Recycling many plastic waste streams via Powder Impression Moulding (PIM) Presentation to NNFCC Thematic Working Group on Biopolymers 5 th 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 (- ) 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 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 (- ) 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 – 2 nd World War – shortages – alternative materials / technologies

First Stage Bulk arrives Second Stage Material sterilised Third Stage Powder/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 Stage Bulk arrives Second Stage Material sterilised Final Stage Product 3DM’s technology can use non segregated waste material as a composite component to produce products for use in the construction industry –

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: 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 20 th April (+ other dates by arrangement) This PIM Challenge / Next steps