Alasdair Bremner and David Binns, Co-founders Alusid: “take low-value waste and transform it into high-value, sustainable surfaces “
Meet Alasdair and David, co-founders of Alusid
1. Describe your startup in two sentences?
Our innovative manufacturing process allows us to take low-value waste and transform it into high-value, beautiful and sustainable architectural surfaces, using up to 35% less energy than conventional tile production.
2. What gave you the inspiration?
We are both trained in ceramics, interested in architecture, and are deeply concerned about the wellbeing of our natural environment. These shared interests and beliefs have inspired all Alusid’s production; a wish to make architectural and interior surfacing materials that are both durable, desirable, and have a lower environmental impact than similar existing products.
Our innovative manufacturing process grew out of David’s artwork, that involved making sculptures from ceramic aggregates combined with recycled crushed glass. Collaboration with then PhD student Alasdair, led us to start developing tiles and other architectural surfaces.
Our research supported by a Research Council grant, explored how naturally occurring materials could be replaced by low-value industrial waste. Through the project titled ‘The Aesthetic of Waste’, we developed a range of prototype architectural surfacing materials, made from over 98% recycled waste.
3. How did you meet?
We met at the University of Central Lancashire. David was the Director of Studies on Alasdair’s PhD. We subsequently collaborated on a number of research projects and exhibitions, whilst beginning to develop the manufacturing techniques that led to the spin-out of Alusid from the University. The company was established with the support of Frontier IP – specialists in commercialising University IP.
4. What has been your greatest success to date? And your greatest challenge?
Signing a long- term partnership deal with Topps Tiles has been our single biggest success. It was important to us as we needed the commitment of a major customer to enable engagement with existing scale manufacturers. This has been key to enable us to rapidly scale up production volumes, whilst delivering considerable energy savings.
This success has also been our biggest challenge. Scaling up from the pilot and lab-scale has been a challenge both technically and logistically, dealing with multiple sub-contract partners and suppliers, convincing them to do adopt at times unconventional manufacturing practices. Operating across different European countries, during the global Covid pandemic, has added further logistical and linguistic challenges.
5. What kind of impact is your business having and how do you measure it?
From the outset, our manufacturing processes have been designed to minimise environmental impact, with the aim being to produce tiles and architectural surfaces that have a much lower carbon footprint than ceramic products made by conventional manufacturing methods.
All our products are made almost entirely from low value recycled industrial waste, much of which may have been otherwise destined for landfill. Using recycled waste, rather than virgin raw materials, also reduces the environmental damage caused by the mining and extraction of raw materials.
The dry-blending process we have developed using selected recycled materials allows us to produce high volumes of produce ceramic tiles using significantly less energy compared to the existing technology. By reducing the firing temperature and using a dry processing technology we are projecting an energy saving of approximately 35%. Our process also uses up to 75% less water than existing ceramic tile manufacturing processes. This translates to a saving of approximately 4.5kg of CO2 per m2 of tiles produced.
6. How has Covid affected your business?
All of our customers prior to Covid were in the retail or hospitality business. The closure of these businesses and subsequent challenges in these sectors has impacted the growth of our UK production and sales of our solid surface products. The ban on travel to Spain and factory shutdowns also delayed product development and the scale up considerably. The energy crisis has also had a major impact on our business, long-term increased prices for natural gas is likely to be a positive for our process, increasing the relative benefits of our technology.
7. When you were little what did you want to be when you grew up?
AB - An architect.
DB – Also an architect!
8. If you weren’t doing this, what would be your plan B?
AB - I don’t really have a plan B. But I’d probably want to be making something with my hands, maybe an off-grid cabin!
DB – Now I am recently retired, my plan A (University Lecturer), has naturally morphed into plan B – ceramic artist, consultant for Alusid, hill walker and shed maker!
9.What would you save in a fire?
AB - Anything living first! Then probably try to save some of the paintings my girlfriend has given me.
DB – aside from family, friends and dogs, probably family photo’s and my kids early drawings.
10. Who is your role model/ greatest influence? And why?
AB - Difficult question, I have had a lot of help on my transition from academic to entrepreneur and have learned a lot from Neil Crabb at Frontier IP. but I would have to say my Father. He helped found and was Managing Director of a successful biotech business and has been a great source of advice and encouragement.
DB – No single person. I have been fortunate to work with many inspiring and talented people – teachers and artists. My greatest influence – Japanese aesthetics, design and culture.
11. What is your happy track?
AB - Anything you can dance to! but if you forced me to pick one - Hey Ya!, Outcast
DB – Likewise, upbeat tracks that I can’t help but want to jig about to – Dad dance!!
12. What’s your motto?
AB - Get your hands dirty.
DB – Aside from also ‘getting one’s hands dirty’, fairness and kindness to our fellow human beings and our planet.
13. What are you most looking forward to in 2023?
AB - Seeing our tiles available in Topps Tiles nationwide.
DB – Likewise seeing Alusid’s products in stores on the high street – but also good health and happy times with my family and friends.