Powder Impression Moulding (PIM)
(Opportunities for Prefabrication and Recycling many waste streams)
Presentation to Construction Sector – January 2007
Niall MacKay – CEO, 3DM Worldwide
Paul Gallen – Senior PM, 3DM Worldwide
Richard Bayfield - Construction Sector Consultant
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
Plastic Waste is currently
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 – Stern Report, Kyoto, California Laws, Attenbrough, Zero Carbon House – exempt from stamp duty 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).
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
First StageBulk arrives
Second StageMaterial sterilised
Third StagePowder/granules
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.
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.
Thus ensuring Local Authorities can meet the targets set by Government.
Allows organisations to apply for wide ranging Government funding that’s available
Material Preparation
Very complex area – research is ongoing
PIM Process viewed positively by WRAP
Initial research shows PIM Process compares favourably to other Plastic moulding techniques
Significant PIM benefit is in ability to recycle at end of product life
Carbon Footprint etc
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
Apart from environmental considerations what are other benefits of PIM Technology?
Typical PIM Process Factory Layout (Delta)
Clean Mould Preheat Mould to 250˚C Deliver skin material Cure skin
Deliver core material to lower mould Position upper mould over lower mould
Clamp moulds together Heat mould until core is molten Core material “foams”
Controlled cooling Separate mould
Remove product Process starts again
PIM Process Stages
Typical Open Mould Designs
Already working with major US automotive corporations and PIM will be supplying Ford via Asimco
Materials Handling Sector
Construction Products
Construction Products
£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
UK Construction Market (key facts)
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.
Ecohoardings – Eco-sheet
Opportunity created by 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
Successful trials by Bovis Lend Lease – Bovis supply chain taking all current production from Caerphilly – demand exceeds current supply - Opportunity
Submitted for Environmental award
www.eco-sheet.com
Replacement for Timber and Injection Moulded products
Stronger, lighter – can be stacked higher
Lower life cycle costs – uses recycled material & is 100% recyclable
Pallet Box
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%.
Replacement Concrete Pipe
Replacement ceramic components
Other bathroom components under development.
Shower Tray
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 & Development Opportunities – Water Tanks
PERA Research
Brunel University
Bovis Lend Lease
Severnside Recycling
Others tbc
PIM Research Opportunities – DTI Advanced Materials / Packaging Waste (final stage) – Funding invitation Nov 06, Confirmed Partners include:
Reduces environmental impact
Adds considerable value to waste materials
Produces: added value end products, lighter, easier to handle, quicker to install, very robust, non-maintenance
At end of life product is totally recyclable
PIM Benefits
Summary
Several Opportunities within Construction Sector
Very Flexible High Technology Manufacturing Solution - Bespoke modular design that’s configured to suit client’s requirements – extremely versatile process
Capable of mass production of thermoplastic/ composite moulded products
Capable of encapsulating other components
Capable of using co-mingled post consumer waste and then re-cycle at end of product life
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
Business model – license technology – e.g. RJ Plastics (West Midlands Jan 07)
Confidential Business plans available for sheet and other products – contact Niall
More info at:
www.3dmworldwide.com
www.3dmct.com
3DM Worldwide plc
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
PIM Challenge / Next steps
