Recycling Plastic to Resin for Paint ProductionCopy Link

Berger Paints Nigeria Plc (BPN) is seeking innovative solutions for recycling waste plastic into resin for paint production in Nigeria. Resin forms an essential matrix to hold pigment, additives and other paint components, and typically comprises 10-25% of paint volume. Berger has identified an opportunity to explore alternative sources of polymer which also have environmental benefits of converting waste to wealth. BPN desires two separate solutions, one for water-based and another for solvent-based resins for paint production.

Solutions are invited from, but not limited to, the following sectors:

• Chemistry
• Coatings
• Manufacturing
• Biotechnology
• Plastics
• Recycling
• Design
• Construction

Berger Paints Background

Berger Paints Nigeria PLC is a leader in the Coating and Allied Industry in Nigeria since 1959 – a legacy inherited from Lewis Berger, the German Colour Chemist who founded Berger Paints in 1760.

The company has a reputation for setting standards in the paint industry in Nigeria, and has pioneered a wide range of speciality products in this dynamic and ever-changing market. Berger Paints Nigeria PLC is the first company to unveil an ultramodern fully automated factory with an annual capacity of 10,000,000 litres of paint production.

They operate in 5 business segments: Decorative/Architectural finishes, Industrial coatings, Marine & Protection coatings, Automotive/Vehicle refinishes, Wood Finishing and Preservers. These are supported with a manufacturing plant and main distribution centre in Lagos, over 25 depots/business partners’ outlets, Colour World centres and a countrywide distribution network of dealers in strategic locations. 

They are committed to development and manufacture of paints and allied coatings which are technologically correct, environmentally friendly and formulated to withstand harsh tropical conditions. They have an arrangement with the biggest heavy-duty coating manufacturing company in South Korea, KCC Corporation, and Berger Paints are the company of choice for major corporate and government supply and application projects.

Challenge Background

Plastic waste is a global challenge and is especially acute in Nigeria, where it pollutes both urban and rural areas, causes fires in landfills and blocks drainage, causing flooding. Responsible management of plastic waste includes the possibility of recycling it for additional usage. BPN has explored the possibility of building plastic waste into their supply chain using circular economy thinking.

Resin (binder) is a key constituent of water-based and solvent-based paint production. It forms an essential matrix to hold pigment, additives and other paint components and typically comprises 10-25% of paint volume. Due to foreign exchange (FX) sensitive markets, resin is usually sourced locally, rather than imported.

BPN has identified an opportunity to explore alternative source of polymer which also have the environmental benefit of solving the plastic waste problem by converting this waste into a critical factor of production. They are specifically interested in conversion of waste plastic into resin for paint production. They are open to exploring diverse plastic waste streams - including Polyethylene Terephthalate [PET], High-Density Polyethylene [HDPE], Polyvinyl Chloride [PVC] or other plastics - to convert into suitable resins. 

Some initial work in this area showed promise but was stalled by a lack of quality outputs and theoretical assurance. The output of this work was not clear as to the categorization of the resin obtained. Thus applicants should ideally clarify:

• Product parameters such as viscosity, adhesion and relevant qualities
• Minimum amounts of waste needed to produce batches of resin
• Carbon chain length of binders (polymers vs monomers)

Berger Paints Nigeria Plc is seeking innovative solutions for recycling waste plastic into resin for paint production in Nigeria. BPN desires two separate solutions:

• Resin suitable for water-based paint production
• Resin suitable for solvent-based paint production

The ideal solution would focus upon the technical transformation process required and also indicate the best way of sourcing the waste plastic needed. The latter is preferred and not obligatory, and may utilise any existing local services or systems. 

Berger Paints would like to lead the industry in developing a plastic to resin (re)supply chain. Their findings would be shared with government waste collection agencies and these innovative services could also serve other paint manufacturers. Innovative thinking is welcome for this challenge.

Early-stage solutions are welcome, but TRL must be aligned with project objectives (ie: capable of running a valid pilot with a minimum of 10 litres resin required).

Berger Paints Nigeria is open to discuss IP arrangements with challenge winners. They would seek to find a mutually beneficial commercialization route. 

Applicants should include relevant details as attachments, such as:

• Process diagram
• Technical data
• Business model
• Lab images

Additional Info

Some benchmarks of current requirements are:

• The current average cost of water base  styrene acrylic resin is about 2,500 Naira/kg, which fluctuates with currency rates.
• BPN typically uses 50 tons/month of resin for water-based paints and 15 tons/month for Alkyd based paints.
• As well as environmental improvements, it is desirable to make efficiency savings of 10-20% of existing costs ($5-10,000 per month)
• The average batch size of paint produced are usually 5,000 litres, and smaller batches may be possible (500-1,000 litre). However, lab scale production may be used for this project.

