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The impact presented in this case study is the commercialisation of 15 products with perfume microcapsules by Procter and Gamble (P&G), made possible using capsule mechanical strength data provided by Prof Zhibing Zhang's research group at Birmingham. Use of microcapsules gives improved freshness performance, and thus commercial advantage, compared with traditional formulations; they have been incorporated in P&G's four major billion-dollar brands — Downy, Febreze, Lenor and Tide. This has significantly improved their competitiveness enabling P&G to retain their leading position in the USA and Western Europe. A novel micromanipulation technique developed at the University of Birmingham has been used extensively to obtain mechanical properties data for the micro-particles, including microcapsules prepared in Birmingham and provided by companies, which is related to their formulation and processing conditions and end- use performance. In addition, the knowledge generated has helped 15 other companies to commercialise new functional products containing micro-particles.
Research at the University of Bradford has enabled many major vehicle and brake manufacturers to improve the design of their brakes and braking systems to increase customer satisfaction and sales, and reduce costs. Methods have been developed to predict the thermo-mechanical and dynamic performance of brakes and provide design improvements. Durable solutions have been developed for noisy brakes, which have reduced warranty costs for approximately ten international collaborating companies including Bentley, where a squeal noise from the front brakes of a new vehicle had prevented it from being released for production. Our research has been embedded into short courses, which have trained over 250 engineers since 2008 and is incorporated into Jaguar Land Rover's (JLR) professional training.
Applied acoustics in the built environment and its broader uptake is focused on the development and commercial adoption of techniques and technologies resulting from research in applied acoustics, demonstrating the following impact:
Research at the University of Leeds, in partnership with the US company Agilent Technologies, has directly resulted in the development of high performance vector network analyzer instrumentation used by electronics, aerospace and defence companies globally to measure the high frequency properties of electronic devices and materials. University of Leeds research also directly resulted in the development of two further Agilent Technologies products — a high frequency dielectric probe kit and a capacitance scanning probe microscope. Agilent Technologies confirms that the collective sales of these products are in the region of tens of millions of dollars annually since 2008.
Research in the Department of Civil and Structural Engineering at the University of Sheffield on dynamic performance and vibration serviceability has contributed to internationally applied guidance on building serviceability for floors, buildings, stadia and other structures and has led to the spin-out Full Scale Dynamics Ltd (FSDL). Based on our research FSDL provides applied research and consultancy services, and has delivered projects approaching £1m since 2008. FSDL has demonstrated significant reach through its work with blue chip clients nationally and internationally. Our research has impacted on leading national sport infrastructure (such as Premiership Football stadia and notably the Olympic 2012 Velodrome) and public companies to deliver economic benefits by providing evidence based compliance, demonstrating that stadia, hospitals, manufacturing plants and other public structures comply with safety and vibration serviceability standards. Interventions based on our research and implemented via FSDL have, on numerous occasions, avoided potentially serious economic and safety consequences due to the poor vibration performance of structures.
For aerospace vehicles, the development of new materials and structural configurations are key tools in the relentless drive to reduce weight and increase performance (in terms of, for example, speed and flight characteristics). The economic drivers are clear — it is widely recognised that it is worth approximately $10k to save one pound of weight in a spacecraft per launch and $500 per pound for an aircraft over its lifetime. The environmental drivers (ACARE 2050) are also clear — reduced aircraft weight leads to lower fuel burn and, in turn, to lower CO2 and NOx emissions. With such high cost-to-weight ratios, there is intense industrial interest in the development of new structural configurations/concepts and enhanced structural models that allow better use of existing or new materials. Analytical structural mechanics models of novel anisotropic structures, developed at the University's Advanced Composites Centre for Innovation and Science (ACCIS), are now used in the industrial design of aircraft and spacecraft. Based on this research, a new, unique anisotropic composite blade, designed to meet an Urgent Operational Requirement for the MoD, is now flying on AgustaWestland EH101 helicopters that are deployed in Theatre. In addition, the new modelling tools and techniques have been adopted by Airbus, AgustaWestland, Cassidian and NASA and incorporated into LUSAS's finite element analysis software. These tools have, for example, been used to inform Airbus's decision to use a largely aluminium wing design rather than a hybrid CFRP/aluminium wing for the A380.
Research undertaken in the University of Cambridge Department of Physics has provided benchmark data on, and fundamental physical insights into, the high strain-rate response of materials, including powdered reactive metal compositions. The data have been used widely by QinetiQ plc. to support numerical modelling and product development in important industrial and defence applications. One outcome has been the development of a reactive metal perforator for the oil industry which significantly outperforms conventional devices. These devices `perforate' the region around a bore-hole, thereby substantially enhancing recovery, particularly in more difficult oil fields, and extending their economic viability. Over a million perforators have been deployed since their introduction in 2007.
The production of plastic (polymer) waste and the difficulties associated with its disposal is a major environmental challenge. Many polymer food packaging structures are made using thermoforming processes in which hot thin oil-based polymer sheets are forced under pressure into moulds and then cooled to become thin-walled packaging structures. These structures are not eco-friendly and do not degrade after use. Thus unless they are recycled, which is a complicated process and mostly does not happen, these structures cause major environmental problems worldwide.
Researchers in Brunel Institute of Computational Mathematics (BICOM) have undertaken extensive computational modelling of the thermoforming of packaging structures made from bio-materials (thermoplastics). This computational work, together with the necessary laboratory experiments which were executed by Brunel engineers, has contributed to a far better understanding of the behaviour of starch-based biodegradable food packaging. In turn, the availability of such knowledge has contributed to the steady move by food packagers and food retailers towards the adoption of such packaging which is helping to reduce the amount of long term non-biodegradable waste produced.
Since 1995, Loughborough's research into vibro-impact systems (VIS) has made handheld breaker tools safer for operators and has also increased machining efficiency. Users have been prone to detrimental `hand arm vibration' effects of multiple impacts, including the debilitating condition `white finger'. JCB applied the research findings in its HM25LV breaker design, introduced in 2008, which despite being more powerful exhibits half the hand arm vibration of competitors. JCB has sold more than 1,800 units in the UK and abroad.
Packaging is vital for sales and for product protection for all process industries, with the most widely used world-wide being board and film. For example, the grocery sector alone represents about 70% of the UK packaging market, with 10 million tonnes of packaging used each year.
Packaging materials are variable, which poses significant challenges in packaging machine design. A further challenge has arisen due to environmental legislation that requires the use of thinner, lighter weight materials. There is a need to meet these challenges since the size of the world market for packaging machinery is around €20bn, of which 2% is associated with the UK. Research at Bath has helped address these challenges in a number of inter-related areas:
Research has been undertaken in collaboration with industrial companies consisting mainly of SMEs, end users and research associations. Impact has been gained by embedding the results within the collaborating companies and by on-going use of the results by research associations.