Print this page

Manuplas Waste Foam Recycling Process Benefits Local Zoo

Tue, Mar 24, 2015
Manuplas Waste Foam Recycling Process Benefits Local Zoo
Plymouth-based Manuplas – an Advanced Insulation company specialising in the design, engineering and manufacture of floatation and buoyancy solutions for the marine and offshore sectors – has invested in an in-house recycling project that has seen the company reduce its impact on the environment by recycling an impressive 38-tonnes of lightweight Polyethylene Foam and Expanded Polystyrene Foam. 
 
With densities ranging from 0.02 – 0.18 g/cc as delivered, the foam-based material used by Manuplas for its surface-based marine solutions is between 5 and 50 times lighter than water. The material is purchased by the company in sheets or rolls, with multiple layers being thermo-laminated and rolled to create a lightweight but solid looking cylinder. These cylinders are produced in numerous sizes and used as fender systems for small boats or yachts, or the large floating structures seen in docks and shipyards. 
 
This thermo-laminating process creates an, uneven edge to the cylinders so Manuplas over sizes the diameter and length of each section, which is then profiled to the correct specification and formed to create domed or chamfered edges. This creates a substantial amount of high value foam offcuts that were of little use to the company because they couldn’t be melted down and reprocessed or recycled. 
 
As Manuplas research and development manager David Hamnett explains: “The grade of foam used is not recyclable by traditional methods so, with financial support from Business Link, we started investigated alternative recycling options. We also began looking for organisations that could put the recycled material to good use and discovered opportunities at Paignton Zoo Environmental Park. 
 
Following its research, Manuplas purchased a compactor to reduce the volume of discarded foam going to landfill and has, since recycling operations began in 2011, completely eliminated this particular waste stream, which equated to approximately 75% of the company’s total waste volume. It also reduced the associated high transportation and disposal fees that were costing the company nearly £10,000 a year. 
 
Used in the manufacture of products for the marine, offshore oil & gas, renewables and leisure industries, Manuplas successfully recycled approximately 2,000 cubic metres of lightweight foam between January 2012 and March 2014. The recycling process shreds the large foam offcuts into smaller manageable pieces that are then fed into a closed chamber where, using high-pressure compactors, air content from the foam cells is removed. This results in foam that, instead of its original 0.03g per cubic centimetre density, has a density (0.8g per cubic centimetre) similar to that of timber. Once the compaction process is complete, the processed 300 millimetre square extrusions are cut into one-metre lengths and palletised. 
 
At this point Manuplas could have just sent the compacted product to landfill. However, being environmentally conscious and keen to avoid this, they decided to find a solution that meant the material was, at the very least, recyclable or useful to someone else. So they contacted local organisations to ask if the compacted foam extrusions or logs (which do not rot and require no on-going treatment) would be useful. 
 
“Happily, having received positive responses from Paignton Zoo Environmental Park, Manuplas subsequently donated a significant number of the compacted logs for landscaping and animal enclosure projects!” reports David.
 
As Paignton Zoo Environmental Park’s environmental officer Peter Morgan explains, the organisation regularly purchases wooden sleepers for landscaping and light construction projects but, with the old stock of railway sleepers rapidly depleting and hard to come by, they were purchasing stock manufactured from newly felled timber. 
 
“While all timber used at the Zoo comes from FSC-certified suppliers, the fact that trees are still being felled to produce the sleepers didn’t fit with the organisation’s ecological or ethical objectives. However, being members of NISP we were made aware of what Manuplas was doing at a sustainability workshop and, having been invited to witness their recycling project and view the resulting product, its Eco Posts proved ideal replacements for our landscaping projects.”
 
NISP is the world's first National Industrial Symbiosis Programme and provides a platform to encourage businesses to implement resource optimisation and efficiency programmes that remanufacture or retain materials and other resources in productive use for longer through ‘industrial symbiosis’. 
 
