Innovation Exchange challenge: Binders or resins for recyclable biocomposite panels

Background

Taner’s Sons Design Studio, a design practice with offices in London (UK) and Nicosia (Cyprus), has developed a new bio-composite material for the construction sector called Pit-Board. Designed for use as sustainable interior panelling and in furniture products, Pit-Board is made from discarded olive pits and was launched to the market over the past two years.

While the product has received strong interest, a key challenge has emerged around its end-of life treatment. Taner’s Sons Design Studio is now looking to enhance the circularity of the material by making it fully recyclable without compromising the mechanical, aesthetic, and performance qualities it currently offers.

The Challenge

The challenge is to identify and test a binder system (or alternative bio-resin or natural resin solution) that enables the product to be recycled or reprocessed at the end of its life.

This may be, but is not exclusive to, custom-developed binders.

Technical expertise and testing facilities are required to validate this and set up a viable system for collection, reprocessing, and reuse through a co-developed and closed-loop recycling process.

The chosen solution will likely be at TRL 7 or above. The aim is to be at production capacity to be ready to manufacture product within 12-18 months.

This iX is in the Foundation Industries and supply chain challenges group, therefore, the solution provider will be eligible to apply for £25,000 to develop the proposed solution towards meeting this challenge. The funding will cover a 3-month project, the details of which will need to be refined with Taner’s Sons Design Studio.

Eligibility

This iX is in the Foundation Industries and supply chains challenges. Due to the nature of this challenge and the funding support available, there are the following eligibility criteria:

• Entrants to this competition must be a UK registered business.
• Entrants can only apply to one of the Foundation Industries and supply chains challenges.

Functional Requirements

The current production methods produce its largest size panels at 2000mm x 1000m x 18mm. A panel of this size uses 19.2kg of resin. Panels are also produced at 1000mm x 1000mm x 18mm and at 900mm dia x 18mm.

It is envisioned that a successful solution will be ordered in quantities of 150-300 litres once a month.

The current manufacturing facilities are based in Cyprus – where the raw material of olive pits are. There is an export opportunity for the chosen solution provider, with the potential in the future to bring manufacturing to the UK.

Technical Requirements

The solution must be compatible with existing HDPE and chrome moulds. There are also further requirements for moisture content, density, water absorption, thickness swelling and bending strength, detailed on the iX site at the link below.

Operating Conditions

The solution’s intended use is for furniture items for indoor use only. The solution must be capable of being CNC machined.

The solution should be in the price range of £8-10 per kg or less.

Rewards & Market Opportunity

Successful applicants will be given the opportunity to pitch their solution to Taner’s Sons Design Studio. The winning applicant, as selected by the company, will then be eligible to apply for £25,000 grant funding to kickstart the development of the proposed solution through a 3-month project. The selected solution may be trialled by Taner’s Sons Design Studio with potential for further adoption if trials are successful.

The solution has potential to be deployed globally with existing and potential customers.

It is envisaged that the solution will initially be procured in 150-300 litres once a month.

Taner’s Sons Design Studio will provide support during the development of a solution, sharing existing knowledge and materials. They will supply existing moulds and raw materials for testing purposes.

The chosen solution will be introduced to the existing supply chain, once all tests have been completed and approved.

The benefits package for a successful applicant may also include:

• Support from Innovate UK Business Connect.
• Support in the development of a prototype or pilot.
• Technical support.
• Invitation to attend or present at Innovate UK Business Connect events.
• A potential business collaboration.
• Investor introductions (if investment is required).
• Support if any Innovate or similar competitions are relevant.