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Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006 Niall MacKay – CEO, 3DM Worldwide Paul Gallen – Senior PM, 3DM Worldwide Richard Bayfield - Construction Sector Consultant

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Page 1: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Powder Impression Moulding (PIM)

(Opportunities for Prefabrication and Recycling many waste streams)

Presentation to Construction Sector – December 2006

Niall MacKay – CEO, 3DM Worldwide

Paul Gallen – Senior PM, 3DM Worldwide

Richard Bayfield - Construction Sector Consultant

Page 2: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 3: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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)

Page 4: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 5: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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).

Page 6: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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 largestcreator of waste and the largest potential user of plastic recyclate;

to develop standards and specifications both for plastics recyclables and recyclate.

Page 7: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 8: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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.

Page 9: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 10: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 11: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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?

Page 12: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006
Page 13: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Typical PIM Process Factory Layout (Delta)

Page 14: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 15: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Typical Open Mould Designs

Page 16: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Already working with major US automotive corporations and PIM will be supplying Ford via Asimco

Page 17: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Materials Handling Sector

Page 18: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Construction Products

Page 19: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Construction Products

Page 20: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

£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)

Page 21: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 22: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 23: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 24: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 25: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

Replacement ceramic components

Other bathroom components under development.

Shower Tray

Page 26: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 27: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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:

Page 28: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 29: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

Page 30: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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

3DM Worldwide plc

Page 31: Powder Impression Moulding (PIM) (Opportunities for Prefabrication and Recycling many waste streams) Presentation to Construction Sector – December 2006

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