SMARTER RUBBISH IDEAS

MGM Modules Ltd is the R + D operation pioneering the methods and processing plant to convert waste plastics, tires and many other varieties of waste into solid masses we call plubber modules. The patented process of compressing mixed waste, tires and tire pieces with steel reinforcing then remelting clean sources of plastic waste to encapsulate the solidified waste produces slabs, blocks, bricks and other forms as a substitute or supplement for concrete and other building materials.

It is common knowledge and most are acutely aware of the challenges related to the millions of tonnes of waste plastics and tires produced globally causing massive impacts on the environment. Many are also aware concrete production is considered one of the highest sources of CO2 reported to be as high as 8% of global emissions from the production of cement, quarrying and transport while also consuming massive volumes of sand and water.

In a nutshell the advantage of this efficient low carbon footprint method is its potential to repurpose large tonnage of rubber and many other varieties of waste by encapsulation with non toxic plastic waste producing products for a large global infrastructure market. This is squarely aimed at reducing the demand and thereby the environmental impacts related to the production of concrete while diverting all varieties of plastics, end of life tires and other solid waste from landfill.

Plubber modules can be built to rigorous specifications to endure structural stresses and environmental elements providing a reliable substitute for concrete in many substratum applications or act as structurally integrated core sections to reduce the volumes required in concrete constructions. This is aimed at applications such as foundations and retaining as used in civil construction, road building, flood control, reservoirs and tidal erosion as well as fireproofed products used above ground including flooring, footpaths, structural components, landscaping and general construction uses.

Because production costs can be supplemented by carbon credits, levies and charges to repurpose the waste we believe the product developments have sound potential to reduce the costs of projects. The process can be wholly powered by renewable electricity where available and is energy efficient utilising the latent heat from the extruded stream of molten plastics to meld to the waste distributed in the molds. With future development, the method can include all mixed and contaminated solid waste from industry, commercial, domestic and construction including contaminated soils and even low grade medical waste.

THE ENVIRONMENTAL UPSIDE

It has been estimated the world produces more than 400 million tonnes of plastics yearly including around 135 million tonnes of single use plastic items and somewhere between 1.6 and 2 billion waste tires so converting anywhere near this tonnage into building products could equate to substantial reductions in CO2 emissions and a logical evolution of building material alternatives. In many 1st world countries the levies on waste and carbon credits will support the production costs of the modules and low labour costs in the 3rd world should reduce the costs and environmental impacts of projects assisting poorer economies to reduce carbon emissions while minimising waste to landfill and providing climate resilient infrastructure and housing.

It is thought somewhere between 30% and 50% of the waste tires produced yearly are burned as fuel to make cement at temperatures of around 1600 degrees C or melted in pyrolysis furnaces (oxygen deprived ovens) at around 600 degrees C to produce crumb rubber, carbon black and fuels usually using the fuel gas and sometimes the oil content of the tires to heat the process. While tires are a rational alternative to burning coal for making cement and pyrolysis produces valuable and reasonably carbon efficient products when compared to virgin materials these activities not only cause high CO2 emissions but also dangerous air pollution from the escape of fine ash particulates.

Cement production world wide has been estimated as producing up to 4% of carbon emissions and while this is improving the quarrying of stone, sand mining and transport to make and distribute concrete is cited as responsible for another 4% of carbon emissions and uses massive volumes of potable water. Modern innovations in production and deployment are achieving improved efficiencies and of course concrete will remain an essential material due to its strength and versatility but it is logical to reduce its impacts where possible. As noted above plubber modules can act as reinforced inner core sections of concrete infrastructure thereby reducing the volumes to be poured.

We believe eco friendly alternatives should be used where possible and remelting waste plastics at up to 260 degrees with suitable processing and plant design has very minimal effects on air pollution so the products have a low environmental impact and a low carbon footprint other than the emissions in relation to the production of steel reinforcing. As noted above because the melting of plastics can be achieved with electricity the carbon footprint is further minimised when renewable energy is utilised including solar electricity, heat recovery and solar heat transfer technology.

The MGM Modules method provides for increasingly effective management of waste and via product development and attention to detail has potential to ensure intrinsically safe encapsulation of many difficult waste streams such as contaminated plastics and soils that may contain a huge array of poisonous additives within plastic formula such as flame retardants. There are increasing controls on the mismanagement of various toxins in wastes streams that can be released from inappropriately recycled plastics, electronics and rubber so MGM Modules Ltd. is focused on eliminating these threats to the environment.

The added advantage of turning waste materials at sources within cities into versatile products close to the market reduces the costs of deploying the products and the costs of transporting tonnes of waste to landfill. This means via planning the public can dispose of all waste plastics in the same way they collect recyclable plastics so assists in reducing micro-plastics entering the environment and provides industry with a cost efficient opportunity to ensure their plastic waste and end of life tires are turned into environmentally sound products.

THE OPPORTUNITY

I think it is fair to say plubber modules have worldwide potential and having established the patent in NZ, we are very lucky to have Remarkable IP based in Queenstown managing the process via the Patent Cooperation Treaty (PCT) so a large investment in establishing the patent in approximately 150 countries to assist commercialisation. We are also very fortunate to have extensive consultancy services and access to plant facilities at Extrutec Ltd in Marsden assisting the evolution of product development and processing plant.

MGM Modules Ltd. is planning  the establishment of Plubber Modules Ltd. to start production and sales while continuing the product development and further IP within future R + D phases. This is aimed at further evolution of the methods, processes and plant design to create better product outcomes to prove the global potential and engage with suitable stakeholders. The initial simple plan is to produce various sizes of slabs and blocks made from clean sources of waste HDPE, LDPE and Polypropylene suitable for a variety of applications such as flooring and footpaths and as core sections of other modular concrete products such as foundations, abutments, retainers and medium barriers. The future evolution and testing of products that include mixed and contaminated plastics and the developments to include scrap rubber and solidify whole tires will benefit from establishing the processing and plant equipment.

Accordingly we are now open to interested parties contributing to this low tech green future by providing technical input, services and investment into the first commercial production operation empowering an economical and environmentally sound solution. A full Information Memorandum is available on request or should you have any questions please feel free to contact MGM Modules Director Mark Molloy.