The most exploited forms of plastic are polypropylene, polyethylene and polystyrene, EPS or XPS (extruded polystyrene), popularly known as styrofoam.
Approximately 230,000 t of polystyrene end up on landfill, in the ocean or elsewhere every year. It takes about 500 years for polystrene to dissolve, while industrial dissolvement costs approximately $ 3,000 per tonne. In some US states polystyrene is banned, while Canada announces a ban on the production and trading of disposable plastic starting from 2021.
Due to the fast pace of global warming, unstable climate conditions and large quantities of slow-degrading waste, ecological packaging solutions will become a necessity in the future. Insulation takes a more significant place in the process, as these implies cutting costs for both heating and cooling buildings interiors.
Given that renewable energy sources are not equally effective as non renewable ones in terms of their economic exploitation, insulation becomes a key factor that can equalize the effectiveness and utilization of both renewable and non-renewable energy sources.
Unlike polystyrene, natural materials are degradable, reusable and can be obtained from local resources from all over the world, regardless of the country's economic development. The packaging itself can also be produced in the small-scale industry for small markets. The demands of large markets can be fulfilled by mass production in factories. Another problem solved in this way is the reduction of CO2 emissions.
We came across new material that could be used as a thermal insulation alternative. This material is sawdust and it is a by-product of woodworking operations. Purchase price is low but it needs lots of space to be stored in, since 70-80% of it makes air. Given that "airness" is the main quality of insulation materials, sawdust is a great solution for which inspiration was found in the best nature insulation product
the birds nest.
The biggest challenge was the lack of sawdust compactness
without losing it's airiness. Solution is a honeycomb cardboard, which is also used as a filling for interior doors.
By merging these two natural materials and technologies, we had a completely new product
the fusion pack.
Cardboard honeycomb panels are already being manufactured and are becoming as mechanical protection. But no one tried to fill them with some natural material. That completely changes and enhances properties with its thermal insulation performances can make a big difference globally in the delivery and construction industries.
In serial production the price would be less than $ 1 / m2
One automatic machine that can produce 3000 m2 / day would cost 500-700 thousand dollars.