Public Funding for Gencoa Limited

The global vacuum leak detection market is valued at $800M in 2022 and projected to grow at CAGR of 6%. There is also significant demand for leak detection in other non-vacuum sectors such as electric vehicle batteries and pharmaceuticals. Currently this need is serviced almost exclusively by helium detection using quadrupole-based mass spectroscopy. These systems are costly (~£30k) and have on-going high maintenance costs. In addition, helium is expensive and in critically short supply. Gencoa seeks to address this market with a disruptive new methodology based on remote plasma optical emission spectroscopy. Building upon its already successful 'Optix' gas sensor, Gencoa will deliver a turnkey, automated solution which is capable of comparable performance without the need to use helium, and at a significantly lower price point (~£15k). The use of an optical gas detection method means that the company will have a distinct market advantage over mass spectrometry in terms of price and robustness. The target markets would be both domestic and international entities that utilise vacuum processes or have a requirement for leak detection of sealed systems and components, providing the opportunity for Gencoa to enter market sectors outside of its normal activity areas such as electric vehicle battery manufacturing, hydrogen infrastructure, refrigeration, air conditioning and other industries which require leak testing for quality assurance.

ProductivAI will develop a novel toolkit for process optimisation in PCB manufacturing and vacuum coatings industries, enabling process efficiency improvements resulting in reduced energy consumption and reduced waste and improved ability to meet challenging (and commercially attractive) specifications and short turnaround times. Current lean six-sigma methodologies provide efficiency gains through continuous improvement following highly manual procedures over process iterations. ProductivAI will make a step change in the ability of companies to achieve "right first time" production output to challenging specifications and stringent quality criteria whilst reducing energy consumption, waste and cost through higher yields, more efficient processes and faster throughput with potential for significant annual savings. These benefits will be achieved through the use of a machine-learning optimisation approach tailored, for the first time, specifically to the needs of electronics and coatings industries and integrated within a lean six-sigma framework. The system will automate and massively speed up process improvement and reuse of historical data to optimise process conditions. Novel aspects of our approach include the use of a special two-stage optimisation process which provides rapid global optimisation even for complex processes and the use of data synthesis to achieve faster and more accurate model training. This novel technological approach will be integrated into a lean six-sigma framework for rapid adoption by practitioners within the aforementioned industries. The algorithms will be implemented in a software platform for ease of use and integration with other quality and enterprise software tools. The effectiveness of the toolkit will be demonstrated trough two use cases in PCB manufacture and vacuum coatings, providing the two advanced manufacturing industry companies with direct gains in process performance.

Infections are so common that they are an ever-present risk to the public. Fighting such infections is becoming continually more difficult as the resistance to antibiotics increases. For example, Hospital Acquired Infections - HAIs - increase treatment times, and in extreme cases lead to the death of a patient (an estimated 3.5% of patients who acquire a HAI are reported to die from their infection ~28,000/year in England). Furthermore, the costs incurred to manage a patient who acquires an HAI is around three times higher than that of managing a patient without a HAI. In England, the cost of treating patients infected whilst they are in a hospital is £2.7 billion p.a. and accounts for 7.1 million occupied bed days (corresponding to 21% of the annual number of all bed days across NHS hospitals in England) and 79,700 days of absenteeism among front-line health care professionals. To put the 7.1 million occupied hospital bed days attributable to HAIs into perspective, 5.3 million bed days were occupied by cancer patients in England in 2014; Lung disease in the UK was associated with an estimated 6.1 million occupied bed days in 2011 (BMJ Open 2020;10:e033367\. doi: 10.1136/bmjopen-2019-033367). Typically, the microbes and viral strains that cause such ill health are transmitted by a number of means, most of which originate from contact with a contaminated surface. It is possible to apply various antimicrobial treatments to surfaces and materials, however these are usually applied during the manufacturing stage and have a lower level of performance. Vigorous cleaning of surfaces has varying effectiveness and the chemicals used are damaging to the environment. The project will investigate the feasibility of creating a highly antimicrobial surface that can be applied to the existing built environment with relative ease and reduce the need for surface cleaning. If this can be successfully realised then there will be significant clinical and economic benefits which would accrue from a reduction of the impact that HAIs impose on patients, the NHS and society as a whole.

