ECO/10/277239 CAYLEY
Project Presentation
Maik Wonneberger
Project Coordinator, INVENT GmbH, Braunschweig, Germany
CIP Eco-innovation
ECO INNOVATORS DAY
Sectorial cluster meeting Green Business
Brussels, 09.11.2012
SUPPORTED BY:
This project is co-funded by the European Union within the CIP
Eco-Innovation initiative of the Competitiveness and Innovation
Framework Programme, CIP.
© 2012 CAYLEY Consortium
Consortium
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© 2012 CAYLEY Consortium
Project Aim
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 Industrial implementation of environmentally friendly panels.
• Basis of the panels: Renewable polymers or recyclable thermoplastic sheets
and natural fibre fabrics.
• Target markets: Interior of aircrafts, trains, busses, ships etc. (mainly
transportation sector).
• Applications foreseen for the panels: ceilings, fairings, compartments, etc.
• Eco-innovative benefits:
1. Substitution of hazardous materials (e. g. phenolic resins).
2. Substitution of non-renewable resources (crude oil) with materials based
non renewable resources (natural fibre, linseed oil based polymers, …).
3. Weight reduction (resulting in less fuel consumption/CO2 emission of
vehicles).
© 2012 CAYLEY Consortium
Project Facts
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Project Overview
Budget
Duration
Starting date
Partners
1.591.547 €
2 years
16.07.2011
4 (from 3 countrys)
Selected Indicators (at the end of the project)
Estimated reduction of CO2 emission
4.500 tons/year
Estimated substitution of dangerous substances
92 tons/year
Estimated Waste minimization
14 tons/year
Estimated reduction of hazardous waste
92 tons/year
Estimated market size
2.410 companies,
1.200.000 €
Basis: Assuming 40 years life cycle of an average aircraft & 20% substitution of current panels for novel
green panels at the end of the CAYLEY project. Estimated production of 400 aircrafts/year.
© 2012 CAYLEY Consortium
Partner Roles
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• Project co-ordination
• Development of biopolymer based panels
• Technology up-scaling
• Marketing & Business
plan development
INVENT (SME)
Braunschweig
Germany
• Development of flax
fabrics
• Development of flax
fabric based pre-pregs
• Up-scaling and
marketing of the fibre
based raw materials
LINEO (SME)
Meulebeke
Belgium
• Provision of technical
requirements and
specifications
• Development of panels
based on inorganic
polymers
• Evaluation of ecoindicators
BOEING R & TE
Madrid
Spain
• Development of
thermoplastic based
panels
• Dissemination activities
• Evaluation of ecoindicators
AIMPLAS
Valencia
Spain
© 2012 CAYLEY Consortium
Results Achieved (I)
Lightweight
sandwich panels
Weight: 1,5-1,7 kg/m²
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Good fire
properties
Good
production rates
PHR*: 50-60 kW/m²
THR*: 50-60 kW*min/m²
Time/panel: 10-15 min
Required < 2 kg/m²
Required
PHR < 65 kW/m²
THR < 65 kW*min/m²
*PHR=peak heat release THR=total
heat release
Required
15 min or less
© 2012 CAYLEY Consortium
Results Achieved (II), Next Steps
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• Development and production of
1. pre-pregs (= pre-impregnated fibre material) based on fire proof flax fabrics
and bio-polymers (linseed oil based).
2. pre-pregs based on fire proof flax fabrics and inorganic polymers.
3. thermoplastic sheets based on fire proof flax fabrics and recyclable
thermoplastic polymers (standard types and also types on the basis of
renewable resources).
• Production of flat panels from these three types of semi finished products for
the purpose of material testing, characterisation and manufacturing trials
Next steps
• Production of three-dimensional panels with representative dimensions and
shapes of real aircraft interior panels.
© 2012 CAYLEY Consortium
Barriers and Opportunities (I)
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Standards or certification that hamper or encourage the uptake of our
eco-innovative solution:
High quality requirements are mandatory for materials used in aircrafts. The
certification of sufficient fire properties and other material properties can open
the door for market-entry. Without official certification of the fire properties the
panels will not find any application.
Environmental legislation (e.g. waste legislation) and other policy
measures (e.g. Ecolabel) that could promote our eco-innovative solution:
Stringent legislation of hazardous waste from glass fibre reinforced plastics,
encouragement of waste that can be carbon-neutral incinerated (e.g. natural
fibre reinforced bio polymers.)
© 2012 CAYLEY Consortium
Barriers and Opportunities (II)
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Other issues that are key to a successful market introduction of our ecoinnovative solution:
Establishment of confidence of customers (e. g. aircraft producers, train
producers, component suppliers) in the new eco-friendly products, e. g. by
demonstration activities.
The call for eco-friendly solutions from the end user (e. g. airlines, carrier, train
operators) may increase the interest of vehicle producers in our ecoinnovation.
Request of more eco-friendly means of transport by the passengers can be
another factor.
How should a future eco-innovation funding instrument look like in order
to bridge more effectively the gap between technology and market uptake of eco-innovations?
Support by corporate consultants for development of market entrance
strategies that require cross-sector marketing of products and respectively a
large network (especially useful for SME’s)
© 2012 CAYLEY Consortium
Thank you for your attention!
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The
Consortium
www.cayley.eu
Your contact:
Mr. Maik Wonneberger
Christian-Pommer-Straße 34
D-38112 Braunschweig
Tel: +49 531 / 2 44 66 – 95
Tel: +49 531 / 2 44 66 - 0
Fax: +49 531 / 2 44 66 - 88
Maik.Wonneberger@invent-gmbh.de
info@invent-gmbh.de
www.invent-gmbh.de
Project Coordinator
© 2012 CAYLEY Consortium
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Sir George Cayley
1773 - 1857
“Father of Aeronautics”
Constructor of the worldwide first glider (1852)
© 2012 CAYLEY Consortium