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IrelandDesgning the Pelletizer: Creating the Technology That Makes Circular Manufacturing Possible for Autex Acoustics®
Designing a world-first technology is not an easy or straightforward process. There are many ups and downs, dead-ends and re-routes. But once complete, the result is a satisfying reminder that the challenges are worth it.
For Autex Acoustics, the proud innovators of the world’s first Pelletizer, the design journey was exactly this: a very long process with a lot of dead ends.
“The Pelletizer project started as a search for existing technology, we searched the world and couldn’t find a simple effective process. So, we had a go at making one,” says Jonathan Mountfort, Autex Acoustics’ Creative Director.
“The thought behind the project was, ‘If this textile has come from a solid material, then a truly circular product should be able to return to a solid material’. There ended up being seven reworks, and now that it’s running I can see more opportunities for development. It will only get better.”
“…it is just another step in our continual effort to reduce our impact on our natural environment.”
One of the primary challenges the team encountered was determining how to maintain a uniform material output. Variations in material density resulted in differing textures and shapes, leading to inconsistencies in the final product.
“We took twice as long as we set out to, and nearly doubled the cost — as you would expect when designing an industry first technology,” Mountfort quips.
This machine now gives Autex Acoustics a concrete way to manufacture their products sustainably and in a circular fashion. While collecting used products or material scraps is one thing, turning them into something valuable extends the life of the material and significantly reduces waste destined for landfills.
The creation of this machine provides Autex Acoustics with a practical method for manufacturing circular products. While collecting used materials or off-cuts is important, converting them into valuable products extends the material’s lifecycle and significantly reduces landfill waste. Additionally, since components and accessories made from RePET (like SpinFix™ and Frontier™ End Caps) can be repeatedly recycled using the same process, the result is a genuinely closed-loop system.
The development and implementation of the Pelletizer into Autex Acoustics’ manufacturing process marks only the first step.
“Our aim is to make this process widely available,” Mountfort says. “While this is an important and pioneering achievement for our business, it is just another step in our continual effort to reduce our impact on our natural environment. Now that we have rolled this technology out to each of the countries that we operate in, we want to ensure that we continue to improve, increase, and partner with other businesses in the industry to scale the capacity. Eventually we can build out an industry solely fueled by reclaimed materials that are re-manufactured into high-value long-lasting products.”
SpinFix™
SpinFix™ uses clips made from recycled PET. This process improves the ease of reuse and recycling at end of life. Using SpinFix clips add a 6mm air gap to improve acoustic performance.
