the proper way. We could convince the customers that we were not only trying to sell them yarn. But we were willing to work with them on developments.
So we were able to let's say already be proactive and work with the customers on not only today's business, but on the business of tomorrow. And that was one of the major things, which I think differentiates us from say most of the other manufacturers, having people inside who are capable of working with customers.
Doing what customers want to do and thinking about the future than the one of the major parts also in that whole story is that Beekaylon is really investing huge amounts of money and time in research and development. We want to be sustainable as possible. We want to be trying to even create circular products.
To let's say to look at our environment as well. We are looking at our personnel our staff, how are we working with the staff? As an example, you might have seen that we have our programs for COVID vaccinations going on, which is really astonishing. If you see what the company is trying to do to protect their most valuable assets, which is personnel, which is your staff.
Your staff is your biggest asset. Like I said before, you can buy the best car in the world. If you don't know how to drive it, you will be in an accident. And our machinery is to state-of-the-art the best money can buy. But our biggest asset is our really experienced and well-trained personnel and implementing SOP.
So we have a lab. we do the test, not only when we start production, but during the whole process, every step is tested, not once, but twice to assure that whatever we send to a customer is absolutely state of the art. And if you look at how quick we were able to develop ranges with With the biggest global players.
Right. It's absolutely fantastic. And even as we speak, we are now looking at, okay, we can make a hundred percent recycled PET. We are working on the a hundred percent recycled, PA six. We are working on antimicrobial yarns. All those benefits we have and that proactive position that Beekaylon is taking. Is getting our customers excited and willing to work with us.
And of course, you're only as good as your last supply. Of course every company has an economic aspect, but our targets to win competition battles is quality. And that's what was one of the reasons why I joined. Because we are able to guarantee the best quality we can supply. If you look at the most critical markets we are working with, customers are giving us the opportunity to work with them because of our service and quality. And that's really amazing. And they also know that we are, Once we do the business, we have running products with them. We are having the normal day by day supplies, but we are already working again on the products for next year. Yeah. Because achieving a good customer supplier relationship is one thing.
Keeping that is the most important one. And over the 30 years, I can really be honest that I see that we are really doing an amazing job on that. And it's all thanks to the team. Right? I have worked in many companies and sometimes you see groups and it's normal, right? Everybody works in a certain area of a manufacturing company and some of them is just logistics, sales, development, production, and I have never experienced the more. Let's say resolute team as I have with peak alone. So everybody is working together instead of only in their own small area. That's what we always try to do.
So we are really looking at all the areas in the world, the differences between products because we want to be able to supply anything in automotive, anything in residential and anything in contracts and hospitality applications that our customers need. So we want to have a very broad palette of possibilities and yarns.
And having all those machines and all those possibilities, we can say that we can supply to any customer, whatever he needs. So if you look at Europe, we work with the high end of the market in Europe, in Australia, New Zealand, in USA, Japan, Asia, Pacific And it's really not because we are nice people.
We are, but we are supplying, let's say a premium product, which is always the most essential part of doing business with anybody being trustworthy doing what you tell that you will do and doing it also, right. It's I can promise you something, but I have to keep my grants. And that's something where I am really happy with the fact what we are doing with Beekaylon and. We can supply, let's say the highest end of the market carpet tile producers by combining different yarns, different colors, we are able to supply anything in automotive, BA six polyester, whatever customers need. We are able to do it in the residential market. And we are not only saying that we want to have the big volume products.
Of course you want that, but we are also looking at, let's say the specialty. The higher end of the markets, the new developments, and as a company with which has done the huge investments that Beekaylon has done looking at factory machines, personnel, they invested huge and they keep on investing because we are extending already.
So we have already the possibility to set machines with their own guidance systems. So everything is controlled, not only by humans, but also by technology. And that was also able to, to that is that makes us able to guarantee the quality on all the steps in the process and being as flexible as possible.
The main target is making new developments, creating the future for our customers and ourselves. So only not have a business today, but also have the business tomorrow and be able to already think about where the world is going.
