Plaswire’s Blade Recycling Breakthrough

Andrew Billingsly, CEO at Plaswire, joins to discuss how the company recycles wind turbine blades into construction materials, timber replacements, and utility products. Plus carbon fiber recovery, zero-dust cutting technology, and plans to license blueprint factories worldwide. Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard's StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary's "Engineering with Rosie" YouTube channel here. Have a question we can answer on the show? Email us! Andrew Billingsly: Exactly.  Allen Hall: Are we good?  Andrew Billingsly: I'm truly impressed with this great operation you've got. You really moved this forward, isn't it? That's great. We try. Yeah.  Allen Hall: Yeah, we try. We're not  Andrew Billingsly: trying. You do.  Allen Hall: So I, I will put an intro to this episode when we get back to the states. So I'm just gonna say, Andrew, welcome to the show. And then we will start talking.  Andrew Billingsly: Where do I look  Allen Hall: here?  Andrew Billingsly: Right? Just, just here.  Allen Hall: Yeah. Don't worry about those. We'll figure that out later. That's,  Andrew Billingsly: yeah. A bit of AI in that. Yeah.  Allen Hall: Yeah.  Andrew Billingsly: And you'll see as well. Andrew, welcome to the program. Thank you very much, Alan. Joe, really great pleasure to be here today.  Allen Hall: So we're here to learn about PLA wire and all the great things you're doing in Northern Ireland because you're involved in a lot of recycling efforts in wind, outside of wind. You're doing very novel things, which I think the world needs to hear about. Let's just back up a minute, because not everybody. And particularly [00:01:00]in North America has heard of PLA wire, even though you, you're all over LinkedIn. What does PLA wire do? What is this basic fundamental of PLA wire?  Andrew Billingsly: Basically, we're a processor of polymers. Okay?  Andrew Billingsly: So that's how we see ourselves, that's how we frame ourselves. We're a polymer processor with a waste management license. Uh,  Joel Saxum: I think the important thing here, and this is why I wanted to have this conversation, you and I have been talking in the background for a few years, is. The rhetoric around a lot of the world is we have this problem with recycling blades. We can't figure it out. Nobody's got any solutions. Um, and if they do, it's very agricultural as we say, right? They're just grinding them up, using 'em in this, that, and what I tell people is like, no, no, you're incorrect here. There are people doing this. There is, there is solutions out there. It just needs to be, we need, we need to talk about it. We need to put it out there.  Andrew Billingsly: Absolutely. Uh, I fight very hard to tell the true story. Of course, there's a [00:02:00] lot of greenwashing in every sector of every industry in the world, and those who do it right have to defend themselves. I mean, unfortunately, that's what we have to do. Fortunately, mostly we're able to do that if we work hard at it. For us, we do not have a problem in general, dealing with wind farm waste. Wind farm waste is for us blades. Because we've taken a pragmatic approach to it. We have to look at how we deal with any waste coming into our, uh, process to ensure it's environmentally handled, that it's handled correctly, environmentally, that it meets a price point so that whatever we do with it, we can sell that product, ensure that it's sustainable in how we operate, and it's fully circular. So that's how we've addressed wind blades. We were invited into the industry and we worked out what was needed in the industry. But [00:03:00] before we went all full on with it, we had to make sure we could make products that was saleable, that was usable, and could be utilized within the industry wherever possible. But you thought outside of the box  Allen Hall: quite a bit because the way I think the wind turbine blade recycling efforts have gone is to say, well, we'll, just like Joel was saying, we'll just grind them up. You're taking polymer outside of the wind blade world that you've been using in aerospace and other industries and saying the valuable part of the wind turbine blade is the fiber and the resin, whatever remains there. If I combine that with other polymers, I can create products with a lifetime that can replace other more expensive items, metal items, cement items. That is the, the, the wisdom that went into what you have done. How did you come up with that?  Andrew Billingsly: I think I was born outta the box. Frankly. I've been told that several times.