Thermoplastics
and their ability to meet stringent rail
impact strength.”
Recycling potential
An additional benefit of using thermoplastics is
of its life, it is typically disassembled and recycled. The outer
metal shell and interior metal parts are melted down for other
applications. “Many interior parts such as seatbacks, armrests
and window masks, which have previously been manufactured
using FRP, are typically sent to a landfill because of limited
recycling options for fibreglass materials,” says Gum. “In contrast,
thermoplastics are manufactured with sustainability in mind, from
inception to the end of the lifecycle.”
Kydex thermoplastics do not have to go to landfill after their
final application. Instead, they can be transformed from waste
to energy by incineration. Recycled
thermoplastics can also be used
in new market applications such
as automated warehouse trays.
Thermoplastic scrap can be pulverised
for use in specific applications such as
hidden parts. At Kydex Thermoplastics,
this is completed through the help of
partner Ultra-Poly.
In-house partner
Working together with Kydex
Thermoplastics, Ultra-Poly researched
how to repurpose processed PVC
material for new or lower-quality
applications (also known as cradleto
cradle material management).
Because PVC-based materials were
not part of Ultra-Poly’s existing scrap
stream, the teams have collaborated
for more than a year on potential
solutions, working side by side as
Ultra-Poly moved into Sekisui SPI’s
South Campus in Bloomsburg,
Pennsylvania. Now selling
22,000,000 lb (10,000,000kg) of
Railway Interiors International ANNUAL SHOWCASE 2019 62
PVC a year, Ultra-Poly has increased recycling and sustainability
capabilities even further for Kydex thermoplastic trim scrap.
Why does it matter?
The recyclability of Kydex thermoplastics makes it a sustainable
choice, but why does it matter? Sekisui SPI says it comes down
to the passenger experience. While a traveller may not be aware
of the behind-the-scenes work required to create the window mask
they lean against, the precision and care put into that piece of
a train’s interior matters. It provides durability against daily traffic
and safety in the event of an accident.
“Every thermoplastic kick panel and bulkhead partition provides
an enhanced interior design that ultimately reduces overall train
weight,” says Bake. “Envision a part such as a seatback, tray table
or window mask that weighs less than FRP. Even for one fleet, the
drastic weight reduction would reduce fuel usage and impact on
the environment. We see sustainability in the form of fuel efficiency
and a conscious effort to design with recycling in mind as a key
driver in mass transit. There is an opportunity in rail to transition
from traditional fibre-reinforced thermosets to lighter thermoplastic
materials that are recyclable and offer a lot of design options.”
BORN AGAIN
Ultra-Poly helps Kydex
Thermoplastics prevent
thermoplastic trim scrap from
entering landfill. Instead of
hauling scrap away, Sekisui SPI
gives it to partner Ultra-Poly,
which is conveniently located
at Sekisui SPI’s South Campus
site. The scrap is then chipped,
reground and pulverised.
Through this partnership,
the thermoplastics are given
a second (or third or fourth)
life as automated warehouse
trays and parts that are not
front-facing. The reground
material can also be reused
in specific Kydex products
where applicable.
With the ability to run
100,000 lb (45,359kg) orders
in less than 24 hours, Ultra-
Poly’s speed and Kydex
Thermoplastics’ commitment to
quick response manufacturing
are a perfect match.
FREE READER ENQUIRY SERVICE
SEKISUI SPI
To learn more about this advertiser, visit
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RIGHT: Shawn
Gum, appLab
applications
engineer, using
the Faro laser
line probe
ABOVE: Shawn
Gum reviews
and edits
a design in
Sekisui SPI’s
new appLab
INSET: Kydex
thermoplastic
regrind
material
industry requirements while maintaining
their recyclability. When a railcar has reached the end
/prii