9th September 2010 16:47
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Techno-Commercial Evaluation of Advanced Materials Manufacturing
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Problem Statement
The development of low cost multi-ply laminates with compatible core materials in sandwich type panel structures that have a broad spectrum of applications. Before investment decisions can be taken an in-depth evaluation of potential markets is essential. |
Improvement Approach
The improvement approach was to carry out an evaluation of competitive processes and products, and also the evaluation of potential applications and the economic feasibility of the proposed panel products. |
Benefits
Defining product variants, assessing market opportunities and examining the cost implications for a future full-scale manufacturing operations. An appropriate exploitation strategy has been put forward for consideration for thermoplastic sandwich panels. |
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Company Contact Information
DRD Consultants
DRD Consultants, DRD Co Ltd., 1 Belasis Court, Belasis Hall Technology Park, Billingham TS23 4AZ UK
Tel.
+44 (0) 1642 566900, Fax. +44 (0) 1642 566665
E-mail
info@ChemEngJobs.co.uk
www.ChemEngJobs.co.uk
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The 1980s was a period of intense competition with the focus on technical leadership. A stream of new product forms, making use of the polymer in powder, fibre or film form, were launched into low volume aerospace applications at a time when the market was not price sensitive. The challenge to develop new manufacturing technology, which could support the establishment of a volume market in thermoplastic composites, was not taken up. Instead, thermoplastic fabricators attempted to apply existing fabrication techniques developed for handling deformable tacky thermoset materials rather than developing new technology, which took advantage of the new stiff dimensionally-stable thermoplastic materials. This failure to establish the manufacturing capacity necessary to support higher volume, lower cost applications outside aerospace subsequently contributed to a comprehensive exodus of the major chemical companies from the composite materials business in the economic downturn of the early 1990s. |
For IMT the 1990’s were a period of hibernation, with development activities limited to collaborative work on composite formability. Most commercially available polypropylene glass composite sheet was still being made via a relatively expensive textile production route, which offered limited product variety. However, by 2002 a resurgence of market interest in thermoplastic composites prompted a redesign of the continuous off-axis prepreg process developed by IMT and an evaluation of the technical viability and operational costs involved in this innovative approach followed in the form of a recent Test Case carried out by the SIM-SERV project. This simulation allowed full analysis of the key process and cost variables and concluded that the new flexible manufacturing process would result in a stepwise reduction in laminate manufacturing cost and also deliver multi-ply products with improved material properties. This should lead to the products being used more extensively within manufacturing industries throughout Europe and the rest of the world. |
The broad scope of the current Test Case is to explore the commercial logic of extending IMT’s continuous processing technology to product forms, which can be derived from the low cost multi-ply laminates, which will become available with the commercialising of its new off-axis prepreg process. The company has identified, for this purpose, the combination of the resulting multi-ply laminates with compatible core materials in sandwich type panels products. But, before any decision can be taken on implementing an appropriate development programme, an in-depth evaluation of the potential markets for these products is required. Also, although a scheme has already been worked out for undertaking the actual manufacture of these novel panel products, further evaluation is deemed necessary to assess the economic results of such a course of action.
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Information has been assembled on competitive products, relevant manufacturing processes and the potential applications and markets involved. Combined with existing data on multi-ply laminate manufacture, this has been used to develop an appropriate exploitation strategy for the company. |
The techno-commercial assessment carried out in this test case has confirmed that multi-ply thermoplastic sheet, manufactured from polypropylene and long filament glass fibre is a viable competitor in a wide range of industrial markets which in many instances are in excess of €1-2billion/annum.
The product possesses very significant advantages in terms of product strength, lightness and thermal insulation. Above all, it provides an important entry point into the burgeoning market for environmental and sustainable products.
Several potential markets have been identified where the product would give environmental as well as cost/performance benefits. Cold storage and refrigeration have been identified as sectors where prefabricated, composite insulated panels could be specially produced as a secondary product. |
In order to expedite market exploitation it will be necessary to focus on a single or narrow spread of markets, conduct more in-depth planning before commissioning pilot production and eventual construction trials. Potential backers and/or the foreseen lead times in achieving regulatory approval in sectors like the building industry could determine this choice.
Investment in an initial manufacturing unit could be at an intermediate scale and potentially, would provide an excellent return on investment. The investment risk associated with starting up a new process may be reduced considerably once the mainstream production machine has been proven in the course of a DTI sponsored trial. Investment in a production scale unit would require further and detailed assessments of economic viability, revolving around customer take-up of the product in priority market areas and detailed assessment of remaining areas of technical risk. It is expected that new products using this new material and approach would result in a cost savings over existing products of 20-30%.
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