www.malamacomposites.com
!
!
Malama Composites manufactures proprietary rigid urethane foams made from bio-based, renewable resources.
!
Our Bio-Foams enable customers to make their products strong, light-weight, less toxic and far more energy efficient than traditional
petroleum-based foams.
!
That is why, at Malama, we are truly GREEN TO THE CORE!
!
The Competition
Existing PUR foams are petroleum-based, toxic and difficult to recycle. A-Side: Toluene Di-Isocyanate (TDI) 3 B-Side: Petroleum polyols
Malama Technology
A-Side
Methylene Diisocyanate (MDI)
B-Side
Polyols derived from soy, castor or recycled PET
Our products are made from renewable resources, contain no toxic chemicals, and can be easily recovered and recycled.
Sustainable Advantages
Our products are cost and performance competitive withpetroleum-based PUR foams, but demonstrate significant human health and environmental benefits.
FEATURES BENEFITS
High bending & sheer strength Yields resilient, durable products
High R value & moisture resistance Ideal for insulating homes, cars, appliances Uniform density and cell structure Machines and surfaces accurately
Made from low-cost plant polyols Price competitive with petro-based foams Zero emissions (Berkley Analytical) Safer work places and living environments Fully recovered and repurposed Superior lifecycle performance
Carbon negative (USDA-NIST Study) Every pound sequesters 2.6 lbs of CO
US PUR Market
$9.5
BILLION
Construction $6.9 Billion Appliances $1.4 Billion Packaging $450 Million Industrial Design $200 Million 6 Transportation $550 MillionProducts & Applications
MP/TV and
Theatrical Sets Insulated Packaging Surfboards and Wakeboards Structural Insulated Panels (SIP’s) Orthotics and
Prosthetics Consumer Appliances Stand Up Paddle Boards Factory Build Homes Store Fixtures and
3D Signage Architectural Moldings Yachts and Power Boats Motor Homes & RV’s Trade Show Exhibits
Museum Displays Automotive Components Industrial Design Applications Pipe Insulation Products Arts & Crafts
Retailers Metal Building Structures Tool & Die Molds Formwork Marine Applications
Malama’s four main product lines enable us to address the entire global marketplace for rigid PUR foam applications.
Malama Composites has created Studio BioFoam® specifically for hand sculpting and machine shaping.
Industrial Design
Studio BioFoam® is a zero emission material with water as the blowing agent. It has been successfully tested by major studios.
!
This product also has a significant market in trade show exhibits, museum displays, 3D signage and industrial design applications.
Malama has developed AinaFlow®, a non-toxic foam for use in the surfboard, wakeboard, and stand-up paddleboards.
Consumer Products
The industry currently uses carcinogenic foam made from Toluene Di-Isocyanate. TDI poses significant health risk to the workers who pour the blanks and the craftsmen who shape the boards.
!
Additional markets for AinaFlow® include architectural millwork, consumer products, marine and aerospace applications.
Malama has released Pacific BioFoam™, a new two-part pour foam for the pharma and biotech industries.
Insulated Packaging
Biotech companies ship vaccines, blood samples and temperature-sensitive medical devices in foam “coolers.” They demand VOC-free packaging that can be more easily recycled.
!
Pacific BioFoam™ meets thermal and impact standards, as proven by Westpak, which certifies packaging for this industry.
Pacific BioFoam™ is ideal for automotive products, consumer appliances, boat hulls, door cores, metal building panels, moldings and most cast foam parts.
!
!
!
!
!
!
!
Automotive & Marine
11
The potential US market for Pacific BioFoam™ exceeds $2.4 billion dollars, over $8 billion worldwide.
Malama has developed AinaCore® as a structural insulated panel product for the building industry.
Building Materials
Typical structural insulation is made of extruded polystyrene (XPS) or polyisocyanurate (PIR) foam made from petroleum polyols and
filled with carcinogenic brominated or chlorinated fire retardants.
!
AinaCore® is a Class A fire-rated, 2-pound foam with zero VOC emissions, high R value, and no toxic chemicals or fire retardant.
13
AinaCore
®AinaCore® has the highest technical specifications of
Market Drivers
Powerful mandates drive adoption of Bio-Composites:
RSB – Roundtable on Sustainable Biomaterials
Biomaterials produced from sustainable sources
!
USGBC’s LEED Certification Program
Energy & resource efficiency; Indoor air quality
!
EPA’s Environmentally Preferable Purchasing
Environmental impact; Lifecycle performance
!
USDA’s Bio-Preferred Purchasing Program
High plant-based content; Domestic sourcing
!
DOE’s Challenge Home Program
Energy efficiency; Indoor air quality; Durability
!
!
15
Materials Evolution
“It is high time that we match the intelligence of our homes with that of our cell phones.”
CEMENT STEEL SILICON
The advent of new materials is pivotal to
ACASA System
Our Vision: To forever change the way we design and construct the built environment….
!
…through the use of sustainable materials, integrated technologies, and innovative building systems.
