Capacitor Foil World Market Outlook: 2013-2018

  • March 2013
  • -
  • Paumanok Publications
  • -
  • 98 pages

Details

This new market research study from Paumanok Publications, Inc. offers visibility to a granular level on the supply chain for anode and cathode foils to the aluminum electrolytic capacitor industry. The study shows the value and volume of demand for thin gage foil consumed in the capacitor industry, as well as the value and volume of etched and formed anode and cathode foils consumed in the aluminum electrolytic capacitor industry. The study breaks down the complex merchant and captive markets for capacitor foils and shows which capacitor manufacturers etch and form their own foils; and which third party companies are active in supplying ready to use etched anode and cathode foils to the global capacitor industry. The study shows the historical growth in the market over the past decade and shows trends in pricing for capacitor grade anode and cathode foils. The study shows a detailed break-down of the costs to produce aluminum electrolytic capacitors by type and configuration and illustrates the value of foil consumption in radial leaded, vertical chip, snap mount, screw terminal, solid polymer aluminum chip, motor start and axial leaded aluminum electrolytic capacitors. Global market shares for thin foil suppliers to the capacitor industry are given; as well as market shares for thin foil supply of 99.8% cathode foils and 99.9% anode foils.

Forecasts in terms of value, volume and pricing for capacitor foils is given from 2013 to 2018 as well as end-market drivers in consumer audio and video imaging; computer and peripheral; power supplies, renewable energy, automotive, telecom power, and specialty markets are addressed. Forecasts are given for capacitor foil consumption by capacitor configuration to 2018.

Table Of Contents

Table of Contents

1.0 INTRODUCTION: 9

About the Author: 9
Research Methodology Employed: 10
The Paumanok Research Methodology: 10
Government Data Collection and Resources: 10
Secondary Published Sources: 11
Primary Intelligence Gathering: 11
Fixed Capacitors and Their Respective Sub-Categories: FY 2013 11
The Capacitor Supply Chain: 12
Mining of Raw Materials: 12
Raw Materials Processing: 12
Component Manufacturing: 13
Component Distribution: 13
End-Market Consumption: 13
Recycling of Critical Materials: 14
Technical Economic Maxims Related To Capacitors: 15
The Two Technical Economic Maxims Associated with Capacitors: 15
Ubiquitous Nature of Capacitors In Electrical and Electronic Circuits: 15
Financial Considerations With Respect To This Report: 16
The Fiscal Year Ending March 31, 2013 16
Currency Translation 16
Volume, Value and Pricing Data: 16
Global Economic Conditions and Outlook To 2018 16
Positive Market Indicators: 17
Negative Market Indicators: 17

2.0 TECHNOLOGY OVERVIEW: 18

Introduction: 18
Bauxite and Alumina: Recovery, Crushing, and Grinding 18
Settling 18
Precipitation 19
Calcination 19
Smelting 19
Energy Costs 21
Capacitor Foil Production 21
Anode Foil Purity: 22
Cathode Foil Purity: 22
Foil Etching: 22
Foil Forming: 22
Anode Foils: 22
Cathode Foils: 22
Anode Foil Thickness: 22
Voltage Across Terminals 22
Dielectric Withstanding Voltage: 22
Nominal Formation Voltage 22
Rise Time 22
Rise Time Voltage 22
Hydration Process 22
Hydration Resistance Test 22
Rise Time after Hydration Process 22
Dielectric Withstanding Voltage after Hydration Process 22
Initial Capacitance 23
Capacitance after Hydration Process 23
Tensile Strength (N/cm): 23
Etched and Formed, Anode Foil, Low Voltage 23
Etched and Formed, Anode Foil, Medium and High Voltage 23
Variations In Foil Capacitance Between 85 and 105 Degrees C 23
Unique Specifications for Photoflash Foils 23
Etched Foil Specifications For Cathode 23
Foil Roll Sizes: 24
Electrolytic Capacitor Development: A Complex Process 24
Best Practices In Cost Savings For Aluminum Electrolytic Capacitors: 25

