Public Funding for Karm Research Group Limited

Hospital acquired infections (HAIs) pose a significant health concern, are responsible for a large number of deaths & substantial healthcare costs globally. It is estimated that 80% of HAIs are spread by touch & despite improved cleaning protocols, their prevalence remains unacceptably high. The development of surfaces & coatings that can actively kill microbes provides a significant opportunity to help maintain a microbially-clean environment, particularly for touch surfaces where healthcare workers, patients & visitors are in frequent contact & maintaining regular surface disinfection is impossible. It is well documented that copper & its alloys (brass & bronze) have intrinsic antimicrobial properties with activity against a broad spectrum of microorganisms. Studies on the incidence of HAIs in intensive care units showed a patient’s risk of acquiring a HAI can be reduced by up to 58% when just 6 key stainless steel touch surfaces were replaced with antimicrobial copper alongside existing infection control procedures. However, the rising cost of copper & the expense of cast alloy products, limits wide uptake throughout the NHS. Karm Research Group Ltd (KRG) seek to develop a novel nanocomposite electrodeposited metal matrix antimicrobial touch surface that is superior to the existing cast copper healthcare sector products in terms of antimoicrobial efficacy, surface characterisation, aesthetic appearance & at a fraction of the cost. The project aims to incorporate nanoparticulates into the antimicrobial metallic matrix & evaluate the enhancement in technical performance whilst still retaining high microbial destruction. KRG have recognised the need for lightweight, improved antimicrobial efficacy, metal coated medical devices, products & fixtures, and believe this project will provide a world leading coating solution in a completely new product arena with global market opportunities within a number of sectors.

KRG have conducted research into the Antimicrobial efficacy of novel nano composite surfaces. The research aims to identify and result in the development of a far more cost effective and proficient continuous antimicrobial surface solution for infection control.

The printing industry forms part of the UK’s 5th largest manufacturing industries, employing ~140k people (BPIF). Packaging forms the largest part of the global printing market, set to reach $820bn by 2016 (Pira 2012), with consumers buying more packaged products worldwide than ever before. Currently, Gravure & Flexography (Flexo) are the preferred methods of printing, constituting 45% & 50% of the global market. However, Gravure printing is used by the majority of UK & EU flexible-packaging materials producers as it can produce millions of impressions without suffering image deterioration; it produces correct colour tone reproduction & uses less energy/m² than alternative methods. The Gravure industry is hampered by the expense & turn-around time of the engraved copper coated hollow steel printing cylinders used to transfer the image onto the substrate. Due to the on-going trend to smaller print runs, high emphasis is on reducing time required for job changes. In this regard, Gravure is currently outmatched by flexo printing. Whilst Gravure cylinders have an average delivery time of 5 days, flexo printing forms are available within 24hrs at much lower cost. Having completed basic prototyping to prove the technical feasibility, Karm Conductives Group seek to advance the novel Hybrid Cylinder Technology (HCT) that will help provide a future for the Gravure printing industry. HCT is based on the electroplating of conductive polymer (ICP) thermoplastic to create an innovative functional metal coated plastic material for use as Gravure printing cylinders. The project aims to overcome the significant challenges associated with design, scale-up & manufacturing of the electrically conductive thermoplastic polymer with surface electroplated copper. A series of prototype cylinders over a range of lengths/diameters will be developed & trialled on press to demonstrate mechanical & functional viability of HCT Gravure cylinders. Expected mkt introduction 2015

The printing industry forms part of the UK’s 5th largest manufacturing industries & employs circa 140,000 people (BPIF). The packaging printing market is a growth market globally, set to increase from $540bn in 2008 to $800bn by 2020 (ERA 2011), with consumers buying more packaged products worldwide than ever before. Gravure printing is used by the majority of UK & EU flexible-packaging materials producers. Compared to other printing forms, Gravure can produce millions of impressions without suffering image deterioration; it produces correct colour tone reproduction & uses less energy per meter squared than alternative methods. Currently, Gravure & Flexography are the preferred methods of printing, constituting 45% & 50% of the global mkt. The gravure printing industry is hampered by the expense & turn-around time of the engraved copper coated hollow steel cylinders. Due to the ongoing trend to smaller print runs, high emphasis is on reducing time required for job changes. In this regard, gravure is currently outmatched by flexography printing. Whilst gravure cylinders have an average delivery time of 5 days, flexography printing forms are available within 24 hrs at much lower cost. KC now seek to explore the technical & commercial feasibility of developing a novel Hybrid Cylinder Technology (HCT) that will help provide a future for the Gravure printing industry. HCT is based on the electroplating of conductive polymer thermoplastic to create an innovative functional metal coated plastic material for use as gravure printing cylinders. This will involve the investigation into various blends of conductive polymers and their compatibility with different electroplated metals in a variety of forms. The project will result in a basic prototype of an electrically conductive thermoplastic polymer with surface electroplated copper suitable for use as Gravure printing cylinders with a variable/changeable diameter. Further prototyping will follow with expected market introduction in 2014