powder impression moulding (pim) (opportunities for prefabrication and recycling many waste streams)...
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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 Slide 2 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 Slide 3 Context (- Climate Change ) Increased harmful carbon dioxide (co2) emissions since industrial revolution (i.e. changes from long term temperature trends began in early 20 th Century evidence via trees etc) Problem of climate change now widely accepted across world compelling scientific evidence more at www.3dmct.com (links)www.3dmct.com 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) Slide 4 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 Slide 5 Context (- www.recycleplastic.org.uk )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). Slide 6 Overview Challenge - Large growing problem unlikely to be solved by legislation Opportunity - Need for new technologies C.f. Value Engineering 2 nd World War shortages alternative materials / technologies Increasing social / political pressure Slide 7 First Stage Bulk arrives Second Stage Material sterilised Third Stage Powder/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. Slide 8 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 Slide 9 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 thats available Slide 10 Material Preparation Slide 11 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 Slide 12 Slide 13 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? Slide 14 Slide 15 Typical PIM Process Factory Layout (Delta) Slide 16 Clean MouldPreheat Mould to 250CDeliver skin materialCure skin Deliver core material to lower mouldPosition upper mould over lower mould Clamp moulds togetherHeat mould until core is moltenCore material foams Controlled coolingSeparate mould Remove productProcess starts again PIM Process Stages Slide 17 Typical Open Mould Designs Slide 18 Already working with major US automotive corporations and PIM will be supplying Ford via Asimco Slide 19 Materials Handling Sector Slide 20 Construction Products Slide 21 Slide 22 100 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) Slide 23 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 3 rd Party estimate UK market 1 5 Million sheets p.a. Ecohoardings Eco-sheet Slide 24 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 Slide 25 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 Slide 26 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 Slide 27 Replacement ceramic components Other bathroom components under development. Shower Tray Slide 28 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 Slide 29 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: Slide 30 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 Slide 31 Summary Several Opportunities within Construction Sector Very Flexible High Technology Manufacturing Solution - Bespoke modular design thats configured to suit clients 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 Slide 32 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 Slide 33 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 1 st Mover Opportunities + business support (e.g. www.eco-sheet.com, www.ecohoarding.com)www.eco-sheet.com www.ecohoarding.com Research opportunities Others? www.3dmct.com PIM Challenge / Next steps