Centro di progettazione design &

tecnologie dei materiali

Rocco Rametta

Centro Congressi “Cittadella delle Imprese”Taranto – May, 25th 2011

SCUOLA NAZIONALE SUI RIFIUTI

LA VALORIZZAZIONE DEI RIFIUTIRiciclo Materiali e Recupero Energetico

CETMA

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CETMA is a private RTO Research and Technology Organization (according to Community Framework for State Aid for Research and Development and Innovation - 2006/C 323/01)

Shareholders :-Public companies

- ENEA- University of Salento – Lecce

-Private companies- D’Appolonia S.p.A. (engineering, consultancy and research)- Telcom S.p.A. (rotational and injection moulding production company)- InfoByte (software and virtual reality development )- IGEAM – Altran (engineering and environment consultancy)- CEMIT (engineering and realization of industrial plants and structures)

CETMA is located in the area of “Cittadella della Ricerca” near Brindisi

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A well equipped laboratory of advanced materials tecnologies

One of the biggest Virtual Reality Center in Europe

A prototyping laboratory

Laboratories and offices take up about 5.000 sq.mt

RTOs are a fundamental element to ignitethe “Virtuous Knowledge Circle”

PUBLIC RESEARCH:

KNOWLEDGEPRODUCTION

NEW KNOWLEDGEDEMAND

ECONOMICAL DEVELOPMENT

KNOWLEDGE INTENSIVE

BASED SERVICES

CREATION OF HIGH QUALIFICATION

JOB MARKET

RTOs:ENGINEERING

ANDCONTEXTUALIZING OF KNOWLEDGE

ENGINEERING SYSTEMS

EVOLUTION

RTOs

FUNCTIONS

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RTOs provide support to SMEs along the innovation process towards economic

outcomes

R&D

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Economic outcomes

Innovationprocess

Basic researchInvention

New ideas

Capitals to transform ideas in innovationsThe importance of seizing funding opportunities

RTOs provide support to SMEs along the innovation process and the “Valley of

Death”

Applied researchInnovation

Product development

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Eco Innovation supports innovation and competitiveness.A dynamic gazelle means high growth enterprises which are the focus of the CIP.

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CIP Eco-Innovation will support projects:• Concerned with the first application or market replication of eco-innovativetechniques, products, processes or practices, which• have already been technically demonstrated, but• due to remaining risks need incentives to penetrate significantly the market.

Competitiveness and Innovation Framework Programme (CIP)

Analysis of technical/economical needs of enterprises

Study of submission calls within framework and check of opportunities

Directing SMEs interests towards specific calls

Looking forward of SMEs Ideas

Find right partners

… which SMEs can rely on

CETMA’s activities as RTO

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… but before surfing the EC net …

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CETMA – A multidisciplinary center

• Materials and Structure engineering• Computer science and engineering• Industrial design

• Very broad range of applications• Effectiveness of innovation

processes, specially for SMEs

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Second level Software (data management, knowledge management)Second level Software (data management, knowledge management)

Competences Competences –– Department of Information Technologies Department of Information Technologies Third level Software (advanced visualization, UM interaction)Third level Software (advanced visualization, UM interaction)

First level Software (HW control and automation)First level Software (HW control and automation)

Competences Competences –– Department of Industrial Design Department of Industrial Design Third level Third level –– Virtual Prototyping, Interaction and validationVirtual Prototyping, Interaction and validation

Second level Second level –– Physical prototyping and validationPhysical prototyping and validation

First level First level –– 3D modelling, concept design 3D modelling, concept design

Second level – Modelling and simulation

RVE

Fibre

RVE

Laminate

RVE

Fibreglass + PP matrix

Tensile test simulationAbsorbed energy

comparison: Thermoplastic material

(Tw) Thermosetting material (Tm)

impact velocity [7Km/h]

(Tm)

First level – Characterization and testing of materials and components

10,2°C

18,2°C

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IR oven

PressCartesian robot for material moving

Conveyer belt

Department of Materials and Structures Engineering (MAST) – CompetencesThird level – Scaling-up, prototyping, process technologies

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CETMA aims at providing technical support to industrial companies involved in innovating and developing their processes and products, mainly in the field of composite material, by offering specialist engineering services.