As Paignton Zoo counts down to its 100th birthday, they have a programme of events planned and decided to redevelop an old zoo building and landscape the areas surrounding the soft play and education centres in what has become its Urban Zone. The zoo’s curator of plants and gardens studied the use of recycled materials for landscaping and, using the foam Eco Posts, subsequently created curved, undulating borders and retaining walls at the entrance to the Urban Zone and what became Investigate, a new exhibit housing a display of bugs, scorpions and spiders, which coincided with Paignton Zoo’s Year of the Invertebrate. 
 
Summarising for Paignton Zoo Environmental Park, Peter Morgan says that the effect the Eco Posts has created at its Investigate exhibit is unique, couldn’t be matched using timber sleepers and, thanks to Manuplas’ kind donation, has saved the charity significant amounts of money that can be put to good use elsewhere. 
 
The donations have saved both organisations a considerable sum of money and, instead of the mundane appearance of the previously used traditional timber structures, the Manuplas logs have created a visually striking look that is more in keeping with the Zoos’ natural environments. What’s more, the 38 tonnes of foam waste recycled since Manuplas started the process is equivalent to the weight of more than ten of Paignton Zoo’s female African elephant, Duchess!
 
For further information on its foam products for marine applications or the foam recycling project, call Manuplas on +44 (0)1752 771740, email sales@manuplas.co.uk or visit www.manuplas.co.uk. 
Tagged under

Share and subscribe

MEDIA

Show all Media

Quotes

  • “Offshore oil platforms are becoming increasingly complex in response to the needs of oil fields that are more difficult to exploit and located in increasingly hostile environments. As a result there is a drive for lighter, more robust materials that are quicker to install.”

External Links

About Us

Advanced Insulation (www.aisplc.com)

Since its formation in 2007, Advanced Insulation has become a single source provider for insulation and fire protection systems to the oil and gas industry, and represents one of the most respected and progressive names in topside and subsea insulation worldwide.

Advanced Insulation offers a wide range of products to meet the growing demand for fire protection and thermal insulation systems adaptable for elevated service temperatures and pressures.

AL-KO Kober (www.al-ko-co.uk)

Since 1931, AL-KO Kober has been manufacturing premium, high quality components used in the Automotive, Commercial and Leisure industry.

The extensive range of chassis components, premium accessories and spare parts are engineered to last, ensuring whatever product you have purchased, you will benefit from the generations of development and enjoy a lifetime of service.

Arc Energy Resources (www.arcenergy.co.uk)

Arc Energy Resources is one of the UK’s leading specialists in weld overlay cladding and fabrication for the oil & gas industry. The company’s expertise provides protection against corrosion and wear for a variety of process and pipeline equipment for use in any hostile environment.

The company recently made a major investment in two new Rotating Head welding machines costing £500,000. This has increased productivity and extended the size and scope of work it can handle, which now includes complicated component geometries for the full or partial cladding and fabrication of a huge range of component sizes weighing up to 15 tonnes. The company’s in-house designed cladding workstations feature state-of-the-art control systems developed to suit its customer’s specialised engineering requirements, and can clad bores up to four metres diameter and areas of restricted access within bores as small as 20mm diameter. Arc Energy also offers in-house test weld, heat treatment, PMI and NDT facilities.

Industry certifications include ISO 9001:2008 quality management, ISO 3834-2 fusion welding of metallic materials, and the internationally renowned ASME U and R Stamps, as well as ISO 14001:2004 environment management, Investors in People and OHSAS 18001:2007 Health & Safety management system.

Curtiss-Wright Industrial Group, which includes the legacy brands of Arens Controls, Penny & Giles, PG Drives Technology and Williams Controls, is a recognized leader in providing components and sub-systems which enable customer specific solutions for on- and off-highway vehicles. These include medium- and heavy-duty trucks, buses and motor coaches, construction and agricultural vehicles, materials handling, and other specialty vehicles, as well as sophisticated wheelchairs and scooters for medical mobility.

