Carling : the renaissance of a petrochemical site

Carling, Total’s petrochemical complex in eastern France.

In 2013, Total took steps to make the site — hard hit by structural excess capacity in the European petrochemical industry — competitive again.

A transformation costing €180 million that Total pledged to conduct while maintaining jobs.

Franky Smisaert, Carling/Saint-Avold General Manager

“The site had been operating at a loss for many years. So Total’s senior management approved a complete makeover to safeguard its future.”

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“By shutting down the loss-making steam cracker, Total sent a strong signal about the complex’s new industrial positioning.”

Laurent Hauser, Supervisor, Polyethylene Unit

The heart of the plant stopped beating, but in a way was transplanted elsewhere. We came at it from a fresh angle.

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Total adjusted its polymer production and developed a new hydrocarbon resin business to make the site a leader in Europe.

Three production units were upgraded and two new ones were built, one to produce resins and one to produce polypropylene for automotive parts. Carling became European center for Cray Valley, Total's hydrocarbon resins business. These new activities give Carling access to high-potential markets such as electronics and automaking.

Franky Smisaert, Carling/Saint-Avold General Manager

The complex’s transformation was a unique, pioneering project for Total. There were two parts, one industrial and one people-focused.

Aurélie Blaise, PS-PPC Logistics Assistant Manager

Back in 2013, we were all worried. We didn’t really know what the plan for Carling was. We didn’t know if it were going to be closed or if new units would be added to keep us going and working.

Johan David, Resins Integration Project Manager

“They told us Total was going to invest in a new C4 resins project. We were relieved that we were going to stay. We have roots here. Our families are here. We were glad to be staying.”

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During the transformation, Total supported contractors and kept its promises to customers and employees. Eighty percent of employees saw their jobs change, partly or completely. Human Resources oversaw the transition and provided personalized solutions for everyone.

Nearly 200,000 hours of training supported the site’s transformation.

Johan David, Resins Integration Project Manager

Total’s culture is ours. It’s part of us. It’s not something you just wake up with. You acquire this experience working at the site.

Franky Smisaert, Carling/Saint-Avold General Manager

For me, the most important thing is the competencies, the people here at Carling.

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Total, the No. 2 petrochemical producer in Europe, carried out this industrial transformation in partnership with local economic stakeholders, enabling Carling to become a European leader in hydrocarbon resins and polymers.

Franky Smisaert, Carling/Saint-Avold General Manager

We completed the project on time and budget. There were no layoffs or compulsory transfers. And for the first time in years, Carling is in the black. Now that’s what I call a success!

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