This production line is the first in Western Europe which makes such innovative SPC products for both the interior and the exterior. The products are sold on the market under the Aqua- Step brand name and a unique feature is that not only is the production fully circular, but also the end product in turn can be fully recycled. The first products for the interior are being sold on the market under the names Aqua-Step XL and Aqua-Step boards.

In the official launch of Aqua-Step we read that SPC (Stone Polymer Composite) consists largely of limestone with a small percentage of PVC. That’s how they offer sustainable and circular products for the wall, the ceiling, and the façade. We visited them for a more detailed account from commercial director Wout Haverkort.

Surface technology and new joint
He comments: ‘HDM has been in existence since the late 1980s as a wholesaler mainly in ceiling panels. This changed around 2018 when two businesses came together. The first was in the field of surface technology, the second in material. Our surface technology, Solid Paint®, is based on electron beam curing technology, which gives the surface the required properties for the application. And so, for instance, you can provide more scratch resistance. Or, what’s important for the facade, you can guarantee greater UV resistance. For this surface technology we work together with the German company Celotec, which is part of VEKA AG, one of the market leaders in PVC profiles for windows.’

We’ve also been developing a new connection called Click ‘N Screw. ‘Two parts are connected to each other with a special “tongue” on the long side of the panel. There is a click, but what is unique is that screws can be applied to a notch to facilitate invisible fastening. This system, which is licensed by i4F, is suitable for the floor, the ceiling, the wall, and the façade.
Wout Haverkort then explains what the big problem was in finding a good base material for the Solid Paint® surface. Not only did it have to be suitable for indoors and outdoors, and therefore waterproof and weather-resistant, but also something onto which a Click ’N Screw connection could be milled. SPC proved to be the perfect solution.

Solution for the base material was found in Taiwan.
‘We found the ideal base material soon afterwards in Taiwan, namely SPC. This consists for 75% of limestone, just under 20% PVC, and additives with which you join the commodities to each other. These additives are not harmful for the environment, there are no harmful emissions, and the big advantage of SPC is that you can apply our surface technology and connection technology on it. It also proved to be highly suitable for outdoors because it’s a stable panel which hardly swells at all. Another big advantage is that SPC can be recycled for the full 100%, so the process, in combination with the Click ’N Screw technology, is completely circular.’

Nothing is lost.
As Wout Haverkorts continues his explanation, it becomes clear that the story of 100% circularity is much more than just another sales tactic. What’s special is that literally nothing gets lost in the production. ‘Some explanation about the production, which will come to about eight million square metres in the next five years, is necessary. Our panels are made in two steps. Firstly, we mix raw materials and we shape the panel by means of extrusion. This is done without any adhesive, as the Solid Paint® surface adheres securely to the substrate via heating. In the second step we fit the click connection and determine the size. For outdoors we have two dimensions: 2.60m by 32cm and 2.60m by 97cm. The 97cm is a standard panel, the 32cm has the Click ’N Screw profiling to enable invisible fastening to create seamless wall cladding. An additional asset is that you don’t need to be a technological expert to fit them.’

‘Two things make our story completely sustainable. Firstly, we need a lot less energy than other products on the market because we only have to heat up to 220°C. Then, our production circuit is closed by a full capacity for recycling. You can take it as read that literally all waste is recycled. The waste items are ground into powder and used again in the production. We apply a QR code to the rear side of the panels. If you want to return a product, you scan the code and we take it back to deploy it again in the production.’

Façade cladding is given a high priority.
It should be clear that a lot will be happening at HDM in the near future. The main question is which directions they wish to take. Façade cladding seems to be very prominent on the list.
‘The façade cladding market forms a serious challenge for us. We’re a new player on the market, so first of all we have to introduce the product to people and gradually build up a market share.’

‘The big asset which we have, certainly with façade cladding, is our sustainability and recycling story. If you look at the market, you notice how criteria are getting stricter, with the Scandinavian countries often setting the tone. The stricter the requirements, the more attractive our product. Then there’s the particularly big asset of simple and speedy assembly, linked to a good fire safety class. At present, we offer B, but very probably we can soon move up to A2 without too many extra additives.’