University-industry co-operation: leading to successful innovation

Professor Marianne Gilbert, Institute of Polymer Technology and Materials

Engineering, Loughborough University, UK

PVC Activities at Loughborough

PVC Innovation Centre

PVC Innovation Centre

Aims to provide the highest quality research and development,

networking and training for the world-wide PVC community

PVC Innovation Centre –established November 2003

Prof Marianne Gilbert Dr Les Holloway

Prof Brian Brooks Dr Dave Hitt

Dr Paul Fleming Stuart Patrick

Barry Haworth Dr Noreen Thomas

Who we are:

First Brazilian PVC Conference – June 2005

PVC Innovation Centre

What we offer:• Research and Development programmes• Consultancy services• Training resources• Networking opportunities

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Research and Development

• Dedicated research projects• Product development• Sponsored research studentships• Joint research grant applications• MSc projects• Market research• Company strategic planning

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Consultancy services

• Specialist advice

• Product assessment

• Equipment hire & material/product testing

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Networking opportunities

• Network development

• Education and recruitment initiatives

• International research project awareness

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Training Resources

• Full-time and part-time MSc programmes• External PhDs• In house dedicated training sessions• Short Courses• Conferences/seminars• Industrial placements

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PVC Training Course- Content

• Introduction to polymer science and technology

• Polymerisation• Science of PVC• PVC processing• Manufacturers and

markets

• Role of key additives• Material characteristics • Product performance• Applications of PVC-P

and PVC-U• Sustainability and

environmental aspects

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Next PVC Training Course!

• Third course 5 – 9th September 2005

• Short Course or part of Materials for Industry post graduate programme

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Facilities

• Polymerisation reactor

• Processing, rheology and sample preparation

• Loughborough Materials characterisation Centre

• Mechanical testing

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New equipment

• PVC twin screw extruder

• Dry blending equipment

• Haake torque rheometer and extruder

• Raman spectrometer

The VinylSUM Research Network

Established April 2004

Introduction• EPSRC network for the sustainable use

of materials funded April 2004 – March 2007

• Organised by the Institute of Polymer Technology and Materials Engineering (PVC Innovation Centre) based at Loughborough University

• Dr Noreen Thomas, Professor Marianne Gilbert are Investigators with Stuart Patrick the co-ordinator

Objectives I• To establish a forum for an industry-wide

discussion of the research required to improve the sustainable use of PVC

• To review research work already completed and that still in progress to find the knowledge gaps in terms of materials processing, additives and properties.

Objectives II• To develop an approach for a full evaluation of

sustainability issues on a life cycle basis, and set up a modus operandi in which the whole industry works together to achieve the objectives for sustainable use which can then be applied to other polymers

• To become a source of impartial information to all stakeholders

MembersIPTME, Loughborough UniversityCES (University of Surrey)IRC, Bradford UniversityWolfson Centre, Brunel UniversityBiocomposites Centre, Bangor UniversityEVCHydro PolymersBritish Plastics FederationEuropean Council of Vinyl ManufacturersEuropean Council for Plasticisers and Intermediates (ECPI)European Stabiliser Producers Association (ESPA)The Natural Step (TNS)Costdown (Recycling)

Literature Review Topics I• General PVC references, recent reviews• Additives – general• Additives – stabilisation• Additives – plasticisers• Additives – plasticiser issues• Chemical modification• Fire retardants and smoke suppressants• Life cycle assessment

Literature Review Topics II• Nanocomposites and related topics• Polymerisation• Processing• Processing – foams • Products• Recycling and waste treatments • Resins and compounds• Sustainability

Conclusions from literature

review

Stabilisers• There has been extensive work, with the

majority of the published literature being Patents (primarily from German based companies) on possible organic based stabilisers for PVC

• A particularly interesting development is the work carried out by Starnes on plasticiser thiols*

*W. H. Starnes, J. Vinyl & Additive Tech. (2001) 7 250-253

Plasticisers• Phthalate plasticiser replacements are

still attracting attention, including benzoates, citrates, Hexamoll, and Mesamoll

• Blending with elastomers still of interest

• There is still very little research being published on plasticisers from natural / renewable resources

Methods used to reduce plasticiser migration

• Surface modification• Nanocoats• Hybrid coatings• Polymeric plasticisers

Life Cycle Assessment• PVC sustainability issues

• Life Cycle assessments of PVC covering overall studies,

windows, flooring, cable, pipe and use in packaging,

textiles and automotive areas, also production, additives

and end of life

• Environmental issues associated with PVC

• Recycling and waste treatment issues and methods

including re-use, mechanical and chemical recycling,

incineration and landfill

Research Projects

Improving Sustainability of PVC through Novel Materials, Processes

and Life Cycle Methodologies

N L Thomas, M Gilbert, B Haworth (IPTME, LU) and

A Azapagic (CES, UniS)

POLYMERISATION NANOCOMPOSITES

INCORPORATION OF

ADDITIVES DURING

POLYMERISATION

Non aqueous polymerisation

Stabilisation Plasticiser migration

Flame retardants

Processing

Sustainable Processing for Rigid PVC:

Novel Processing Routes for Post-Consumer Recyclate

B Haworth (IPTME, LU) and A L Kelly (IRC, Univ. of

Bradford)

Post-consumer PVC-U recyclate

Recyclate Analysis

‘Near-conventional’formulation

and slip modification

Supercritical CO2

assisted extrusion

Analysis of 2nd life products

L.C

.A.

CFD

Simulation

Visit our web sites:

• www.lboro.ac.uk/departments/iptme/PVCIC

• www.vinylsum.org .uk