3.0 CAPACITOR FOIL MARKETS: FY 2012-2013: 27

Introduction and Market Overview: FY 2012 and FY 2013 27
Global Market Value and Volume For Etched Capacitor Foils: FY 2012 and FY 2013 27
Captive and Merchant Markets for Etched and Formed Foils: FY 2012-FY 2013 27
Etched and Formed Foil Pricing: FY 2012 and FY 2013 27
Ten Year Market Analysis for Capacitor Foils: FY 2003 to 2013 28
Historical Reference, Global Consumption Value, Volume and Pricing For Capacitor Foil in
the Capacitor Industry: 2003-2013 28
Historical Volume Trend In Capacitor Foil Consumption: 10 Year Analysis: 28
Historical Value Trend In Capacitor Foil Consumption: 10 Year Analysis To 2013 29
Historical Pricing Trend For Capacitor Foil: 10 Year Analysis: 30
Correlation Between Foil Consumption and Capacitor Production 31
Capacitor Foil Conversion Into Square Meters: 2013 31
Value, Volume and Pricing for Capacitor Foil: FY 2012 and 2013 31
Capacitor Foil Pricing: FY 2013 32
Historical Aluminum Price Trend: 32
Aluminum Process Materials Pricing: What Impacts Feedstock Pricing 33
Capacitor Foil Mark-Ups at Different Stages of Production: FY 2013 34
Competitive Advantages in Foil Anodization 34
Competitive Advantage of In-House Etching of Aluminum Foils 35
Price of Thin Foil and How It Is Sold 35
Merchant Market Prices For Anode Foils: 35
Merchant Market Prices For Cathode Foils: 35
Anode and Cathode Foils Price Structure by Voltage Rating 36
Global Consumption For Capacitor Foils By Type (Anode Versus Cathode): FY 2012 36
Anode Foils: Volume, Value and Pricing: FY 2012 36
Cathode Foils: Volume, Value and Pricing: FY 2012 36
Capacitor Foil Sales By World Region: FY 2012 37
Global Market for Thin Gage Capacitor Foil By Country: FY 2012 37
Global Market For Etched and Formed Capacitor Foil By Country: FY 2012 37
Aluminum Electrolytic Capacitor Factories By Country: FY 2013 38

