Grant: CCI Applied Research and Development Grants

Enviroshake® is a leading manufacturer of composite roofing and siding products, specializing in recycled plastic alternatives to slate and cedar roofing shingles. Since 1988, Enviroshake has been a pioneer in the industry, pushing the boundaries of innovation to meet the evolving needs of consumers worldwide. Currently, two of their key target markets, California and the UK, demand roofing materials with a Class A Fire Rating to ensure a high level of protection. This is a crucial requirement for Enviroshake's products, which they are currently unable to meet. The existing formulation uses ammonium polyphosphate (AmPP), but only 35% of AmPP has been found to pass the fire-rating test, rendering it ultimately unreliable. In addition, Enviroshake recognizes the benefits of injection molding, which include higher production efficiency, improved quality, and the ability to produce more complex geometries. These advancements could play a vital role in enhancing their product offerings and meeting market demands. In collaboration with Lambton College, Enviroshake aims to develop a fire-rated product that meets all elements of the ASTM E108 fire-rated roof covering and does so at an affordable cost. While also focusing on transferring their existing extrusion-press moulding production methods to injection moulding methods, including characterization of the mould and formulation changes while maintaining all other physical product characteristics. The success of this collaborative project will enable Enviroshake to achieve transformative advancements in both product performance and manufacturing processes. By developing a reliable Class A fire-rated shingle, Enviroshake will be able to confidently expand into the USA and UK markets, while ensuring compliance with the stringent fire safety regulations. This expansion is expected to lead to increased sales and market share. Transitioning from extrusion-press moulding process to an optimized injection moulding method will result in substantial cost savings due to the improved efficiency and the ability to produce more complex and high-quality shingle designs. Implementing this new process will streamline manufacturing, reduce waste, and lower environmental impact, providing a significant competitive advantage. As a result of this project, Enviroshake anticipates creating an additional 12 positions and generating revenue above 137M within five years post-project completion.