Extrusion line for the recycling of obsolete and damaged plastic sheets to repurpose as trays for the sustainable packaging industry

点击翻译按钮获取中文摘要

Accurate Safety Manufacturing Ltd fabricates a number of products including safety edge protection, to prevent falls from height, stainless steel growing trolleys, along with a tooling shop to manufacture plastics moulded trays from our thermoforming machine. We have an existing client in the growing industry of Mushroom packaging which has committed to using our tray mould manufacturing solution for the long term.We wish to achieve Net Zero as a company by end of 2023, we have a number of ways we want to achieve this and this project would significantly help us on our journey. We will use obsolete and damaged plastic moulds from our current clients as raw material for a new granulated extrusion sheet line, bringing the circular economy into both our business and that of our clients. This will be initiated with our existing customer MMC but we will extend this service across other industries.**Key Objectives**Currently, we manufacture these trays using pre-cut sheets which are expensive to transport and require cutting so there is wasted plastic, which will either end up in landfill or be incinerated. Our project plan is to implement a process where we repurpose the used plastics trays as a new product, with a new dramatically lower cost which will allow us to significantly scale our operations through increased sales and higher profit margins.**Focus**1. Reusing obsolete plastics as a raw material2. Reducing raw materials costs by taking the process as a step back by using granules rather than ready-made sheets.3. Implementation of an extrusion line producing new bespoke sizes of a new ABS/HIPS sheet. This will reduce waste and our environmental impacts.4. Scaling of the operation to improve sales and profitability.5. Onboarding new clients and industries.**Innovation**We are planning to increase productivity and reduce waste and therefore energy usage by utilizing augmented reality and AI checking via a portable device, such as a phone or tablet.Using a combination of pre-informed AI, and portable AR, we aim to perform in-line checking of all tooling, prior to production starting, virtually faulty checking before any manufacturing commences.We will also be filling IP around this AR technology and our unique use in supplying a new Mycelium packaging technology industry.