4.0 COMPETITIVE ENVIRONMENT and MARKET SHARES IN CAPACITOR FOILS: 40

Competition In The Supply Chain For Capacitor Foils: 2013 40
Understanding The Capacitor Foil Supply Chain, Yield Ratios and Stockpiling: 40
Dramatic Shift In The Thin Foil Supply To The Capacitor Industry in FY 2013 41
Understanding The Players At Each Level of The Supply Chain For Capacitor Foil: 41
Thin Gage Foil For Electrolytic Capacitors: Suppliers by World Region 42
Japan Vendors of Thin Gage Foil For Capacitors 42
European Vendors of Thin Gage Foil For Capacitors 42
American Vendors of Thin Gage Foil For Capacitors 43
Global Trends In Thin Gage Capacitor Foil Supply: FY 2013 43
Top Vendors of Thin Gage Foil For Capacitors (Anode and Cathode Combined): FY 2012 44
Top Suppliers of Thin Gage Foil For Capacitor ANODE: FY 2012 44
Top Suppliers of Thin Gage Foil For Capacitor CATHODE: FY 2012 45
Major Vendors Of Thin Gage Capacitor Foil (99.99% and 99.8% Purity Foils) 46
Showa Denko - Rolled Aluminum Products Division (Sakai Plant) 46
Toyo Aluminum KK 46
Mitsubishi Aluminum Company Limited 46
Sumitomo Light Metal Ind. Ltd. (Sumikei Aluminum Foil Company Limited Operations).47
Nippon Foil Manufacturing Company Limited 47
Xinjiang Joinworld Co.,Ltd., 47
Southwest Aluminum (Group) Co., Ltd 47
Norsk Hydro ASA (VAW) 48
Constellium Singen GmbH 48
UC Rusal (SAYANAL) 48
Merchant Market Suppliers of Etched Capacitor Foils to the Capacitor Industry: FY2013 49
Major Merchant Market Vendors Of Etched Capacitor Foil: FY 2013 49
Japan Capacitor Industrial Company Limited 49
Becromal SpA 50
KDK Corporation 50
SATMA (PPC) {Kendeil} 51
Capxon International Electronic Company Limited 51
Xinjiang Joinworld Co.,Ltd., 51
Nanotong Southlight Electronic 52
Guangdong Dongyangguang Aluminum (East Sunshine Aluminum) 52
Zhaoqing Huafeng Electronic Aluminum Foil Co.,Ltd., 52
Captive Manufacturers of Etched and Formed Capacitor Foils For Internal Consumption: 53
Aluminum Electrolytic Capacitor Manufacturers and Their Captive Foil Capabilities: 53
Nippon Chemi-Con (KDK Corporation, Iwate Electrolytic Industry Corp, and Hidaka
Electron Co. Ltd) 53
Nichicon Corporation (Ohmachi Factory; Tomita Factory) 54
Rubycon Corporation (Shin-EI Capacitor Foil, Inc.) 54
Panasonic Industrial Devices Company/Sanyo (Kyoto Japan Foil Plant) 54
SamYoung Electronics (Sangdaewon Foil and Poseung Foil Plants) 54
Man Yue Technology Holdings Limited (Rifeng Qingyuan Electronic Co. Ltd) 54
Lelon Electronics Corporation (Liton Technology Corp.) 55
Aihua Group (Aishi) (Yaan Aihua Electrode Foil and Lifu Electride Foil Plants) 55
Hitachi AIC (Hitachi Chemical Company Foil Operations) 55
TDK-EPCOS AG (Becromal SpA) 55
Capxon International Electronic Company LImited (Baotou Foil Plant; Yichang Sanxia Plant
and Qinghai Plant) 55
Kaimei Electronic Corporation (Jamicon) {Taiwan Fong-Tien Factory} 56
Kemet Electronics Corporation (Former ACOM and CDE Foil Operations) 56
SamWha Electric (JCC JV-Chungbuk Korea Foil Operations) 57
Vishay Intertechnology (BCC Zwolle Foil Operations) 57
Aluminum Capacitor Manufacturers: FY 2012 Sales and Market Shares 57
Competitive Environment in Aluminum Electrolytic Capacitors: FY 2012- 57
Nichicon Corporation (RIC: 6996) 59
Annual Revenues For NICHICON: 2011, 2012, 2013 Forecast 59
Quarterly Revenues For NICHICON: 2010-2012; FY 2013 Forecast (Yen in Billions) 60
FY2013 Quarterly Estimates and Outlook For Nichicon 60
Nippon Chemi-Con Corporation (RIC:6996) 61
Quarterly Revenues For Nippon Chemi-Con: 2008-2012 Actual and FY 2013 Forecasts (Yen
in Billions) 61
FY2013 Quarterly Estimates and Outlook For Nippon Chemi-Con 62