• Research activities on materials and technologies

• Product design and development (CAD, FEM)

• Technology scouting & structured innovation

• Setting up of manufacturing processes

• Prototypes and small series production

• Assistance in the start-up stage and technical Training University & Academy

Equipments Supplier

Industrial user

MaterialSupplier

CETMA MAST department - Mission

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SIMModelling and Simulation

6 Engineers

TECTechnologies and Processes

9 Engineers + 2 Scientists + 2 Technician

ENCIVEnvironmental and Civil Engineering

7 Engineers

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- materials engineers

- civil engineers

- mechanical engineers

- aerospace engineers

- industrial chemist

technicians

students and fellows

FEM & CAD ToolsLAB

Laboratory of Materials Technologies

Dep

artm

ent o

f Mat

eria

ls a

ndSt

ruct

ures

Eng

inee

ring

… thanks to people and know-how …

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Technological Equipment

- Laboratory Scale

- Industrial pilot plants

Material characterization equipment

-Physical, mechanical and chemical tests

Laboratory of Materials Technologies… and to the available equipment

Start: 1 July 2009 - End: 30 June 2012Budget: 1.275.556 €

Numix Project

Coordinator: Consorzio CETMAPartners:

• DFS Montenegro Engineering • ACCIONA INFRAESTRUCTURES S.A.• Centro Riciclo Vedelago S.r.l.• SGI Studio Galli Ingegneria S.p.A.

CIP Eco-innovationPilot and market replication projects

Call 2008

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Specific objectives of the project

A)To promote industrial processes for the use of scrap resulting from the sorting of waste plastics to produce:

1. expanded granules to be used as aggregate for lightened concrete, substituting the expanded clay;

2. densified flakes to be used as aggregate for mortar and as raw material for product 1.

B) To develop a sizeable European market.

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Mortar

Lightened concrete

Short extruder

(densifier)

Production process definition

expanded granules

densified flakes

Double screw

extruderblowing agent:

gypsum powder

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Expanded granules manufacturing:

Through previous R&D activities, CETMA developed a foaming/extrusion processes in laboratory and pilot scale.

Production process definition

The density reduction occurs at the exit of the extruder, where thermodynamic processes leads to bubbles formation in the plastic mixture.An in-line cutter provides for the granulation of the extruded material.

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Product characterisation(ongoing activities)

Initial trials have been made with mortar and concrete mix designs.

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Title: Efficient Utilisation of Plastic Waste through Product Design and Process Innovation

Start: 1 July 2010 - End: 30 June 2013

PROWASTE project

Coordinator: Consorzio CETMAPartners:

- Università del Salento - Masmec s.p.a.- Ogle S.r.l.- Inserplasa- Solteco- Cicloplast

CIP Eco-innovationPilot and market replication projects

Call 2009

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PROWASTE technical description

Traditional intrusion process to realize plastic lumbers:The extruder melts the heterogeneous polymer mixture and forces it into a mould, consisting of simple geometry cavities with a high aspect ratio, to produce beams. The process is carried out at low pressures.

Change introduced in the traditional intrusion process:Introduction of pultruded rods near the upper and lower surfaces of the beams. The rods are encapsulated in the plastic during intrusion without substantial modification of the existing production plant.

Method for the manufacturing of high performance recycled plastic lumber

PROWASTE

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To promote an innovative industrial process for the production of high performance recycled plastic lumber.

PROWASTE objective

J Enhancement of flexural stiffness and creep resistance of the beam

J Reduction of the thicknesses

J Lighter urban/outdoor products

J Greater aesthetic features than the recycled plastic furniture currently available

J Possibility to use the new plastic lumber for new applications where weight and bending properties are important issues (pallets and railway ties).

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“Innovative recycled plastic based panels for building field “

CIP Eco-innovation - Pilot and market replication projects Call 2010

Objective: To promote an innovative, eco-sustainable and more environmentally friendly recycled plastic-based panel for elevated floors and exterior coatings, using as raw material mixed plastic coming from domestic, commercial and industrial waste.

ECOPLASBRICK project

Coordinator: Consorzio CETMAPartners:

- Albanian Constructor Association - Pandora Group.- MOTULAB S.r.l.- Consorzio TRE- ACCIONA Spa

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The panel is obtained for compression molding of a mixed plastic waste core, and gres face-sheets.The process is very simple, is carried out without using of resins or glues and results in a final product more environmentally friendly with respect to the competitors. It allows a great product variability in terms of:-thickness, -Facesheets material, -aesthetical aspect, -durability,-applications,-eco-sustainability.

The product

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A pilot installation as ventilated facade was exhibited during the last Architectural Biennale in Venice.

The product

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CETMA

Cittadella della Ricerca - S.S. 7 – Km 706+030 --- 72100 Brindisi (Italy)

Tel. +39.0831.449111 --- Fax +39.0831.449120

www.cetma.it e-mail: info@cetma.it

Design CETMA - The present document is CETMA property. Can’t be copied and handout to others without permission - All rights are reserved

Centro di Progettazione, Design & Tecnologie dei MaterialiCentro di Progettazione, Design & Tecnologie dei Materiali

Materials and Structures Engineering DEPARTMENTMaterials and Structures Engineering DEPARTMENTTechnologies and Processes AREATechnologies and Processes AREA

Rocco RamettaRocco Rametta

… thank you for your attention