If you would like additional information or clarification of any issues, please contact the Global Alliance Africa, Open Innovation Lead: babar.javed@iuk.ktn-uk.org

Future plans for integrating innovative processes/products into Berger’s supply chain

Paint and resin composition details are available upon request.

• Up to GBP 25,000 seed funding (Subject to T&C)
• Opportunity to pitch your solution to Berger Paints Nigeria Plc.
• Collaboration/partnership with Berger Paints Nigeria Plc.
• Technical support from Berger Paints Nigeria Plc team.
• Sector expertise from Innovate UK 
• Support in the development of a prototype or pilot 
• Invitation to attend or present at Innovate UK events
• Investor introductions (if investment is required)
• Application support for any Innovate UK or similar competitions that are relevant

The identified solution must/should address the following:

• Solution must apply to packaged paints
• Solution must support water or/and solvent based paints
• Solution must identify valuable, reusable components
• Versatility and capacity to scale are desirable
• Solution must be integrated at a suitable point in supply chain
• Solution must be sustainable

• Solution must involve recycling and follow circular economy principles
• Solution may be delivered by external contractor or via in-house team
• Solution must produce consistent product quality
• Solution must operate with high accuracy thresholds
• Solution/process must comply with health and safety standards

• Solution should operate in context of normal temperatures and humidity
• Solution should be applicable during normal working hours
• Solution must be viable for paint manufacturing/processing plants
• Solution should minimise carbon emissions and contribute to waste reduction

• 01 Oct 2024 – Competition launch
• TBC Oct 2023 – Information session/Q&A (TBC)
• 15 Nov 2024 – Deadline for applications
• Dec 2024 – Selection and notification of finalists
• Dec 2024 – Pitch day & selection of winner
• Jan 2024 – Collaboration discussions
• Jan 2025 – Pilot programme activated

• The solution’s operation should aim to be cost-effective and/or profitable in terms of ROI
• Winning solution providers may become long-term partners, gaining access to Berger Paints supply chains
• External contractors and in-house technical arrangements will be considered
• The opportunity may later extend beyond plastic waste to other waste streams also
• There may be opportunities to collaborate with government waste agencies and/or other paint manufacturers

Proposed solutions may not be viable if they are:

• Not compliant with health and safety
• Unsuitable for water-based and solvent-based paints
• Unable to produce reliable quality outputs
• Unable to use Circular Economy thinking
• Unsuitable for Nigerian market conditions

Entrants to this competition must be:

• Established businesses, start-ups, SMEs or individual entrepreneurs
• Africa-based entrants, UK-based entrants and those from RoW are invited to apply

Due Diligence requirements for seed funding:

• UK applicants must ensure that receiving the £25k seed funding will not exceed the £315,000* state aid threshold under UK Minimal Financial Assistance regulations over the current and last 2 fiscal years [or *200,000 euros for applicants affected by EC de minimis regulations]
• Further information will be required later relating to company policies, financial history and recent grant funding received.

Applications will be assessed on:

• Relevance to the topic
• Innovative nature of the subject
• Coherence of the proposed business model
• Feasibility/ economic viability
• Development potential
• Maturity of project/solution
• Ability to launch project quickly/Ease of implementation
• Price/quality ratio
• Suitability for the Nigerian Market

• Existing background IP associated with a potential solution will remain with Solution Provider(s). Where any new IP generation is envisaged, it will be subject to the mutual IP agreement of the Solution Provider(s) and Innovation Challenger.
• Any commercial deployment of a transferred solution or newly developed solution, through licensing, joint venture, partnership or direct investment, will be subject to the commercial agreement between the Solution Provider(s) and Innovation Challenger.
• Where necessary, a non-disclosure agreement (NDA) may be signed to uphold confidentiality in the engagement between the Solution Provider(s) and Innovation Challenger. (This would be expected to be after company selection. It is suggested that details of IP not be disclosed initially. Focus on the outcomes of the technology proposed).
• Innovate UK does not take any share of IP ownership or enter into commercial ventures through the iX programme.

• The application form for this challenge will require applicants to provide company information and answer 3 questions - Idea Summary, Technology Readiness and Intellectual Property – each with a limit of 300 words.
• Optionally, supporting documents can be attached to the application. We recommend that supporting documents are limited to those which are directly relevant to the application. Please note that applications with no supporting document will not receive any penalty in assessment. Supporting documents which the Assessment Panel deems to be superfluous may be disregarded. Examples of useful additional documents include product images or short specification sheets, slide decks detailing the solution and/or company background, or solution case studies.
• We recommend that you complete the application form in Google Chrome as other browsers may have compatibility issues. The application form does not need to be completed in one session and can be saved for future edits. Please ensure that you toggle “Stage Complete” for each section before submission. Note that you will no longer be able to edit your application once you have clicked “Submit Idea” at the bottom of the Summary page.