20
Composites
But with sustainability now topping the agendafor housebuilders and developers, the aestheticfinish and performance credentials of productsmay no longer be the only driver in terms ofspecification.
Manufacturers across the board – from brick-to boiler-makers – are coming underincreasing pressure to innovate and providesustainable solutions that help customersachieve their green aims and meet therequirements laid down by the Code forSustainable Homes and BREEAM targets.
Domestic consumers, too, are becomingmore aware and proactively supportive of thedemands of the green agenda. These days,consumers are more likely to act on their eco-conscience and look forenvironmentally-friendly products which don’tcompromise on choice, or bump up the cost.
Now a pioneering new production techniquewhich combines recycled plastic bottles withfine stone particles, is promising torevolutionise the engineered stone market andeven parts of the wider building materialssector, answering the sustainability questionhead on.
Echotect technology, originally developed byShell’s research and development department,can now create an extraordinary new materialwith the same aesthetic and performancecharacteristics as engineered stone.
In effect, the technology delivers a 100%recyclable marble facsimile ideal for use infloor tiles, wall tiles, bathroom vanity tops, eveninternal walls and other flat surfaces.
Capable of manufacture in any colour and avariety of finishes – from matt for floor and walltiles to highly polished for more decorativeapplications – the product is identical totraditionally manufactured stone products,offering the same durability, flexural strength,and frost- and scratch-resistance.
Commercial trials have produced slabs of upto 0.8m wide, and of infinite length, in
thicknesses ranging from 5 to 30mm which arethen cut to size to produce tiles or panelsaccording to their application.
Stephen Eastwood, chief executive officer ofEchotect BV, explains: “The key to the successof any new product is how well it performs andhow good it looks. This is particularly true in thetile market, which has traditionally been drivenby aesthetics almost as much as long-termperformance in situ.
“Internationally, the industry is working hardto respond to environmental issues and targetsfor reduction in carbon consumption – and thisis creating a third strand for the specifier toconsider.
“Since the earliest trials, we have seen themassive potential that Echotect technologyoffers to the tile and countertop market, andindeed the wider building materials sector.
“Until now, there has never been aninnovative new technology which couldchallenge historic manufacturing processes toproduce products which match the aestheticsand performance of traditional engineeredstone. And, with the added, inherentsustainability credentials that the Echotectprocess offers, we are very excited about thepotential this technology has to completelytransform the way we manufacture tiles.”
By reusing two waste resources – end of lifepolyethylene terephthalate (PET) and finesecondary aggregate from the quarryingindustry – Echotect has gone further than theinvention of a new material: it has created anew market for products that would otherwisego to landfill or incineration.
Up to 200 bottles are recycled per 1m² ofmaterial. This could have a huge impact for the13bn drinks bottles discarded every year in theUK and, as Echotect materials are themselves
100% recyclable, they would not add to thewaste stream at the end of their lifecycle.
Existing manufacturing processes across theindustry have remained the same for morethan 30 years. The Echotect alternative offerstile producers an intriguing new opportunity tomove to a retrofitable, non-chemical processwhich uses half the energy of traditionalmanufacturing techniques. This means thatproducers can cut carbon emissionssignificantly during manufacture, which in turnwould reduce each tile’s embodied energy.
So, with all these aesthetic, performance andsustainable credentials, the proposition is clearfor any forward-thinking manufacturer thattakes it from the research and developmentstage and brings the products to market.
Stephen Eastwood adds: “We are indiscussions with a number of leadingmanufacturers who are interested in licensingthe technology and launching these stunningproducts to the trade and consumer marketsover the next couple of years.
“Long-term, the potential applications of thisrevolutionary technology are endless. Wheretiles and countertops lead, other uses willinevitably follow.
“Alternative applications are currently beingdeveloped in parallel, and we envisage therewill be a whole host of alternative second andthird wave applications in the future. Ratherlike the ‘Intel inside’ quality stamp, Echotecttechnology will become the byword forenvironmentally-responsible, precisionengineered quality building products for thediscerning customer.”
To learn more about Echotec, readers areencouraged to contact its team directly.E [email protected] echotect.com
Initially pioneered by Shell, the technology hasbeen pioneered by Echotect BV at itsmanufacturing facility in Switzerland. CEO StephenEastwood demonstrates the finished product
From recycled bottles and fineaggregate waste, Echotect
has produced strikingengineered stone tiles
Engineered stone is one of the mainstays of the UK tile market. Customers love the smooth finish,durability and aesthetic of marble, while installers appreciate the lightweight, straight-edged andgeometric finish made possible by a precision-manufactured stone tile.
Echotect’s revolutionary technology
TUK141_Pages_t 30/06/2011 16:38 Page 20