We are a leading provider of electronic throttle controls, transmission shifters and sensors for commercial off-highway equipment and heavy trucks, so helping to address the long-term trend towards attaining higher fuel efficiency and lower emissions. We also supply operator controls and advanced motor controllers for hybrid and electric vehicles, such as buses, forklift trucks, pallet stackers, wheelchairs and rehabilitation chairs.

With a proud legacy spanning more than 85 years, Curtiss-Wright is a global innovative company that delivers highly-engineered, critical-function products and services to the commercial, industrial, defense and energy markets. Building on the heritage of Glenn Curtiss and the Wright brothers, we have a long tradition of providing reliable solutions through trusted customer relationships.

Further information is available from the Curtiss-Wright Industrial website (www.cw-industrialgroup.com) or by calling +44 (0)1202 034000.

Euchner (UK) Limited (www.euchner.co.uk)

Safety for people, machines and products has been the maxim of this family-owned company since 1953. Stefan Euchner is the third generation to take the helm.

As specialists in industrial safety engineering, Euchner develops and manufactures products and solutions tailored to the requirements of customers from a wide range of sectors. Using its guards on machines and installations helps to minimise hazards and risks, which in turn protects people and processes. For its 800 employees around the world, safety is the watchword.

Further information is available from the Euchner (UK) Limited website (www.euchner.co.uk) or by calling +44 (0)114 256 0123.

Industry Superstore (www.industrysuperstore.co.uk)

Industry Superstore is a one-stop-shop for a wealth of budget-friendly, high-quality products tailored to industry!

Further information is available from the Industry Superstore website (www.industrysuperstore.co.uk) or by calling +44 (0)1892 664499.

Exmac Automation Limited has many years experience in the design, manufacture, and installation of unit conveyors, conveyor systems and associated materials handling equipment for most industry sectors.

Exmac Automation is part of the MacDonald Humfrey group of companies and are market leaders in the supply of automated materials handling equipment to the automotive, aerospace, white goods, warehouse & distribution, nuclear, pharmaceutical and food & beverage industries.

The group supplies to most industry sectors and have over 250 employees with many years experience in the design, manufacture and installation of unit conveyors, conveyor systems and associated materials handling equipment.

Projects have ranged from individual standard conveyors and bespoke handling applications, through to complete turnkey contracts involving conceptual and process design, installation and commissioning.

We are ISO 9001 accredited and constantly strive to achieve continuous improvements in the overall quality of our products and service.

Exmac Automation has has established a reputation for supplying high quality, robust systems at competitive prices.

In-house resources enable us to provide clients with a single source for complete systems integration including simulation, engineering, machining, fabrication, assembly, controls, installation & commissioning and after sales service.

Our 70,000 sq ft facility in Worcester has extensive design, manufacturing and assembly resources. Our skilled team of customer focussed automation professionals offers a broad base of knowledge and experience in a wide variety of industries.

A large workshop enables us to carry out comprehensive pre-installation assembly and factory acceptance tests on all projects.

Fulton Limited (www.fulton.co.uk)

The Fulton name has been synonymous with steam since the company first introduced the vertical tubeless steam boiler in 1949 and Fulton was established in Bristol in 1966. Fulton is still one of the world’s leading manufacturers, producing an unrivalled range of multi-fuel steam boilers. But increasingly these are ordered by customers as part of bespoke turnkey systems designed to meet exacting specifications.

Today Fulton Limited is an important design and manufacturing base in Fulton’s global network that also includes production facilities in the USA and China. The company’s UK facility makes it possible to manufacture products more efficiently and assemble completed units for whenever and wherever they are needed throughout the UK and in export markets.

Once just a steam boiler manufacturer, Fulton now specialises in ready-to-ship skid mounted and fully packaged boiler plant rooms to meet the current demand for off-site fabrication. The company puts great emphasis in providing sales and application advice and a full commissioning and after sales service to a growing customer base in hospital and healthcare facilities, food and beverage processing, laundries and other applications.

