Zelfo
Production Characteristics
Production
based Ecological Factors:
Raw materials:
A selection of raw or recycled materials
can be used requiring no oil based synthetics or
additional binders in the forming process.
Virgin Raw
Materials: A primary source of raw
material is Hemp or Flax which has high strength
and flexural properties, others include: wood
fibre, reed, straw, miscanthus, sugar-cane,
sisal, jute
etc. Ecologically there
is a high carbon absorption rate therefore a
positive contribution to the reduction of the
greenhouse effect. The selection of locally
sourced raw materials
for the Zelfo process can also help support
regional farming communities.
Recycled Material
Usage: Various waste and recycled materials
with high Cellulose content can be used. Old
paper and related second hand fibres are highly
appropriate as they are efficient ready made
fibre sources. Locally sourced waste materials
reduces costs, helps local communities and reduces
Power consumption: In the early production stages power consumption is high. Ecological power purchasing can offset this.
Process:
During
the material manufacturing stage there are no harmful
gases, and almost zero waste water/environmentally
damaging waste materials. Any excess material
produced during the end product manufacturing stage can
be reintroduced into the process and reused
for product manufacture. There is therefore
almost no waste.
Transportation:
selection of raw materials from a distant source
is a factor effecting environmental damage done
by transportation. This also relates to colour
pigment selection.
Manufacturing
Processes:
Flat product
(boards): Trials are underway for this process.
Pressed forms:
Simple pressed forms can be made using standard
press machinery.
Curved forms:
This is the area in which Zelfo excels. Using
spraying machinery it is possible to follow
most forms with Zelfo, limits to production
are usually set not by the forming possibilities
but by the space available for drying product
Extrusion:
Based on trials carried out over a number of
years extrusion of Zelfo is problematic.
Injection
Moulding: Trials are underway for this process.
Finished
Material Characteristics:
(Refer
also to website Properties page)
Strength:
10 mm thick finished material has similar characteristics
of fibreglass and MDF combined.
Flexibility:
5mm thick finished material can be bent to in
one direction around a soft curved form.
Heat Resistance:
Zelfo 1 (with a mineral binder) has be
used as a heat absorbing material for products
from the electrical industry. Standard Zelfo
has a high heat resistance and is equivalent
to 'Class
Surface Finishes:
A single object can have several finishes i.e.
polished, engraved, textured, and be multi coloured.
Translucency:
By using thin film spray application it is possible
to achieve an 'organic look' translucent material.
This is functions best with white fibres.
Colour:
A complete spectrum of colours is available,
several of which are generated from natural
‘earth colours’. Mineral based colours are also
used such as Iron Oxide (ecologically unproblematic)
or for more brilliant colours i.e. bright blue:
Cobalt (less ecological). Other colour
sources are available depending on
clients requirements
Durability:
High density Zelfo displays high impact
resistance, beyond for example MDF. To date it is believed
that the life of an object made from Zelfo is
equivalent to most board manufactured
from wood based materials.
Acoustic Properties:
Zelfo 1: Sound absorbing/damping. Zelfo
2: Resonates well, therefore is suitable for
musical instrument bodies.
Maintenance:
A product that has been polished and oiled can
be refurbished in a similar manner to a wood
product, i.e. sanded and oiled.
Further
Design Issues:
Water Absorption:
Zelfo in its natural state is water resistant
but not water proof. End use of a product
where excess moisture can be expected i.e. food
vessels, outdoor products etc should generally
be avoided. It is possible to completely protect
Zelfo from water using natural oils and surface
applied lacquers etc.. However this results in longer product biodegradation
times and that the synthetic film would
remain after the rest of the product has biodegraded.
Sharp Edged Rectilinear
box forms: Products that require absolute square
edged box forms cannot be achieved directly
in the moulding phase due to over tension in
the material during last production stages. Products requiring
rectilinear characteristics require a secondary shaping
process.
Heat Consumption:
The drying process uses forced heat. Dependent on the
products to be dried (thickness of material)
this can have a significant effect on manufacturing
costs and on the time required to process a
product through the factory.
Disposability:
Zelfo dissolves if left immersed in water. As
Zelfo can be produced in various densities the
duration of this process can be from 2 weeks
to several months. Otherwise
can be placed in landfill sites where it will
decompose entirely after a period of several
months depending on climatic conditions. We
always recommend recycling or reuse of the material
back into Zelfo material.
|
