LEATHERWASTE

PROJECT 2012-2015

The project leading to these results has recived funding from the EACI by the Eco-Innovation programme under grant agreement nº ECO/11/304444/S12.629383. The sole responsibility for the content of this newsletter lies with the authors. It does not necessary reflect the opinion of the European Union. Neither the EACI nor the European Commission are responsible for any use that may be made of the information contained therein,

Co-funded by the Eco-Innovation Initiative of the European Union.

JOINING BUILDING MATERIALS AND LEATHER WASTE

Leather sector generates around 30 kg of finished leather waste per ton of skin processed which is nowadays mostly diverted to landfills. Around 27.000Tn of waste are generated at European level.

Leather material has sound absorption and thermal insulation properties. These intrinsic properties, which still remain in leather waste, can be used as baseline to produce an innovative leather composite material, in particular, an insulation panel, for immediate application as road acoustic fence.

TAIMEE project was born from the desire to solve the problematic with the waste generated within leather sector and from the wish to introduce into the market an innovative insulation panel which would reduce the environmental footprint in the construction sector.

TOWARDS ENVIRONMENTAL FRIENDLY BUILDING MATERIALS FROM LEATHER WASTE

TAIMEE will offer a new solution for introducing new recycled materials by recycling methods in the production of building products.

TAIMEE Technology is focused on treating leather waste to obtain an optimal composite material with optimal insulation properties. Eco-binders uses as agglomerant ensures a more ecological final product.

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The TAIMEE project aims to

produce and implement in

the market an innovative

leather material to provide

acoustic insulation properties

for immediate application in

construction sector.

TAIMEE project recovers leather waste from the tanneries and from the production of leather goods, and transforms it in a proper raw material suitable to be used in an industrial productive cycle, to obtain and bring into the market innovative and eco-friendly insulation products. In particular, the project develops an innovative acoustic fence. The project contributes to the introduction of eco-friendly insulation products in the construction sector that improves the noise pollution and the energy efficiency of buildings and the reduction of CO2 emissions, according to the commitment of the European Directive 2010/31/EC on energy performance of buildings and Environmental Noise Directive 2002/49/EC.

TAIMEE has been co-funded by the European Commission through the CIP-Ecoinnovation program under the Grant Agreement number ECO/11/334444

PROJECT CONSORTIUM

TAIMEE has put together a specialized consortium in terms of technological and management knowledge:

innovative leather material to provide acoustic iNSUlation

INTRODUCE INTO DE MARKET AN INNOVATIVE ENVIRONMENTAL FRIENDLY INSULATING MATERIAL

SET UP THE INDUSTRIAL METHODOLOGY REQUIRED FOR THE EFFICIENT PROCESSING OF THE LEATHER WASTE MATERIALS AND THEIR REINTEGRATION IN PRODUCTIVE CHAIN

REDUCE THE ENVIRONMENTAL IMPACT OF TANNERY AND LEATHER GOODS INDUSTRIES, USING TONS OF WASTE DIVERTED FROM LANDFILLS

CONTRIBUTE TO THE REDUCTION OF CO2 EMISSIONS AMD NOISE EXPOSURE, DUE TO THE USE OF NATURAL INSULATION MATERIALS IN BUILDINGS

LEITAT, coordinator. It evaluated the tanning sector, quantified the waste generated and established the leather waste supply chain.

PLASFI developed an eco-binder to ensure leather agglomeration.

ZICLA was the responsible of industrial production and set up the industrial methodology.

ASCAMM tested and validated the produced panels and developed the LCA.

NOBATEK was in charge of the exploitation of the product.

The project coordinator was initially AIICA technological center. However during project negotiation, the part of AIICA involved in this project was absorbed by LEITAT technological center who became the new coordinator-ARA2010 was the first partner involved in industrial production of TAIMEE panels. ZICLA replaced it when ARA2010 leave the consortium.

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C

B

Leather wastes from Tanneries a, b , c, ...

Polyol manufacturing

Isocyanatemanufacturing

CatalystManufacturing

Leather waste management plant

Shredding plant

monocomponent binder manufacturing

monocomponent binder packaging

catalyst packaging

Raw material 1 for the taimee panel

Raw material 2 for the taimee panel

Raw material 3 for the taimee panel

WEIGHING

MIXING

PRESSING

DEMOLDING

MATERIAL STORAGE

PACKAGING

CONSUMPTION POINT

A

A= Waste collection and Homogenisation

B= Obtaining binder and catalyst components

C = TAIMEE panel manufacturing

TAIMEE TECHNOLOGYHot plates technology

Methodology

Mixing the triturated and homogenised leather

Addition of eco-binder and homogenisation

Pouring the mixture of leather and resin on the mould

Press and temperature

TAIMEE PRODUCT RESULTS

TAIMEE is 100% natural material manufactured from leather waste and eco-binder (from renewable source).

