recycling many plastic waste streams via powder impression moulding (pim) presentation to nnfcc...
TRANSCRIPT
Recycling many plastic waste streams via Powder Impression Moulding (PIM)
Presentation to NNFCC
Thematic Working Group on Biopolymers
5th April 2006
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 (- 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).
WRAP’s Priorities (- www.wrap.org.uk )
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.
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
First StageBulk arrives
Second StageMaterial sterilised
Third StagePowder/granules
PIM technology 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.
Allows companies to apply for wide ranging Government funding that’s available
Apart from the environmental benefits, why use PIM technology when other manufacturing alternatives are available?
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
Society now demands environmental improvements, clients also want the commercial advantage
Typical PIM Process Factory Layout (Delta)
Typical Open Mould Designs
Already working with major US automotive corporations and PIM will be supplying
Materials Handling Sector
Construction Products
Construction
Concrete replacement pipe produced using waste nappies material which 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%.
Case study
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
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
Summary
First StageBulk arrives
Second StageMaterial sterilised
Final StageProduct
3DM’s technology can use non segregated waste material as a composite component to produce products for use in the construction industry – www.3dmct.com
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
Can Industry Adopt?
Which Industries?
Automotive and Materials Handling – so far
Construction – to follow? Others??
Open visit to Caerphilly Manufacturing Facility – Thursday 20th April (+ other dates by arrangement)
This presentation @ www.3dmct.com
PIM Challenge / Next steps