5.0 COSTS TO PRODUCE ALUMINUM ELECTROLYTIC CAPACITORS: 63

KEY DEFINITIONS: 63
Total Cost: 63
Fixed Costs: 63
Variable Costs: 63
Aluminum Capacitors: Worldwide Revenues: FY 2013 63
Aluminum Capacitors: Operating Margin: FY 2012-2013 64
Aluminum Capacitors: Cost of Sales: FY 2012-2013 64
Aluminum Capacitors: Cost of Goods Sold 65
Fixed Costs: 65
Variable Costs: 65
Raw Materials: 65
Variable Overhead: 65
Variable Labor: 65
Variable “Other” Manufacturing: 65
Raw Materials Cost Breakdown: FY 2012 and 2013 66
Capacitor (Anode and Cathode) Foils: 66
Can and Sleeve: 66
Electrolytes and Associated Chemistry: 66
Rubber End Seals: 67
Separator Paper: 67
Electrode/Tab Materials: 67
Lead Wires: 67
PPS/Foot Tape: 67
Other Costs: 67
Estimated Costs To Produce Aluminum Electrolytic Capacitors By Type: FY 2012 68
Foil Costs In a Radial Leaded 105 Degree C 5x11.5 mm Aluminum Capacitor: 68
Foil Costs In a Radial Leaded 105 Degree C 12.5 x 20mm Aluminum Capacitor: 68
Foil Costs In a Vertical Chip 4.0x5.5 mm Aluminum Electrolytic Capacitor: 68
Foil Costs In a Vertical Chip 10x10.5 mm Aluminum Electrolytic Capacitor: 68
Foil Costs In Snap-In 105 Degree C 400 or 450 Vdc Aluminum Electrolytic Capacitor: 69
Foil Consumption Value, Volume and Pricing By Capacitor Configuration: FY 2012 69
Foil Consumption Value, Volume and Pricing in Radial Aluminum Capacitors: FY 2012 70
Foil Consumption Value, Volume and Pricing in V-Chip Aluminum Capacitors: FY 2012 70
Foil Consumption Value, Volume and Pricing In Snap-Mount, Screw Terminal and Motor
Start Aluminum Electrolytic Capacitors: FY 2012 70
Foil Consumption Value, Volume and Pricing In H-Chip and Axial Leaded Aluminum
Electrolytic Capacitors: FY 2012 70

6.0 ALUMINUM ELECTROLYTIC CAPACITOR MARKETS: 71

Capacitor Market By Type/Dielectric: FY 2013 71
Aluminum Electrolytic Capacitors: Historical Growth and FY 2013 Global Outlook: 72
ALUMINUM Capacitor Consumption Value by End-Use Market Segment: FY 2012 72
Consumption VOLUME For Aluminum Capacitors By End-Use Market Segment: FY 2012.73
Aluminum Electrolytic Capacitors: Markets By Component Configuration 2012 - 2013: 75
Aluminum Electrolytic Capacitors: Demand By Component Configuration 2010 75
Radial Leaded Aluminum Capacitors 75
Vertical Chip Capacitors (V-Chip) 76
Snap-In/Snap-Mount Aluminum Capacitors 76
Computer Grade/Screw Terminal {Large Can} 77
Horizontal Chip Capacitors (H-Chip) 77
Motor Start (Large Can) 77
Axial Leaded Aluminum Capacitors 78
Worldwide Consumption of Aluminum Electrolytic Capacitors by Capacitance Value In
Microfarads: FY 2012 78
Worldwide Consumption of Aluminum Electrolytic Capacitors by Voltage Rating: 2012 79
Markets for Aluminum Capacitors by Capacitance and Voltage Rating 81
Profit Centers in the Aluminum Electrolytic Capacitor Market Based Upon Capacitance and
Voltage Rating 81

