We work differently, because only the best is good enough when you're dealing with people's lives.
We’ll start by having a chat to understand your business and products, and work out how, with your product and market knowledge, and our technology and fire protection expertise, we can effectively work together.
Using experts both sides of the table, we’ll decide on the best product(s) to progress with. To do this, and to save us both time and money in the long run, we’ll consider market potential, competition, affordability, process technology, testing, and certification timelines.
If you have product development facilities, we’ll come to you. Or you can use our state-of-the-art R&D lab to produce prototypes and go through iterative testing, with daily updates from our core team members.
Product Certification Process Diagram
Supply and production trial
We’ll work with your team in the plant to integrate Zeroignition Solution into your process, in the least amount of time and at as little cost as possible, creating a bespoke supply agreement for you and working with your team to get production underway.
Certification and production
Using the correct third-party certification bodies, our certification experts across the world will make this part of the cycle as quick and painless as possible for you.
There can be more than one iteration of this stage, dependant on your product(s). Once complete you can go to market with the full knowledge that you have a truly unique and safe product.
Product Certification Process Diagram
What Happens next?
What happens next?
Cost Reduction Program
This is done as a matter of course so you can produce quality fire retardant products as cost effectively as possible, which not only benefits you, but everyone using the buildings around the world that contain your products.
Expanded Product Variants
Once we’ve created an effective fire retardant product – what next? We can look into developing a suite of products using the first one as the master, with others in the family potentially offering increased levels of fire performance, further environmental benefits, different usage etc.
Derivative Product Definition
What else can we transform in your existing product line? Or is there a completely new product you want to work on where we can design in fire protection?
The most crucial part of the process for all parties is deciding which product to produce.
This is a collaborative process that involves experts on both sides of the table. As with all product development processes, the cycle may need to be repeated to accurately produce the best possible product. We only deal with the best and ‘okay’ isn’t ever good enough for us – we exist to save lives and our manufacturing partners feel the same – so getting this right is crucial.
1. Chemical and 'Recipe' Evaluation
We assess any obvious challenges we may face in this first phase and highlight possible solutions. We’ll also investigate any further benefits our technologies may bring to the product, such as improving physical properties and fire resistance.
2. Lab Scale Product Development
Here we move theory into practice and produce prototypes within our R&D center. Where possible, we use existing material and recipes and then carry out indicative physical characteristics and fire testing.
3. Production process design
Our process engineering team work alongside yours to create a plan of action to integrate the Zeroignition Solution or Powder into your production process. This highlights any challenges and any potential savings that can be made.
4. Trial production
Once the groundwork has been laid for the process design, a trial run happens. Our technical team attend and are on site to assist with any questions or issues that arise on the day.
5. Production process review
We work with you to assess and test what’s been achieved and start to work on ways to streamline and optimise the production process if required. Once all parties are happy – we then enter the product certification process.
For each material we’re adding improved fire performance, there is usually a different certification process.
This is either based on product usage, local regulation and other challenges that any particular material encounters in the world of construction, whether that be structural or aesthetic.
The example we’ve used is for a wood product, but each material would have its own specific needs. To correctly certify with a professional body, samples are taken of the approved trial production product and it’s then tested for acceptable performance across a number of physical, fire and other criteria, leading to formal certification for sale.
We don’t deal in self certification – only third-party audited and verified certification will do when lives are at stake.
1. Fire Performance
No matter where you are in the world, or where in the world you sell, we are expert in the testing procedures and protocols to prepare for success in any and all fire testing you’ll need.
Fire protection, done properly, is highly effective and a significant improvement over unprotected material. The treatment is a high-quality process as such it requires a methodology that needs to be refined in partnership. There is no one size fits all approach and anyone claiming this is unlikely to be a reliable partner.
2. Structural Performance
Many fire retardant treatments can negatively affect structural integrity, so it’s essential this is checked thoroughly. For instance, when dealing with natural products such as lumber in Europe, it’s imperative the CE marking is re-certified with structural performance testing after FR treatment. This not only supports all your market claims but also guarantees CE marking required under the CPR, in Europe and their equivalents in North America and elsewhere.
Our expert team is perfectly placed to support all your questions and provide leadership in meeting the challenges surrounding this increasingly important characteristic.
3. Hygroscopicity Performance
Dependant on the product’s usage, you’ll probably need to meet hygroscopicity standards, which assess how much moisture (if any) is absorbed by the product in humid conditions. That’s because hygroscopicity can impact fire performance and structural integrity, especially in natural products like wood. We’ve developed technology to significantly limit this and can provide expert advice on mitigation procedures.
4. Leaching Performance
Testing for leaching evaluates the level to which the fire retardant is ‘washed out’ from the material/product in external use, when exposed to environmental conditions like rain and snow. For obvious reasons, if not properly controlled, leaching can have a large effect on fire performance. Fortunately, once again we have mitigating technologies you can utilise.
5. Production Process Evaluation
Following the evaluation of the results of all the testing required, the product development cycle may need to continue, and then we’re ready to go to market. The manufacturing process evaluation defines the necessary steps to perfect the additional and other mechanisms. Done well, this quickly and efficiently leads to the start of full-scale production.
Our team of science, engineering, process and commercialisation experts cover everything from product development to patenting and branding, and we don’t just leave the process at this point. We’re with you for the long term to ensure the market awareness and commercial success of the new product.