Summary of the impact
Research at Brunel University demonstrated how the Powder Impression
Moulding (PIM) process can be adapted to form a solid-skinned and foamed
core polymer lightweight sandwich panel from 100% mixed post-consumer
polymers. The research showed that unlike conventional plastic recycling
technologies, this process was tolerant to high concentrations of
impurities. It was also shown that coarse flakes could be used as
feedstock, removing the need to grind the feedstock to a fine powder.
This, for the first time, established the PIM process as a recyling method
and provides a source of income for industries collecting post-consumer
plastics. In 2009, ERT Plc, who own the IP associated with PIM, signed a
licence agreement with 2K Manufacturing Ltd to manufacture and sell a
range of flat-board products made from 100% mixed post-consumer plastics.
These boards are sold as EcoSheets and are 2K Manufacturing's only
product. 2K buy post-consumer recycled plastics from recycling firms who
run Municipal Recycling Facilities, (MRF), providing them with increased
income from waste collected from consumers, and sell EcoSheets to a
variety of industries and distributors for applications in construction,
agriculture, flood control facilities and military uses. For commercial
reasons, exact production and sales figures are not available, but we
estimate that at least 1 million boards have been produced and sold since
2009. The impact on the end user is that, although the price of an
EcoSheet is comparable to the plywood board it replaces, EcoSheet does not
rot, is more workable, and can be recycled several times.
ERT Plc have licensed the technology enhanced by the Brunel research to a
number of other businesses.Thus the research at Brunel has assisted the
creation of a new industrial sector, and a new product with many
advantages, including reduced reliance on virgin polymers and reduced
environmental burdens (such as landfill costs), over the product it
replaces. This has created economic and environmental benefits at all
stages of the consumer plastic cycle, creating new industries and jobs.