[00:04:00] We're a solution orientated company. Uh, I was talking recently to somebody about how we built our first factory in Northern Ireland that went up in 10 weeks. That's 20,000 square feet. And because the pressure we were under, we had that factory erected and in operation in 10 weeks. And that's just a fact. That's a recorded fact. And I looked back only two years later and said, heck, what did we do there? Yeah, because we had to do it. So we did it. Yeah. We looked at the problem with the wind blade and we thought, we've gotta get a good solution for this. And we'd done that years before with aviation. We were presented with the challenge to deal with plastics arising from the manufacturer's seating. Now the US produces all the plastics for that sector. It comes into Europe for manufacturing seats, a lot of it local to where our factory is, but nobody had a solution. I have to put my hands up now. I broke a few rules here. I filled two [00:05:00] barn up with this material chopped up and ready to sell, but I actually couldn't sell it, but I knew there was a solution. So I worked on that for perhaps 18 months and then it worked. And today we are the main, uh, processor of this plastic that comes out of aircraft seating manufacturing, possibly. We still are the only one doing that.  Allen Hall: So you actually take the plastics from the manufacturer of seating and there's a lot of scrap that's involved in that. Andrew Billingsly: Yep.  Allen Hall: You take all that plastic waste, you bring it back into your facility, you recombine and pelletize it again so that it can be reused somewhere else.  Andrew Billingsly: Yes, that material goes into, uh, an extrusion process with another company now. Okay. Wow.  Joel Saxum: But, but that's the same thing you're doing in wind right now, right? The making it circular, but you're adding or you're, you're adding other second use plastics to it.  Andrew Billingsly: Yeah. So our outta the box thinking was looking back in 2018, how do we grow our business [00:06:00] because recycling plastics within the extrusion world and the injection molding world. What's getting more internal companies getting better at dealing with their own waste and putting it back into the circuit. So what's the waste? Nobody wants. It's the really mucky stuff. It's this material that comes out of, for example, bio digesters that take the supermarket garbage, the yellow label food that people don't buy because it's really is in a bad state. And that goes for digestion and they pull outta those biodigester 10% plastic waste. Hmm. That is a really difficult product to deal with. And not only that, you also find a similar volume of waste coming maybe 24 tons a day, in some cases, sometimes more from the municipal waste processing centers as well. All this waste plastic goes for incineration. Nobody knows how to economically recycle that. So we took on that challenge and produced what we call [00:07:00] RX polymer, which is. Hm, going through pattern now. I got the number only yesterday incidentally for it. And, uh, this enables us then to combine plastics that would not normally combine. So think about polyethylene, polypropylene. Yeah, they mix, but then add in nylon, adding polyester. PET, add in styrene, adding up to 8%, uh, PVC materials. It's an unknown for a polymer engineer, but we did that. And we cooperated with the university in Ireland to prove it. Uh, this is the technology Uni University in Shannon, and we still have an extremely good relationship with them. So we have this polymer. Along comes COVID, we worked with it. We did the deep dive. We went out to find out could we make product with it, could we make a product people wanted, and could we sell that product because what's the point otherwise? And then after COVID. [00:08:00] We went out into the market, met with aviation, had a very substantial and transformative almost meeting with Paul Bella, director at Boeing. So by the end of the year we'd worked out along with some discussions with Air Airbus and with Tarmac Aero serve, how we could help them with their composite wastes as part of our RX polymer January, 2023. We got sucked into a, into the wind sector.  Allen Hall: Mm-hmm.  Andrew Billingsly: January, 2023. We got sucked into the wind sector with a significant phone call from Ted. We had a meeting and agreed to take their first blades. We went out bo more land and that was start of a journey.  Allen Hall: Okay. So it just calls you up and says, Andrew, I need you to start recycling our offshore, mostly offshore or all offshore blades.  Andrew Billingsly: These were initially on shore blades. On  Allen Hall: shore blades. Okay. Andrew Billingsly: And they said, did we know how to do it? Could [00:09:00]we do it?  Allen Hall: Okay?  Andrew Billingsly: And we said, yes.  Allen Hall: You said that? Yes. Without really knowing if the answer is yes.  Andrew Billingsly: Yes.  Allen Hall: Okay. I, I think that one of the things,...