Case studies
Recycling
Farapack was approached by Sustainable Sailing in 2021 with a view to exploring the recyclability of sailcloth. Sails are a composite material consisting of carbon fibres, Ultra-High Molecular Weight Polyethylene fibres and a polyester matrix. The ultimate objective was to separate the sails into component materials, as far as practicable, for reuse. An initial literature review was conducted in order to assess the feasible routes to recycling, and a plan of action was put in place after discussions with the client. Catapult funding (specifically aimed at SMEs) was accessed via collaboration with The University of Sheffield’s Advanced Manufacturing Research Centre (AMRC) in order to set up a small-scale trial with Longworths using their high-pressure steam hydrolysis capabilities which, as a chemical- and solvent-free route is considered to be environmentally friendly. Initial analyses via infra red spectroscopy and microscopy reveal promising results.
Fabric recycling
FPP was contacted by a small UK-based company to assess whether a newly developed high-pressure steam hydrolysis approach could be applied to multi-fibre fabrics. FPP was instrumental to the early success of this project by analysing samples of hydrolytically degraded fabric for residual solids. FPP were able to extract and analyse some potentially valuable compounds from the degraded fibre component. As a result of our analyses, further process development resulted in the optimisation of degradation of one fibre type whilst leaving the majority component virtually unaffected. Furthermore a relatively environmentally friendly method for separating the components has been developed, this is currently undergoing a scale up with an additional collaborator.
Compostable Teabags
A leading UK producer of tea bags approached FPP to advise on its switch from a non-biodegradable polypropylene-based material to a more environmentally-friendly alternative (polylactic acid) for the manufacture of its next-generation compostable tea bags. In essence, insufficient heat was being generated at a suitable rate to efficiently seal the edges of tea bags on their production line. A prompt literature review, timely sample procurement and testing by FPP enabled various grades of polylactic acid) and other key additives to be rapidly screened and either eliminated or trialled by the client.
Cheaper Alternative Latex Adhesives for UK-based Carpet Manufacturer
One of the UK’s leading manufacturers of industrial and residential carpets and carpet tiles sought FPP’s assistance in selecting new latex binders for carpet tiles to meet stringent requirements in terms of cost, processability, ease of formulation, durability and abrasion resistance. Drawing on the expertise of Prof. Steve Armes, FPP characterised a complex industrial formulation provided by the client that contained both latex and calcium carbonate particles. Based on these analyses (which included dynamic light scattering, rheology and thermogravimetry), and using their broad knowledge of commercial polymers, FPP advised the client that cheaper latex suppliers were available, as well as sourcing suitable alternative commercial latexes for the latter company’s in-house evaluation. This technical advice was implemented by the client and resulted in immediate cost savings of ca. £80,000 per annum. Two related recommendations made by FPP were also implemented by the client. This involved significant capital equipment investment to bring a key processing step in-house, with further projected cost savings of up to £ 40,000 per annum.
Working to solve supply chain issues
Farapack was approached by a leading medical device manufacturer in March 2022 to see if they could supply a speciality polymer previously produced for a number of years in another country, when this supply chain became problematic at very short notice. The polymer in question is a crucial component of a more complex system and Farapack were able to perform kilogram scale syntheses of the polymer, plus analysis to specification, and deliver it to the customer within 3 months of initial contact being made. A similar polymer using an alternative starting material has subsequently been produced and analysed. Each batch is currently undergoing extensive testing by the customer but the preliminary results are sufficiently promising for the client to invest in the bulk purchase of starting materials with a view to an ongoing partnership with Farapack. Material has been regularly supplied over the last two years and recently the quantity of material supplied monthly has increased three fold.