7.0 OUTLOOK FOR FOIL 82

Aluminum Electrolytic Capacitors: 2013-2017 Outlook 82
End-Use Product Markets For Capacitors: FY 2013-2018 Forecasted Consumption 82
The Black Box Build: FY 2012-2017 83
Projected Production Volume for Key End-Products Consuming Capacitors (Top 18 end
products): FY 2012-2018: 84
Aluminum Electrolytic Capacitor: Value, Volume and Pricing Forecasts: FY 2013-2018 85
Global Volume of Shipments For Aluminum Electrolytic Capacitors: FY 2013-2018 85
Global Value of Shipments For Aluminum Electrolytic Capacitors: FY 2013-2018 86
Global Average Unit Pricing For Aluminum Electrolytic Capacitors: FY 2013-2018 87
Global Volume of Consumption For Etched and Formed Capacitor Foil: FY 2013-2018 87
Global Pricing Forecast For Etched Capacitor Foil: FY 2013-2018: 88
Global Value of Consumption Forecast For Etched Capacitor Foil: FY 2013-2018: 89
Global Value of Consumption Forecast For Etched Capacitor Foil By Capacitor
Configuration: FY 2013-2018: 89
Foil Consumption Forecasts In Radial Leaded Aluminum Capacitors: FY 2013-2018: 90
Foil Consumption Forecasts In V-Chip Aluminum Capacitors: FY 2013-2018: 90
Foil Consumption Forecasts In Snap-Mount Aluminum Capacitors: FY 2013-2018: 90
Foil Consumption Forecasts In Screw Terminal Aluminum Capacitors: FY 2013-2018: 90
Foil Consumption Forecasts In Polymer H-Chip Aluminum Capacitors: FY 2013-2018: 90
Foil Consumption Forecasts In Motor Start Aluminum Capacitors: FY 2013-2018: 90
Foil Consumption Forecasts In Axial Leaded Aluminum Capacitors: FY 2013-2018: 91

8.0 DIRECTORY OF CAPACITOR FOIL VENDORS: 2013 92

Aluko Co, Ltd 92
Arora Technologies, Inc. 92
Becromal Spa 92
Capxon International Electronic Company Limited 92
Constellium Singen GmbH 93
Guangdong Dongyangguang Aluminum (East Sunshine Aluminum) 93
Japan Capacitor Industrial Company Limited (JCC) 93
KDK Corporation 93
Mitsubishi Aluminum Company Limited 94
Nantong Southlight Electronic Materials Co., Ltd 94
Nippon Foil Manufacturing Company Limited 94
Nippon Light Metal Co. Ltd 94
Norsk Hydro ASA (VAW) 94
SATMA (PPC) {Kendeil} 95
Showa Denko K.K 95
Showa Denko Sakai Aluminum K.K. (SSK) 95
Southwest Aluminum (Group) Co., Ltd 95
Sumitomo Light Metal Ind. Ltd 96
Sumitomo Light Metal Ind. Ltd. Sumikei Aluminum Foil Co., Ltd. 96
Toyo Aluminium K.K 96
UC Rusal (SAYANAL) 96
Xinjiang Joinworld Co., Ltd 97
Zhaoqing Huafeng Electronic Aluminum Foil Co.,Ltd 97
Zhejiang Huayi Aluminium Co., Ltd 97



