Protomax turns old plastic bags and milk cartons into panels and bullet proof doors
Protomax, a plastic engineering company from Penclawdd, say they can even supply armoured, bullet proof and fire proof doors using the same technology.
The panels, which can be provided in a range of colours and sizes, can be used to replace plywood hoardings around building sites, used for pallets, partition walls, desk pods, contoured for shed roofing or used as partition walls.
The outer skin of the panels is made from recycled plastic such as recycled drinks bottles or milk cartons while the core material in the centre can be made from a range of different waste materials.
This waste is reprocessed and mixed with a foaming agent which fuses the materials together to create a cellular foam structure which is used as the core material.
The panels can be strengthened by adding Kevlar or Glass Fibre - a material used in bullet proof vests or made fire proof by adding anti inflammable agents.
The company has been supported by the Welsh Assembly Government with an investment grant towards the design, development and manufacture of the new P2 powder press which is currently being patented.
Ieuan Wyn Jones, Minister for the Economy and Transport, said the technology had the potential to play an important role in recycling and reusing materials that would normally end up in landfill.
Not only does it encourage environmental good practice but the range of applications for these 'green' panels is quite extensive. It is another example of a small Welsh company developing new technology that has far reaching potential and I am pleased the Assembly Government has been able to play a part in supporting Protomax.
Nick Stillwell, Managing Director of Protomax, said the technology was originally designed to provide emergency modular housing for use in disaster zones.
You can actually create a small factory in a 40ft container as the machinery can be easily transported and the panels could be produced on site using local waste material.
But as we began working on the system we soon realised there are a wide range of applications for these panels They can be used where ever plywood is currently used but the armoured panels we produce could be used by the security and defence sectors.
The beauty is that the panels are light and easy to handle but extremely strong and can take up to a ton in weight.
Clients can literally send us their waste material which is reprocessed into a powder that contains a foaming agent. This, together with the recycled plastic used for the outer skin, is placed in the press and fused using the special heating system.
He said a number of car assembly plants were interested in using the panels for vehicle trolleys while several hospitals were investigating their use for office pods/cubicles.
Protomax is currently carrying out major trials for a number of large UK companies.
The panels, which comply with all building regulations, can also later be recycled and reprocessed to form new panels eliminating any need to use landfill.