Download 12MB - ERT for Construction

Powder Impression Moulding (PIM)
(Opportunities for Prefabrication and Recycling many
waste streams)
Presentation to Construction Sector - October 2006
Niall MacKay – CEO 3DM Worldwide
Peter Oldham – Ops Director 3DM Worldwide
Richard Bayfield - Construction Sector Consultant
Plastic Waste is currently
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Incinerated or dumped as landfill (80%+)
The PIM process is unique as it is the only
process capable of converting non-segregated
low hazardous waste materials
Context (- Climate Change )
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Increased harmful carbon dioxide (co2) emissions since industrial
revolution (i.e. changes from long term temperature trends began in
early 20th Century – evidence via trees etc)
Problem of climate change now widely accepted across world –
compelling scientific evidence – more at www.3dmct.com (links)
Main stream international social / political issue - no longer preserve
of “green party” – examples - Kyoto, California, Attenbrough, etc etc
Education policies – raising awareness amongst young worldwide
Strategies to reduce climate change - reduce consumption / reduce
waste / increase recycling
Opportunities for “green” businesses – e.g. Richard Branson (S/Times
10/9/06)
Context (- Climate Change )
Difference in average surface temperature: comparison with
1861-1990 average, Global and Central England, Degrees C
http://www.statistics.gov.uk/cci/nugget.asp?id=368
Context (- www.recycleplastic.org.uk )
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The UK uses over 5 million tonnes of plastic each year. It is
increasingly being used in packaging, construction and
automotive markets.
The UK currently recycles or recovers approx. 19% of all plastic
consumed. This is set to increase to over 25% by 2010.
Strategic material source, less dependent on commodity plastic
pricing.
• Positive corporate social responsibility (CSR) indicator.
• Positive PR opportunity.
• Strategic approach to alleviate the risk of more mandatory
measures (eg packaging taxation).
Context – Waste Recycling Action Programme
(WRAP www.wrap.org.uk)
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PRIORITIES:to provide support for the establishment of a 20,000 tonnes
plastic bottle sorting/recycling facility (i.e. 0.4%) ;
to develop commercial applications for the projects in our
extensive plastics R&D programme;
to increase the amount of recyclate in retail packaging – the
packaging sector is both the largest
creator of waste and the largest potential user of plastic
recyclate;
to develop standards and specifications both for plastics
recyclables and recyclate.
Overview
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Challenge - Large “growing” problem unlikely to be
solved by legislation
Opportunity - Need for new technologies
C.f. Value Engineering – 2nd World War – shortages –
alternative materials / technologies
Increasing social / political pressure
POWDER IMPRESSION MOULDING (PIM)
A novel feature of PIM technology is that it can use non
segregated waste material as a composite component
to produce products for use in many industries.
First Stage
Bulk arrives
Second Stage
Material sterilised
Third Stage
Powder/granules
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PIM - New scaleable Technology producing
plastic/ composite materials to achieve high
strength/low weight thermoplastic moulded
components
Allow use of “dirty” co-mingled post use plastics
to produce high value finished products
Can produce large scale moulded product
Can encapsulate other non-polymer materials to
provide additional product functionality for
example conduit piping into wall panels
Can fully recycle the products once useful life is
exceeded into new/alternative products
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The PIM process allows waste materials to be
very easily converted into added value products.
Thus ensuring Governments can meet the targets
set by signed International Treaties.
Allows companies to apply for wide ranging
Government funding that’s available
Apart from environmental considerations
what are other benfits of PIM Technology?
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to reduce product costs
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to lower tooling costs
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to reduce the number of components
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to reduce the number of manufacturing stages
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to make components lighter/enhance performance
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to give product improved thermal and sound
insulation properties
Typical PIM Process Factory Layout
(Delta)
PIM Process Stages
Clean Mould
Preheat Mould to 250˚C
Deliver core material to lower mould
Clamp moulds together
Controlled cooling
Remove product
Deliver skin material
Cure skin
Position upper mould over lower mould
Heat mould until core is molten
Core material “foams”
Separate mould
Process starts again
Typical Open Mould Designs
Already working with major US automotive
corporations and PIM will be supplying
Materials Handling Sector
Construction Products
Construction Products
UK Construction Market (key facts)
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£100 Billion per annum
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9% of GDP
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Specifiers are key – Land Securities / Bovis etc
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Govt. responsible for 40% of overall spend
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Opportunities at strategic level for new replacement
products using PIM technology
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Ecohoardings – Eco-sheet
Replacement for painted plywood sheet, easy Graffiti
removal, Flame proof, smooth finish, standard wood
fixings – nails / screws etc (also plastic weld)
Lower life cycle costs – uses 80% + recycled
material & is 100% recyclable
3rd Party estimate UK market 1 – 5 Million sheets
p.a.
www.eco-sheet.com
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Opportunity from WEEE directive – 2007
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PIM ahead of market by re-use of WEEE materials
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When directive in force then huge obligation on
producers of electrical products
Initial trial by Bovis Lend Lease / Land Securities
Pallet Box
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Replacement for Timber and Injection Moulded
products
Stronger, lighter – can be stacked higher
Lower life cycle costs – uses recycled material & is
100% recyclable
Replacement Concrete Pipe
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Concrete replacement pipe produced using
offcuts of nappy material - contains Polyethylene
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Pipes have proven in tests to be as strong as
concrete
Achieved 58kN/m exceeding the crush test
EN1916/BS 5911:2002 requirement of 45kN/m by
30%.
Shower Tray
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Replacement ceramic components
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Other bathroom components under development.
PIM Research & Development
Opportunities – Water Tanks
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Environmentally friendly electrochemical water
treatment systems
Developer is affiliate organisation to University of
Wales project now at proto type stage
Trials set up for Utility and Commercial Organisations
using water tanks made from PIM process
PIM Research Opportunities – DTI
Advanced Materials / Packaging Waste
(final stage) – Confirmed Partners subject
to funding:
 PERA Research
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Brunel University
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Bovis Lend Lease
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Severnside Recycling
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Others tbc
PIM Benefits
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Reduces environmental impact
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Adds considerable value to waste materials
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Produces: added value end products, lighter, easier to
handle, quicker to install, very robust, nonmaintenance
At end of life product is totally recyclable
Summary
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Very Flexible High Technology Manufacturing
Solution
Capable of using co-mingled post consumer waste
Capable of mass production of thermoplastic/
composite moulded products across diverse
industries
Capable of encapsulating other components and
materials
Bespoke modular design that’s configured to suit
client’s requirements – extremely versatile process
3DM Worldwide plc
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Is a British plc that develops and licences advanced and innovative plastic
technologies.
Is responsible for developing a unique manufacturing process called PIM
(Powder Impression Moulding)
Holds international patents on the PIM process and associated high technology
processes
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More info at:
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www.3dmworldwide.com
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www.3dmct.com
PIM Challenge / Next steps
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Can Industry Adopt? Which Industries?
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Automotive and Materials Handling – so far
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Extent of Construction take up?
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Flat sheet / Eco-sheet / Ecohoarding / Roofing / Bathrooms
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Pre-fabrication Opportunities
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1st Mover Opportunities + business support (e.g. www.eco-sheet.com,
www.ecohoarding.com)
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Research opportunities
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Others?
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www.3dmct.com