Right. I don't have to explain. Everybody is looking at environment. Everybody is looking at green of solutions, having less CO2 footprint in the world being sustainable. For example, we are working with, let's say one of the few renovated companies in the world, like DSM Niaga those products Niaga if you turn around to Niaga it says again, so those guys are really working on mutual benefits from suppliers and final customers who put up a chain of recycling.
So to create, for example, a mono product. Where all the parts of a carpet are made from the same material where we can collect it afterwards and reuse it so that we don't need to use new raw materials. And especially looking at polyester, for example, where we are already doing this quite successfully, that we are able to reuse.
We use polyester from bottle flakes, for example, all the waste, which are in the oceans in the season. Whatever we can reuse it. We don't have to do to go to direct polymerization, to make chips again from raw material, which come from our earth. And I always say, you should consider waste, not as waste, but as a raw material again.
We don't see customers as customers. We see them as partners in a very demanding competitive business. we always talk about spinning values and I think that's not only your phrase for Beekaylon That's their DNA. I think that's why it fits. That's why I am so happy to be part of this Beekaylon project.
Rajeev
Amazing. I think it's fascinating to hear from such a senior industry veteran like yourself being so excited. And as of you, you have the curiosity of a young child. Again.
Martin Van Dam No, but it's true. It's what I said at the beginning. When I walked in to the first conversation or when I saw the setup, I was being this little boy again in this candy store. Right. Seeing all those different possibilities, that really was amazing. And of course also the trust I have in Beekaylon and Beekaylon trust in me is building up such a strong relationship. That is absolutely fantastic. And then having, let's say the experience which some of our team members are having with the customers and the customers knowing me from my past, but also knowing that I'm working with Beekaylon now, giving us the opportunity to prove ourselves is absolutely fantastic.
Rajeev You make a very interesting and important point Martin, the sense that it is not just the products. It's the people behind the products which actually create the value and the phrase spinning values is such a powerful concept. it it actually ties into the actual product that Beekaylon produces but also the philosophy that the founders of the company have instilled.
Martin Van Dam
I always say that was one of the things where I wanted to dedicate 10 years of my life and my business experience to do that. And that only works if you work with people and with a company who is also having that same target. So it was very important to have the same mutual target with all the respect in the market for all our customers. And I also wanted to say that everybody is working very respectfully with each other. I always say that our chain of operation is as strong as the weakest link in that chain, but you can fix that in different ways. And I think we are working very respectfully with our staff. With our people and with our customers and our suppliers.
Rajeev So just to kind of summarize the whole thing Martin the biggest advantage that you see going forward is that Beekaylon brings in as it's number one it's its value system. And number two, it's focus on quality assurance, R and D and innovation. Right? So even though there are other producers and manufacturers in India and around the world, this is what sets Beekaylon apart.
Martin Van Dam That sets us apart. Having this global team like we are having and having the knowledge about what our customers are doing in combination with. proactive development, research and development in all aspects in sustainable products and the amount of money that companies are willing to invest in that we are really different from any other supplier in the world. And that's really something where I say, yes, state-of-the-art machines, the latest you can buy the best you can buy the best people in the world. And the best ears in the world to listen to customers and having a view into the next decade. That's combination of all those aspects are really something which makes me extremely proud and happy to be part of that. Amazing. So there you have it. ladies and gentlemen, Martin Van Dam from Beekaylon Synthetics. Thanks Martin. Thanks for your time. That was an amazing conversation. I learned a lot. I learned a lot and it is amazing to see. A global team working with an Indian company. and it's refreshing to see such words from such a global industry veteran like you and, you know, it's pretty remarkable.
The textile industry is a constantly evolving sector that balances the art of innovation with the demands of functionality and sustainability. Among its many offerings, Bulk Continuous Filament (BCF) yarn stands out as a versatile and essential material, particularly in the carpeting and flooring segments.
The textile industry is at the cusp of a digital revolution, with AI, machine learning, and advanced digital tools transforming how we approach textile design. These innovations are not only enhancing creativity but also optimizing processes to create efficient, personalized, and sustainable solutions for the modern market.
Textile manufacturing is experiencing a transformation like never before, and at the heart of this change is 3D printing. What started as a technology for industries like aerospace and automotive has now found its way into the world of fabrics and fashion, bringing new possibilities for how we design and produce textiles.
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