Multilayer Ceramic Capacitors (MLCCs) are increasingly being demanded for emerging PEMD applications, where high-voltage and high-temperature demands can only be met by MLCCs. These emerging, demanding applications are predicted to drive shipments in the years ahead. Currently there are no ceramic-based solutions that can achieve this as any such part would be too expensive, composed of banks of capacitors. This demand is exasperated by the current global shortage of MLCCs and significant challenges associated with extracting necessary raw materials such as Palladium(Pd) and Nickel(Ni). Within these emerging applications, Electric Vehicle (EV) power electronics systems are a critical market. Greater vehicle electrification is resulting in thousands of MLCCs per vehicle, the latest EVs having 10,000-15,000 MLCCs/vehicle. Increasing near-powertrain, power electronics require higher voltage (\>30V/µm) at temperatures \>100°C. In order to support EV manufacture and promote adoption, there is a **clear commercial need** for MLCCs with high-temperature and high-voltage performance that are free of Palladium, Platinum(Pt) and lead(Pb) that can be realised commercially. **Kaleidoscope addresses DER challenge through:** * **Growing UK supply chains** for global supply of powders and pastes for high-energy density dielectrics and low-cost, non-reacting Ag-based, Pd/Pt free electrode alloys for MLCCs. * **Reaching for net zero** through meeting the increasing technical demands for a range of emerging "green" applications, such as EVs, the materials supply chains will be better able to serve these markets commercially, reducing CO2 emissions. **Kaleidoscope** addresses these challenges by: * Developing environmentally-friendly, lead-free (non-toxic), high-energy density dielectrics and low-cost, non-reacting Ag-based, Pd/Pt free electrode alloys and industrial-scale scale up (post-project). These approaches, combined with demonstration of MLCC production and performance, will enable our consortium to build UK-based supply chains for global supply of powders and pastes for printing ceramic dielectrics and electrically conducting electrodes for MLCCs. **Kaleidoscope** **will open up the rapidly growing EV power electronics market to MLCCs, addressing net-zero demand.** **Kaleidoscope** **is considered innovative** as it will radically improve upon the nearest current _state-of-the-art best-in-class_ BaTiO3 ceramic-based MLCCs. Developing materials and processes to enable these MLCCs to be produced for niche and volume supply chains, **Kaleidoscope** is considered a game-changing development that opens up global power electronic applications. **Kaleidoscope** consists of 4 partners, including an SME, who have the expertise needed to develop the high-energy density dielectrics and low-cost, non-reacting Ag-based, Pd/Pt free electrode alloys and build materials supply chains for global exploitation.

Society requires new solutions to reduce the probability of COVID-19 cross-infection as people resume their daily lives. However, common touch surfaces have been shown to contain significant viral and microbial contamination. The SARS-CoV-2 virus can be present on plastic and glass surfaces for several days and multiple users of the same touch surfaces creates a continuous biological load that leads to cross-contamination, despite periodic cleaning. Studies have shown that touch screens of mobile phones belonging to medical staff in COVID-19 wards have a \>80% chance of containing the SARS-CoV-2 virus. It is almost certain that people with COVID-19 will have a highly contaminated mobile phone screens. If they then use public transport ticketing machines, the contamination will pass to that surface, as is the case with other forms of touch screen. A new form of transparent coating has been developed using vacuum coating that is extremely biocidal. These new anti-viral coatings will be tested on ticket machines used widely in transport, and thus break chains of transmission arising from numerous people touching the same surface.

Concerns over the safety of food packaging have been growing as studies have shown that re-useable bags can contain bacteria contamination from re-use. Bacteria such as E-Coli and Campylobacter can be present on the outside of food packaging materials, and contact with the bag will cause cross-contamination. Hence the recommendation to use fabric bags and wash regularly. The core of the problem relates to the presence of harmful bacteria on the outside of the packaged food products. Even with high food hygiene standards in the UK, the rates of Campylobacter on the outside of chicken packaging has risen from 6 to 7% in 2020\. A US study showed that 51% of 'bags for life' contain harmful bacteria. The project will create a technology to prevent the survival of bacteria and viruses on food packing. The material stock used to wrap the food will have a biocidal coating on the outside that will rapidly kill any form of organic contamination. Whether the contamination occurs in the factory or at the supermarket, the bacteria and viruses will be killed within minutes.

Society requires new solutions to reduce the probability of COVID-19 cross-infection as people resume their daily lives. However, common touch surfaces have been shown to contain significant viral and microbial contamination. The SARS-CoV-2 virus can be present on plastic and glass surfaces for several days and multiple users of the same touch surfaces creates a continuous biological load that leads to cross-contamination, despite periodic cleaning. A new form of transparent coating has been developed using vacuum coating that is extremely biocidal and will be combined with anti-reflection characteristics. These new anti-reflective, anti-viral coatings will be tested for two applications. The first application is to utilise these coatings for reusable face visors and goggles to afford clear vision with continuous self-cleaning effect and reduce skin irritation from chemical cleaning. The second application will test the coating on ticket machines used widely in transport and thus break chains of transmission arising from numerous people touching the same surface.