Design and manufacturing resources are shared and coordinated around the world, but no matter where your product originates, it will always be produced to the highest quality in a facility that is wholly owned and managed by the Fulton Group, which remains a privately owned family business.

Fulton’s heating and hot water systems can be delivered as fully prefabricated plant rooms or complete skid-mounted units, built to fit a prepared location and connect direct to your services.

Using the latest CAD equipment its design team can accommodate the most sophisticated engineering specifications in surprisingly compact spaces, locating components in the best possible position to suit the installation.

In every sense, today’s Fulton boiler systems are solutions that fit the requirements of the modern age of steam.

Gast Group (www.gastmfg.com / www.jun-air.com)

Since 1921, Gast Manufacturing, Inc. has been designing and manufacturing quality air-moving products. Our vacuum pumps, compressors, air motors, gear motors, vacuum generators, regenerative blowers and Smart Air technology meet the many challenging applications of OEMs and end-users worldwide.

For industrial manufacturing, health care lab, or environmental cleanup applications, Gast provides a full range of ideally suited and cost-effective solutions to any pneumatic problem.

Monodraught (www.monodraught.com)

In the current climate of soaring energy prices and the fear of global warming, increasing attention is being focused on Monodraught’s range of energy-free products.

Monodraught has always sought to invent, explore and develop innovative technologies that harness the wind and sun. Products include Windcatchers, Sunpipes, Suncatchers, Sola-vents, Sola-boosts and Cool-phase.

Nexen Lift Trucks (www.nexenlifttrucks.com)

Disillusioned with the ever-increasing complexity of new forklift trucks and the failure of the major manufacturers to provide a high level of support to their dealer networks, the decision was taken to develop its own range of forklifts.

In 2003 Nexen Lift Trucks was established with the vision to design and manufacture its own range with a combined 70 years experience of the lift truck rental industry. Nexen's ultimate goal is to build worldwide brand recognition based on its product's design and build quality as well as outstanding reliability at competitive prices.

In 2007 Nexen completed the purchase of the second largest lift truck manufacturer in Taiwan, creating the Nexen Motor Corporation. Initially the existing models were improved whilst a European based design team was established to develop a completely new range of trucks from the ground up to meet Nexen's standards.

Q8Oils (www.Q8Oils.co.uk / @Q8OilsUK)

Q8Oils has become a major player in the global lubricants market. Our success is founded on significant corporate resources, a commitment to product development and uncompromising standards of quality and service.

Q8Oils has a unique and innovative approach producing some of the world´s finest quality lubricants. Manufactured in its state of the art plant at Leeds, West Yorkshire, Q8Oils represent the very best and latest in lubricant technology. With over 1000 grades of finished lubricants, base oils, process oils, extracts and waxes.

We are dedicated to serving the needs of our customers by striving to understand, anticipate and satisfy their needs faster and better than our competitors. To achieve this our objective is to develop and supply products and services which reflect customer demands in each of our market sectors.

TLV Euro Engineering (www.tlv.co.uk)

TLV Euro Engineering UK is part of TLV, an internationally-established designer, manufacturer and provider of steam traps, condensate recovery pumps, pressure reducing valves and other specialist steam solutions. The company plays a leading role in the promotion of efficient energy systems and increased environmental conservation on a worldwide scale through its products and consulting and engineering services.

Rockatek (www.rockatek.com)

Cheltenham-based Rockatek Ltd is an engineering consultancy that offers design, analysis and physical testing services that set it apart from others. Its directors have over 40 years’ experience in complex engineering product optimisation and development; and its engineers specialise in engineering solutions for harsh environments and value improving reliability and performance.

Verco (www.ver.co.uk)

Founded in 1965, Verco quickly built a reputation for supplying quality refrigerated glass door and open chill cabinets to supermarkets, convenience and forecourt stores. Verco is now a leading supplier of retail refrigeration and the largest UK manufacturer of glass door cabinets.