TAIMEE product is an innovative and eco-friendly ACOUSTIC FENCE. However, TAIMEE panels can also find application as several other insulation materials.

PRODUCT ADVANTAGES:

An innovative, reusable and recycled product. The use of recycled materials and natural polymers enhances its environmental value compared with other acoustic fences (concrete, metal, wood, methacrylate…).

An acoustic insulating panel due to the fibrous structure of the leather material

A very appealing final product thanks to the different leather waste colors .

Self-supporting panels

Modular design

Easy to assemble and disassemble

Product 100% recycled

TAIMEE WORK PLAN

TAIMEE project is structured in six work packages which include: the definition of the leather waste supply chain, the optimization of agglomerate agent (Eco-binder), the development of the initial production of the insulation leather material, the industrial optimization of the agglomerate agent, the scaling up to full production of insulation panels taking into account the replication potential in different construction applications.

Definition of the leather supply chain. Collection of finished leather waste, homogenization and validation. Leather waste, which comes from different origins, mainly from tanneries and from the production of leather goods in several industries (automotive, upholstery, footwear, furniture) is collected and integrated within the supply chain. To ensure its composition it was necessary to control substances and to establish the parameters for subsequent processes.

Optimisation of the agglomerate agent (Eco-binder). Pre-polymers and foams were tested. The ecologic origin of these agglomerate agents was an important objective of TAIMEE consortium. An eco-friendly pre-polymer (80% of vegetable natural origin), based on bio-polyols, was selected. Selected pre-polymers and foams were optimised at industrial scale in order to optimize the industrial process.

Development of the TAIMEE insulation panel. Different pilot production processes were conducted in order to adapt the technology (hot plates pressing) to this new raw material (shredded leather waste). Dosages of agglomerate agent and operational conditions were analysed for further scaling up. Once operational parameters were optimised, industrial production of TAIMEE panel started. Potential applications for constructive insulating solution were assessed. Mechanical, physical, acoustic and thermal assays were tested. The LCA was developed.

Leather waste, and eco-binder need a production process where waste will be mixed, moulded, and cross-linked to produce the insulation panel.

Technology advantagesThe shredded material could be mixed very well and quickly with the eco-binder

The density and width of the panels could be controlled in order to obtain self-supporting panels.

The resulting panels could be easily de moulded and no residue was released in the mould.

The compacted triturated leather waste resulted in perfectly homogenous and self-supporting panels able to be used as an insulating panel in highways

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TAIMEE panel production saves environmental impacts. More than 228 and 95 kg CO² eq. per panel would be avoided if aluminium and steels panels would be substituted by TAIMEE panels, respectively.

ENVIRONMENTAL IMPACT IMPROVEMENT

The environmental impacts associated to several acoustic barriers were assessed in order to evaluate the environmental impacts avoided when leather used is recycled and when TAIMEE panels replace part of the other marketable acoustic fences from non-eco-friendly origin.

Important benefits are achieved due to the production of the TAIMEE panels and the most important factors are:

TAIMEE panels allow the recycling of leather waste, thus avoiding the environmental impacts associated with leather waste landfilling.

TAIMEE panels are a better environmental option in comparison with other acoustic barriers currently available in the market.

TAIMEE panels do not contain polyurethanes from fossil sources which contribute to decrease the consumption and depend of fossil resources.

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MA

RK

ET A

DR

ESSE

DThe insulating industry in Europe has experienced an exceptional upturn during the last years, creating a very favourable position for the manufacturers of insulation products. The total market for insulation products in Europe reached approximately 192,653,100 m3 in 2012 (equivalent to 5,637,000 tons). By value, the market is estimated at € 9,600 million. By 2017, the demand for insulation products is poised to reach some 213,546,700 m3 (or 6,270,100 tons) provided a 2.2% year on-year growth is sustained. This would correspond to a market value of € 10,570 million at current prices.

TARGET MARKET -ACOUSTIC FENCE

The market of the TAIMEE product is the market of Acoustic fences with different main segments:

• Highways and roads

• Industries where acoustic fences contributes to reduce noise pollution

• Urban areas like gardens (public or private).

In the current European economic climate where the construction of new highways is deemed harder to justify, the need to maintain the integrity of existing assets on highways is becoming all the more important. TAIMEE project is an innovative an eco-friendly solution for acoustic fence

TAIMME PRODUCT POTENCIAL MARKET

ACOUSTIC FENCEfor highway and national road sites

ACOUSTIC FENCEfor works on little roads and village

HIGHWAY COMPANY

PUBLIC GOVERNMENT

DEPARTAMENTAL COUNCIL

MUNICIPALITY

TAIMME PRODUCT KEY ACTORS

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LEATHERWASTE