Hospital aquired infections (HAI) are so common that they are almost expected to occur by members of the public. Fighting such infections is becoming ever more difficult as the resistance to antiboitics increases. HAI increase treatment times and in extreme cases lead to the death of a patient (~1000-2000/year in England). Typically the microbes that cause such infections are transmitted by touching a contaminated surface, or being touched by a contaminated surface. In England the cost of treating patients infected whilst they are in a hospital is £1 billion. Hosptials are cleaned very well however it is impossible to remove 100% of the harmful bacterias. Surface materials such as stainless steel and plastics are an ideal home for bugs. It is possible to apply various antimicrobial coating to such surfaces, however these are usually of a plastic nature with an added active ingredient. Until now it has not been possible to coat a surface with a hard, adherent and durable coating which is highly antimicrobial. We have developed such a coating using a technique called physical vapour deposition (PVD). PVD is commonly used in industries such as electronics and food packaging. We plan to develop this coating and apply it to hospital touch surfaces and surgical instruments. We believe that this innovative coating will reduce HAI, save money, and save lives.

Gencoa Limited have developed a prototype sensor that functions by generating a small plasma within the vacuum and splitting the emitted light into its spectrum via a CCD spectrometer. By analysing this spectrum it is possible to identify species present within the vacuum. This approach, whilst not as sensitive as an RGA, operates over a wide pressure range without the need for differential pumping. This project will aim to demonstrate the feasibility of using this sensing method to identify relevant contaminant, effluent and process gas species for vacuum deposition and surface treatment processes. If the project proves successful, then it would significantly reduce the barrier to entry for monitoring the vacuum environment for a large number of process operators who do not have this capability due to the cost, complexity and operating range of what is currently available on the market. Through better monitoring of the vacuum, this project will aim to demonstrate there is the potential to reduce process scrappage and process time and increase process quality and yield

The aim of this proof of concept project is to develop and demonstrate the use of a new type of sensor to be used in the vacuum deposition process industry. Vacuum deposition is an important technology sector which is critical in the production of semiconductors, photovoltaic panels, touchscreens and architectural glass, among many others. These production techniques rely heavily on sensors to detect small quantities of gas present in the vacuum. However, currently available sensors only offer limited uses and operate over a limited pressure range, necessitating the use of multiple sensors types and expert interpretation. Gencoa Limited intend to address these problems by developing a multi-functional sensor that is capable of operating over a wide vacuum range and provides improved sensor feedback that is automatically interpreted for the user. This will improve the production efficiency and reduce material and energy wastage in these key manufacturing processes.

The aim of this project is to develop a high impact reduction in the risk of failure for orthopaedic implants by controlling the nano-topography of Ti implant surfaces. The project will build on two recent separate areas of research in nanofeatures and nanopatterns. The project will exploit recent technologial innovations in nano-fabrication to develop a novel nanotopography. The project is led by the global market leader in orthopaedic implants, with technical leaders in nanofabrication and nanocharacterisation. This project will develop: nano-patterned surface structures; the manufacturing method to industrially and economically generate the requisite complex surface structure; and assess the potential performance of a prototype implant surface.

The project will see a collaboration of Scapa Group Plc, Gencoa Limited and the University of Liverpool’s Surface Science Research Centre embark on a program of research and development in order to apply novel techniques for the development of a world leading antimicrobial wound dressing. Chronic wound infections are increasingly common as a result of ageing populations and increasing rates of obesity and related diseases such as diabetes. Such wounds can commonly become infected via formation of biofilms. It is the purpose of this project to develop a dressing with the capability to intelligently release antimicrobial agents into an affected wound only when they are required to stop biofilm formation. This level of capability does not currently exist in the market and a successful project will create a world first and world leading pre production prototype. This advance builds on recent technological innovations in nanofabrication and surface nano-functionalisations of soft materials applicable in this sector.

Gencoa have made a very strong patent application disclosing new methods to improve the way that the plasma is magnetically confined and the interaction with anodes (see Appendix B). It is expected that the significant product and processes benefits of this innovation will open a new market for Gencoa. It is also hoped that a 'side' benefit of these new concepts will be reduced energy consumption and carbon footprint of these power 'hungry' production processes. Gencoa have conducted extensive background research into the area and carried out an informal survey of potential customers. The technique of two targets working as a pair with AC power between the two for the deposition of dielectric coatings is an existing aspect of the technology and has prior valid IPR. The patent application has been based on the feedback from the market combined with the current problems and limitations with the existing technology. The new methods employ asymmetric magnetic field designs and the use of magnetic guidance of electrons into a receiving anode. The phenomenon of the asymmetric magnetic fields when used with rotating targets to generate plasma for vacuum plasma processing and coating deposition is novel and is the basis of the IPR. Simulations work completed indicates a good chance of success, but the lack of any scientific and technical validation obviously impedes its commercialisation. The aim of this feasibility study is therefore to thoroughly characterise and refine Gencoa's new magnetic and anode design concepts. Significant outcomes of this project will allow Gencoa to achieve important goals such as confirm the viability of the new technology, gain the necessary scientific and technical knowledge for the development of new commercial rotatable magnetrons and define their operational, technical and design requirements. At the end of the project Gencoa will have a sound knowledge base for the development of commercial products and have background information to help progress the prosecution of any further patent applications. It is hoped that a subsequent 'development' project will follow the feasibility study.

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