The project involves the innovation of both a product and a process.

The innovation of the product lies mainly in the following aspects:

  • using 100% recycled wood only as a raw material (90% of the world’s pallet production is based on fresh wood). No other pallet producer, – not even the world leaders – produces particleboard pallets from recycled wood; there are manufacturers today who produce particleboard pallets but from fresh wood only
  • there are no incompatible elements in the wood recycling cycle as nails are not used and the bonding agents applied are compatible for type and quantity with recycling;
  • Pallet intrinsically compliant with the international ISPM 15 FAO requirements governing the wood packaging market. Raw wood pallets have to be fumigated to eliminate any possible contamination and the diffusion of parasites and toxic organisms through market distribution (compliant pallets carry the FITOK marking).
    Pressed particleboard pallets do not need to be treated because the pressing process temperatures eliminate any possible contamination.
  • The shape studied to render the pallets stackable with one fitting into the other: double the number of pallets can be transported occupying the same space with respect to traditional pallets which, since they are composed of intersecting planks on several levels, they can’t be fitted one into the other and hence take up much more space when stacked. The lower bulk density of recycled wood in comparison to fresh wood, will render this aspect even more advantageous if we take into account that transport costs for the new pallets will be estimated on the weight and not the space occupied. This aspect also impacts on the business model for the pallet market. The dimensions of standard pallets today make them expensive to transport beyond a couple of hundred kilometres, and as such the production model consists of small scale manufacturers covering a limited geographical area. Thanks to the locking stackability, transport costs for the new pallets will have less impact on the cost of the product, and so the market area for each producer can be extended to one thousand kilometres, thus consenting investments to boost productivity levels.

 

Three major process innovations will need to be developed to produce the new recycled pallet:

  1. Implementation and optimization of a control which, by measuring the pH value and moisture content of the particles will be able to improve the blending and pressing stages, adjusting the dosing of the specific catalyser additives to stabilize the pH value in the first case and the length of the pressing cycle in the second case.
  2. Optimization of the press system thanks to a special controlled water vapour injection system to accelerate pressing times (increase productivity and reduce consumptions) and to minimize the application of bonding agents in the blending process (recyclability).
  3. Development of a density sensor, to be integrated downstream of the pressing process, that is able to scan the 3D surface of the pallet for an accurate density measurement. On the basis of this measurement it will be possible to monitor the way the material is laid at press infeed with a feedback control. For this purpose an innovative CdZnTe crystal sensor will be designed which, with respect to the standard scintillation sensors, in addition to ensuring greater stability and duration, also has a spectroscopic capacity and hence consents a better resolution for determining pallet density.