Plastic Extrusions in Renewable Energy

According to a 2022 Oxford University study, the decarbonisation of global energy systems could save the world £9 trillion by 2050. Innovating clean energy sources isn’t just economically effective; it benefits all environmental and social dimensions. As the demand for renewable energy grows, with it comes the need for efficient, durable, and sustainable materials. That’s where plastic extrusions come in. At Condale Plastics, we’re playing our part by creating components that make renewable energy applications, like wind turbines and EV chargers, more efficient and cost-effective.

Expanding Our Footprint in Renewables

Wind

We’re already actively involved in the wind energy sector, where our plastic extrusions are used to improve both the performance and durability of turbine blades. Our materials have evolved from simply distributing resin inside the blades to playing a vital role in joining turbine halves together, ensuring they’re durable enough to handle all the elements. Our extrusions can be machined into sweeping shapes, improving the aerodynamic efficiency of the blades, minimising drag and capturing more energy.

EV Charging

We’ve also been involved in the development of innovative EV charging solutions, particularly for urban environments where off-street parking is limited. Our durable plastic extrusions protect the charger components and ensure everything stays safe and functional, even in harsh weather.

In one particularly innovative project, we helped a company develop unique EV chargers designed for terraced streets. These chargers are embedded in the ground, with only a small, custom-built lance used to connect the car to the charger. We developed complex hexagonal-shaped components that securely hold contactors while maintaining a durable, weatherproof connection system.

Plastic extrusions play a crucial role in the design of the lance and in protecting the electronics housed underground. By using plastic instead of metal, the company could reduce manufacturing costs without sacrificing performance or durability. The flexible design also allowed the chargers to meet strict safety regulations.

Solar Energy

While Condale’s main focus has been wind energy and EV charging, we’ve recently begun trialling projects in the solar energy space, specifically in solar thermal applications. Unlike traditional photovoltaic systems (where light is converted into energy using semiconducting materials placed directly under the sun), these trials aim to explore new ways to thermally conduct heat through polymer materials used in solar water heating panels. Though still in the early stages, these efforts indicate a growing interest in expanding into other renewable sectors, such as solar and potentially hydroelectric power in the future​.

Key Advantages of Plastic Extrusions

What makes plastic extrusions so great for renewable energy? Here are some of the standout benefits:

• Durability and Weather Resistance: Our materials are built to withstand harsh conditions, from UV exposure to high winds. This durability makes them ideal for wind turbines and other outdoor applications.
• Lightweight: Wind turbine blades and solar panels need to be lightweight for easy installation and transport, and plastic extrusions provide this without sacrificing strength.
• Sustainability: We’re committed to reducing waste, using up to 15% recycled materials in our products. Thermoplastics, in particular, are recyclable, contributing to a more sustainable future for renewable energy infrastructure.
• Cost-Effectiveness: Plastic extrusions are generally more affordable than metals, offering a budget-friendly alternative without compromising on quality or performance.
• Customisation and Flexibility: A standout benefit of plastic extrusions is how easily they can be customised. This flexibility allows us to create bespoke solutions that meet the specific needs of different renewable energy applications.

Challenges and Solutions

Of course, it’s not all smooth sailing. High-stress environments, like wind turbines and EV chargers, present their own set of challenges. One big issue is temperature resistance—wind turbine components, for instance, need to withstand high temperatures during the bonding process. We’ve addressed this by shifting to more temperature-resistant materials, which can handle the heat without degrading.

In EV chargers, we’ve had to meet strict fire retardancy standards, especially for public installations. We’ve developed fire-retardant plastic solutions that meet these safety standards while maintaining cost-effectiveness and performance.

The Future of Plastic Extrusions in Renewables

Looking ahead, the demand for plastic extrusions in the renewable energy sector will only grow. With the rapid expansion of EV infrastructure, particularly in cities, there will be an increased need for scalable, affordable charging solutions. Our expertise in plastic extrusions will be critical in meeting these demands, ensuring that EV chargers are durable, weatherproof, and cost-effective.

Plastic extrusions may not be the first thing that comes to mind when you think of renewable energy, but they’re proving to be indispensable. From improving the efficiency of wind turbines to enabling innovative EV charging solutions, these materials offer a versatile, cost-effective, and sustainable option for the energy sector. As the world continues to move toward cleaner energy, the role of plastic extrusions will only become more important, supporting the infrastructure needed for a greener future.

Contact us today to learn how we can help your business with its renewable energy applications.