20 Composites But with sustainability now topping the agenda for housebuilders and developers, the aesthetic finish and performance credentials of products may no longer be the only driver in terms of specification. Manufacturers across the board – from brick- to boiler-makers – are coming under increasing pressure to innovate and provide sustainable solutions that help customers achieve their green aims and meet the requirements laid down by the Code for Sustainable Homes and BREEAM targets. Domestic consumers, too, are becoming more aware and proactively supportive of the demands of the green agenda. These days, consumers are more likely to act on their eco- conscience and look for environmentally-friendly products which don’t compromise on choice, or bump up the cost. Now a pioneering new production technique which combines recycled plastic bottles with fine stone particles, is promising to revolutionise the engineered stone market and even parts of the wider building materials sector, answering the sustainability question head on. Echotect technology, originally developed by Shell’s research and development department, can now create an extraordinary new material with the same aesthetic and performance characteristics as engineered stone. In effect, the technology delivers a 100% recyclable marble facsimile ideal for use in floor tiles, wall tiles, bathroom vanity tops, even internal walls and other flat surfaces. Capable of manufacture in any colour and a variety of finishes – from matt for floor and wall tiles to highly polished for more decorative applications – the product is identical to traditionally manufactured stone products, offering the same durability, flexural strength, and frost- and scratch-resistance. Commercial trials have produced slabs of up to 0.8m wide, and of infinite length, in thicknesses ranging from 5 to 30mm which are then cut to size to produce tiles or panels according to their application. Stephen Eastwood, chief executive officer of Echotect BV, explains: “The key to the success of any new product is how well it performs and how good it looks. This is particularly true in the tile market, which has traditionally been driven by aesthetics almost as much as long-term performance in situ. “Internationally, the industry is working hard to respond to environmental issues and targets for reduction in carbon consumption – and this is creating a third strand for the specifier to consider. “Since the earliest trials, we have seen the massive potential that Echotect technology offers to the tile and countertop market, and indeed the wider building materials sector. “Until now, there has never been an innovative new technology which could challenge historic manufacturing processes to produce products which match the aesthetics and performance of traditional engineered stone. And, with the added, inherent sustainability credentials that the Echotect process offers, we are very excited about the potential this technology has to completely transform the way we manufacture tiles.” By reusing two waste resources – end of life polyethylene terephthalate (PET) and fine secondary aggregate from the quarrying industry – Echotect has gone further than the invention of a new material: it has created a new market for products that would otherwise go to landfill or incineration. Up to 200 bottles are recycled per 1m² of material. This could have a huge impact for the 13bn drinks bottles discarded every year in the UK and, as Echotect materials are themselves 100% recyclable, they would not add to the waste stream at the end of their lifecycle. Existing manufacturing processes across the industry have remained the same for more than 30 years. The Echotect alternative offers tile producers an intriguing new opportunity to move to a retrofitable, non-chemical process which uses half the energy of traditional manufacturing techniques. This means that producers can cut carbon emissions significantly during manufacture, which in turn would reduce each tile’s embodied energy. So, with all these aesthetic, performance and sustainable credentials, the proposition is clear for any forward-thinking manufacturer that takes it from the research and development stage and brings the products to market. Stephen Eastwood adds: “We are in discussions with a number of leading manufacturers who are interested in licensing the technology and launching these stunning products to the trade and consumer markets over the next couple of years. “Long-term, the potential applications of this revolutionary technology are endless. Where tiles and countertops lead, other uses will inevitably follow. “Alternative applications are currently being developed in parallel, and we envisage there will be a whole host of alternative second and third wave applications in the future. Rather like the ‘Intel inside’ quality stamp, Echotect technology will become the byword for environmentally-responsible, precision engineered quality building products for the discerning customer.” To learn more about Echotec, readers are encouraged to contact its team directly. E [email protected] W echotect.com Initially pioneered by Shell, the technology has been pioneered by Echotect BV at its manufacturing facility in Switzerland. CEO Stephen Eastwood demonstrates the finished product From recycled bottles and fine aggregate waste, Echotect has produced striking engineered stone tiles Engineered stone is one of the mainstays of the UK tile market. Customers love the smooth finish, durability and aesthetic of marble, while installers appreciate the lightweight, straight-edged and geometric finish made possible by a precision-manufactured stone tile. Echotect’s revolutionary technology