Periodic Reporting for period 1 - Ecosheet-PRO (An Environmentally-Friendly Alternative to Plywood made from Co-mingled Waste Plastic)
Período documentado: 2015-05-01 hasta 2015-10-31
Also polluting EU landfills is end of life plywood. More than 300k tonnes of plywood waste is generated yearly most of which end up in landfill. China supplies Europe with the majority of its plywood demand. However, 50% of the timber used in Chinese manufactured plywood comes from illegal sources. Not only is plywood being manufactured with non-certified timber, but the glue used to bond the thin wood plies is of a very toxic nature. Tonnes of these toxins end up in EU landfills alongside the imported plywood.
The project objective is to successfully develop and scale up for market readiness, an innovative patented technology for converting low-grade co-mingled waste plastic into a cost effective and direct replacement to plywood in construction formwork applications. This product will meet the construction industry’s need for an environmentally friendly alternative to plywood. Existing solutions require single waste streams (not co-mingled) and are able to achieve the flexural modulus of 2500MPa required to replace plywood in formworks, however at a significantly increased costs (e.g. £150 vs £30). Ecosheet-PRO is able to achieve this, both technically and commercially. The ability to be recycled at end of life makes Ecosheet-PRO unique. Ecosheet-PRO will reduce global demand for plywood (3 million m3 in 2013 in Europe) and challenge the tide of global deforestation. This project would re-define a €9bn global plywood market and help Europe meet its plastic recycling targets. Ecosheet-PRO is expected to create 120 jobs and generate annual revenue of over €77.1m 6 years post project completion.
1. Material and mechanical specification for individual “component layers” of the structural sandwich panel (Ecosheet-PRO) required to deliver overall flexural modulus of 2500MPa and flexural Strength of 25MPa
2. Specialist compounding process capable of producing the required material characteristics using the three major waste plastic streams: Civic Amnenity, Film Waste, and Automotive Shred Residue
3. Specialist fibre wetting process that reinforces/strengthens the Ecosheet-PRO
Ecosheet-PRO plant will deliver huge environmental benefits. 8,500 tonnes of plastic waste will be diverted from landfill for every 250,000 Ecosheet-PROs produced. Furthermore, assuming a longevity ratio for Ecosheet-PRO over plywood of 5:1 means 42,500 tonnes less trees will be cut down to produce plywood. A mature Douglas Fir tree weighs approx. 4 tonnes, therefore 10,625 such trees will be prevented from being chopped down yearly. Assuming 50% of timber imports are illegal (Globaltimber.org.uk) Ecosheet-PRO will therefore be replacing unsustainably sourced timber.
A significant amount of CO2 is produced annually from transportation (>100million kg) due to the import of plywood into Europe (wisaplywood.com). If we can secure just 10% of the market, then a significant amount of CO2 will be removed from the environment.
Formaldehyde, an essential constituent in plywood binding resins, have links to health problems such as asthma and cancer. Ecosheet-PRO won’t pose any health risks to the general public. Ecosheet-PRO can also be recycled numerous times, unlike plywood.