Panthera Group and Condale Plastics Case Study: Pioneering Sustainable Construction with Recycled uPVC

Condale Plastics proudly teamed up with Panthera Group to revolutionise construction with EnviroHoard™, the UK’s first net-zero verified hoarding system made from 100% recycled uPVC. In this case study, find out how our cutting-edge extrusion technology delivered a durable, eco-friendly solution that’s setting bold new standards for sustainability in the industry.

Overview

Panthera Group, a leader in environmentally friendly construction solutions, revolutionised the market in 2021 with the launch of their EnviroHoard™ system, the UK’s first net-zero verified hoarding system to have undergone a cradle-to-grave Life Cycle Assessment. The group turned to Condale Plastics to support their ambitious sustainability goals by providing innovative, low-carbon materials for the hoarding panels.

Challenges

Panthera Group sought to eliminate the use of timber and plywood in their hoarding systems and replace them with a more sustainable, durable recycled uPVC alternative. The goal was to create a hoarding system that aligned with their commitment to net-zero and maintained the strength and flexibility needed to withstand construction site conditions. Panthera faced the challenge of sourcing a material that could be recycled, perform under harsh conditions, and meet their carbon-reduction targets.

Solutions

Panthera partnered with Condale Plastics, a trusted supplier known for their expertise in plastic extrusion and sustainable practices. Condale provided a solution using 100% recycled uPVC, derived from ‘end of life’ window frames and doors through a closed-loop process, where the material can be recycled up to ten times and extruded into EnviroHoard™ Panels. Condale’s ability to extrude 500mm-wide profiles using recycled materials played a critical role in making EnviroHoard™ both environmentally friendly and high-performing. Overall, the innovative solution allowed Panthera to meet its carbon reduction goals without compromising on durability.

Key Contributions by Condale Plastics

• Sustainability: Condale supplied Panthera with recycled uPVC, significantly reducing the carbon footprint of the EnviroHoard™ system. This aligned with Panthera’s goal of reaching net-zero by 2045.
• Customisation: Panthera’s clients often require bespoke hoarding in specific colours. Condale’s extrusion capabilities allowed them to produce panels in custom colours, such as the Cobalt Blue EnviroHoard™, ensuring that each project met specific aesthetic and branding requirements.
• Design & Tooling: Condale collaborated closely with Panthera to design a specialised tool for extruding wide panels. This tool allowed for seamless panel connections, ensuring structural integrity while enhancing the aesthetic appeal of the hoarding systems.

Results

The partnership between Panthera and Condale has enabled the successful delivery of a truly net-zero product, meeting the increasing demand for sustainable construction solutions. Using recycled uPVC in Panthera’s EnviroHoard™ system has set a new benchmark in the industry for sustainability and performance, helping both companies advance their environmental goals.

Client Testimonial

“Condale has proven to be highly cooperative, particularly in working with Daniel Foster, whose extensive technical expertise has been invaluable throughout the process. They take the time to explain the extrusion process and its difficulties, helping us grasp what can and cannot be accomplished with regard to new profiles, colours, etc. Thanks to Condale’s expertise and support, we have emerged as a leader in delivering sustainable, net-zero products, helping our clients meet their own sustainability goals.”

– Neal James, Panthera Group’s Managing Director.

Conclusion

Panthera Group’s collaboration with Condale Plastics has demonstrated how innovation in materials and tooling can drive both sustainability and business success. With the EnviroHoard™ system, Panthera continues to lead the charge in sustainable construction solutions, supported by Condale’s commitment to delivering high-quality, eco-friendly materials.