List of Figures

Figure 1: Fixed Capacitor Market Breakdown by Sub-Category: FY 2013 11
Figure 2: Materials Required To Produce An Aluminum Electrolytic Capacitor 25
Figure 3: 10 Year Analysis of The Global Capacitor Foil Markets (Volume, Value, Pricing and
Correlation With Aluminum Capacitor Markets): 2003-2013 28
Figure 4: Global Volume of Consumption For Etched and Formed Capacitor Foil: FY 2003 to FY
2013 (In Millions of Pounds) 29
Figure 5: Global Value of Consumption For Etched and Formed Capacitor Foil: FY 2003 to FY
2013 (In Millions of USD) 30
Figure 6: Global Average Pricing For Etched and Formed Capacitor Foil: FY 2003 to FY 2013 (In
USD Per Pound) 31
Figure 7: Converting Capacitor Foil To Square Feet 31
Figure 8: Value, Volume and Pricing For Capacitor Foils (Captive Versus Merchant): FY 2012 32
Figure 9: Variations In Value, Volume and Pricing For Capacitor Foil By Channel: FY 2012 32
Figure 10: Price Trend for Raw Aluminum: 1999-2013 33
Figure 11: Capacitor Foil Mark-Ups At Various Stages of Production: FY 2013 34
Figure 12: Global Consumption Volume for Capacitor Foil By Type (Anode Versus Cathode): FY
2012 37
Figure 13: Thin Gage Foil Sales To The Captive and Merchant Markets By World Region: FY
2012 37
Figure 14: Actual Consumption of Etched and Formed Foil By Country: FY 2012 38
Figure 15: Aluminum Electrolytic Capacitor Manufacturers: Factories By Country 39
Figure 16: Structure of The Supply Chain for Capacitor Foils: FY 2013 40
Figure 17: Affects of Yields and Stockpiling on the Supply Chain for Capacitor Foil: FY 2012 41
Figure 18: Changes in The Supply of Thin Gage Foil in FY 2013 41
Figure 19: The Key Players At Each Level of The Capacitor Foil Supply Chain: FY 2013 42
Figure 20: Top Vendors of Thin Gage Foil For Electrolytic Capacitors (Anode and Cathode
Combined) FY 2012 44
Figure 21: Top Suppliers of Thin Gage Foil For Capacitor ANODE: FY 2012 45
Figure 22: Top Suppliers of Thin Gage Foil For Capacitor CATHODE: FY 2012 45
Figure 23: Merchant Market Suppliers of Etched and Formed Capacitor Foils: FY 2012 Market
Shares 49
Figure 24: Top 14 Capacitor Manufacturers Who Etch and Form Their Own Foil: 2013 53
Figure 25:Aluminum Capacitor Manufacturers: Sales and Market Shares: 2012 FY (In Millions of
USD) 58
Figure 26: Costs To Produce Metrics for Aluminum Electrolytic Capacitors: FY 2012-FY 2013
(Global Industry Estimate In Millions of USD) 64
Figure 27: Cost of Sales For Aluminum Capacitors (Raw Materials, Fixed Costs, Variable
Overhead, Variable Labor, Other Variable): 2012/2013 66
Figure 28: Raw Material Cost Breakdown for Aluminum Electrolytic Capacitors By Type:
2012/2013 68
Figure 29: Estimated Costs To Produce Aluminum Electrolytic Capacitors By Type: FY 2013 69
Figure 30: Foil Consumption Value and Volume By Component Configuration: FY 2012 69
Figure 31: Global Capacitor Consumption by Dielectric: FY 2008-2012; 2013 Forecast 71
Figure 32: Global Value of Consumption for Capacitors By Dielectric Type: FY2012 71
Figure 33: Global Consumption VALUE For Aluminum Capacitors By End-Use Market Segment:
FY 2012 73
Figure 34: Global Consumption VOLUME For Aluminum Capacitors By End-Use Market
Segment: FY 2012 74
Figure 35: Aluminum Electrolytic Capacitors Demand By Type and Configuration: FY 2012 to FY
2013 Global 75
Figure 36: Global Consumption Value for Aluminum Electrolytic Capacitors By Capacitance
Range in Microfarads: FY 2012 79
Figure 37: Global Consumption Value for Aluminum Capacitors By Voltage Rating: FY 2012 80
Figure 38: Global Black Box Build Projections: FY 2013-FY 2018 84
Figure 39: Projected Production Volume for Key End-Products Consuming Capacitors: FY 2012-
2018 85
Figure 40: Aluminum Electrolytic Capacitor: Value, Volume and Pricing Forecasts: FY 2013-2018
85
Figure 41: Global Volume of Shipments for Aluminum Electrolytic Capacitors: FY 2013-2018 86
Figure 42: Global Volume of Shipments for Aluminum Electrolytic Capacitors: FY 2013-2018 86
Figure 43: Global Average Unit Pricing for Aluminum Electrolytic Capacitors: FY 2013-2018 87
Figure 44: Global Volume of Consumption For Etched and Formed Capacitor Foils: FY 2013-
2018 88
Figure 45: Global Pricing Forecast For Etched Capacitor Foils: FY 2013-2018 88
Figure 46: Global Pricing Forecast For Etched Capacitor Foils: FY 2013-2018 89
Figure 47: Global Value, Volume and Pricing Forecast for Etched Capacitor Foil By Aluminum
Electrolytic Capacitor Configuration: FY 2013-2018 89

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