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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 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 ) 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 ) 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) 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 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 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 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? to reduce product costs to lower tooling costs to reduce the number of components to reduce the number of manufacturing stages to make components lighter/enhance performance 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) £100 Billion per annum 9% of GDP Specifiers are key – Land Securities / Bovis etc Govt. responsible for 40% of overall spend Opportunities at strategic level for new replacement products using PIM technology 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 Opportunity from WEEE directive – 2007 PIM ahead of market by re-use of WEEE materials When directive in force then huge obligation on producers of electrical products Initial trial by Bovis Lend Lease / Land Securities Pallet Box 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 Concrete replacement pipe produced using offcuts of nappy material - contains Polyethylene 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 Replacement ceramic components Other bathroom components under development. PIM Research & Development Opportunities – Water Tanks 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 Brunel University Bovis Lend Lease Severnside Recycling Others tbc PIM Benefits Reduces environmental impact Adds considerable value to waste materials Produces: added value end products, lighter, easier to handle, quicker to install, very robust, nonmaintenance At end of life product is totally recyclable Summary 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 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 More info at: www.3dmworldwide.com www.3dmct.com PIM Challenge / Next steps Can Industry Adopt? Which Industries? Automotive and Materials Handling – so far Extent of Construction take up? Flat sheet / Eco-sheet / Ecohoarding / Roofing / Bathrooms Pre-fabrication Opportunities 1st Mover Opportunities + business support (e.g. www.eco-sheet.com, www.ecohoarding.com) Research opportunities Others? www.3dmct.com