The Process to Make Products.
Our proprietary, patented process utilizes dry granular or powdered fillers that can be waste material, such as ground glass, e-waste, mine tailings, coal ash and waste plastics; or virgin fillers like clay, minerals and sand. Typically, liquid polyurethanes and polyesters with specialized additives are used in our process. These are mixed in extruders to yield a mud-like mixture, which is then continuously cast into finished products or poured into molds, and cures without added heat into finished products.
Three-dimensional surface finishes like wood grain or slate can be molded in using this process, and colorants can be added to achieve virtually any color. There are many benefits to this exceptional process.
- Complex shapes can be made without machining
- Process can be highly automated - with low labor content
- Large volumes of waste can be used - one extruder can deliver up to 5000 lbs/hour
- No off-gassing or fumes to deal with
- No solvents or wastes
- The material can foam - and allow lightweight products
- Fast curing: Products are ready to ship in one hour
- Can combine various wastes
- Very consistent, high quality products
Costs of Operating a Continuous Production Line
Licenses can be given for very large plants using, for example, 50,000 lbs per hour (250 U.S. tons per hour) of material, which can be 75% waste filler.
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The Return on Capital depends on many factors: product costs & design, sales price, efficiency of the plants, and other factors. Typically the capital would be recovered in less than one year after the start of production.