Corrosion costs the global economy $2.5 trillion each year and accounts for 3.2% of the world’s CO₂ emissions. Hexigone Inhibitors, a UK SME in South Wales, has already developed a corrosion inhibitor made from sustainable, earth-abundant materials. Now the company wants to replace up to 67% of its raw ingredients with recycled ion exchange resin—a waste stream from the pharmaceutical and food industries that currently goes to landfill or incineration. The REPAIR project will demonstrate that this recycled feedstock can produce coatings that protect metal assets longer than conventional toxic inhibitors, reducing both waste and the need for frequent repairs or replacements. If successful, the work could cut the carbon footprint of corrosion protection, lower manufacturing costs, and divert hundreds of thousands of tonnes of industrial resin waste from disposal each year. The result would be a commercially viable, eco-friendly coating that strengthens supply chains for infrastructure, transport, and energy sectors without relying on critical or hazardous raw materials.
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Corrosion costs the world economy an estimated $2.5 trillion dollars every year and is responsible for 3.2% of the worlds CO2 emissions. Traditional inhibitors used to combat corrosion are based on toxic or critical raw materials. However, Hexigone Inhibitors, a highly innovative UK SME based in South Wales, provides a patented new-to-market corrosion inhibitor product formulated using sustainable earth abundant materials. Hexigone's products provide longer lasting coatings protecting assets for increased periods, thus resulting in improved in service lifetimes, reducing the need to replace or repair. Through a recent feasibility study, Hexigone has identified the potential to reuse/recycle a chemical industry end-of-life waste stream as a raw material input for its manufacturing process. Specifically, the use of ion exchange resin by pharmaceutical and food industries runs into hundreds of thousands of tonnes of material every year, with end-of-life products going to landfill or incineration. This project will demonstrate that it is possible to formulate Hexigone's product using 67% recycled/re-used material, thus reducing waste incinerated or sent to landfill, whilst also improving Hexigone's competitiveness through cost savings. The **Recycled Elements for Paint Advancement and Innovation towards a Resilient Environment (REPAIR)** project focuses on leveraging recycled resin products to create advanced, sustainable solutions for the paint industry. The REPAIR project demonstrates a commitment to innovation and resilience, paving the way for greener industrial practices. Objectives: 1. **Sustainability**: Reduce environmental impact by repurposing resin waste and minimising reliance on virgin materials. 2. **Innovation**: Develop high-performance coatings that meet industry standards using recycled materials. 3. **Commercialisation**: Position the product as a market-ready, Eco-friendly alternative, aligning with growing demand for sustainable solutions. Approach: * **Material Development**: Adapt recycled resin for high-quality paint formulations. * **Process Optimisation**: Establish efficient, cost-effective recycling and production workflows. * **Market Validation**: Engage stakeholders, conduct rigorous testing, and ensure regulatory compliance to build confidence in the product. Benefits: * **Environmental**: Reduction in landfill waste and carbon footprint, fostering a circular economy. * **Economic**: Enhanced competitiveness and creation of new market opportunities in sustainable coatings. * **Social**: Contributing to global sustainability goals, benefiting communities and taxpayers alike.
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