ACASA Precedent
“One billion people live in informal settlements of their own making,
without access to adequate shelter, dependable power, or safe water.” UN MILLENNIUM PROJECT
ACASA Mission
Our mission: To create high performance, cost-competitive, energy efficient, healthy, secure communities capable of meeting the challenges of sustainability in the 21st Century.
ACASA System
ACASA combines Malama’s foam panels with light-gauge steel framing and geo-composite coatings to enable rapid
construction of green buildings worldwide.
COLUMNS & BEAMS SIP PANELS COMPLETE SYSTEM
Extrusions carry loads and provide channels for utilities. SIP panels lock into these extrusions providing strength and insulation values 2X to 3X that of wood frame or cement block construction.
ACASA Homes
Interior and exterior surface treatments can be varied to meet the architectural specifications, geographic challenges, and
budget parameters of each project.
!
This dynamic systems approach to design and construction enables mass customization of homes at pre-fabricated cost.
ACASA Homes
Interior and exterior designs and materials can be varied to suit regional cultures, climates and environmental conditions.
Customizable floor plans within each home allow individual users to create personalized homes within sustainable communities.
ACASA Buildings
Utilizing a standardized kit of extrusions, panels and coatings, architects can design a variety of structures, from single and multi-family dwellings,
ACASA System
ACASA will forever change the way we build homes and measure their environmental performance.
!
This system exceeds ICC International Code Certification.
!
FEATURES BENEFITS
MODULAR COMPONENTRY Rapidly deployable to any location worldwide STRUCTURAL SUPERIORITY Stronger, lighter, safer and far more efficient ENERGY EFFICIENCY Lower cost of ownership; Grid independent
COST COMPETITIVE Vs. cement block, stick frame, or steel structures SYSTEMS INTEGRATED BIPV; LED lighting; Internet enabled; H
ENVIRONMENTAL INTEGRITY Zero emissions; Carbon neutral; Locally sourced DESIGN AGNOSTIC Culturally sensitive; Aesthetically inspired
ACASA Communities
ACASA Communities integrate solar, wind energy,
communications, water purification, MSW treatment, community gardens and sustainable strategies.
Factories can be sited in proximity to
communities, employing local labor and materials to the extent possible.
25
ACASA Methodology
By combing Building Information Modeling (BIM), modularized construction and integrated technologies ACASA is able to produce elegant, low-cost, high performance energy efficient
homes to meet global housing needs.
!
!
!
!
!
ACASA Construction
26
Day 1: Architectural plans are translated to machine code.
Component are milled, sorted and packed at an ACASA Center.
!
Day 2: On site steel tracks are laid on the cement foundation to which walls are erected. Windows and doors are installed.
27
ACASA Construction
Day 3: Roof trusses are installed and insulated roofing system laid. Steel cables lock the roofing system securely to the foundation.
!
Day 4: Electrical, plumbing and mechanical systems are run. Exterior and interior surfaces are coated with geo-composites.
28
ACASA Construction
Day 5: Cabinets, appliances, plumbing fixtures, lighting fixtures and communication systems are installed.
!
Day 6: The home is connected to community public utilities. Quality checks are completed and the owner can take possession.
!
ACASA Factory
29
The ACASA Factory is a fully integrated 45,000 M2 facility with the
capacity to produce 5,000 homes/year (100 M2/home). Each
home “kit” is containerized and shipped to the jobsite for assembly. This system enables:
!
1) Rapid construction 2) Zero on-site waste
3) Local training & employment
4) Fully integrated utilities & systems
5) Near-sourcing of materials & assemblies
30
Proprietary A & B side chemicals are combined on a continuous urethane foam line. The plant generates zero air emissions.
31
After a 7 days of curing, urethane foam ‘buns’ are cut to size on a Computer Numeric Controlled band saw. Each panel is sized to match a specific home and tagged for packaging
32
Roll formed steel is slit and bent into proprietary structural shapes. Members are cut to length to match building requirements.
33
Proprietary geo-composite coatings are blended, bagged in super-sacks, and palitezed for delivery to the jobsite.
34
A CNC milling line produces household cabinetry and architectural millwork using formaldehyde-free MDF and bio-based laminates.
35
The logistics center stores electrical, plumbing and lighting fixtures, appliances, computers, panels, water purification systems, as well as completed doors, windows and hardware.
36
The Shipping Center loads all components in reverse order of assembly into steel containers, one per household. These
containers remain at the job site until the unit is completed.
37
The ACASA Facility houses administrative offices, a training center, and repair shop. This facility can continue to provide for the
community with continuing education, training and security.
38
Operating 5 days a week the plant is capable of producing100 homes per week with the capability of 5,000 homes a year.
!
The plant employs 120 people plus 25 crews of 10 workers in the field.
Factory Capacity
5,000 Homes 65 Million BF 6.47 Million Feet 570,000 CF 100 M2/Home BioFoam Steel Framing GeoComposites
39
Neighborhoods
5000 homes provides 500,000 square meters of living space which provides housing for 20,000 people.
ACASA Values
40
1) Strategies that minimize environmental impact
2) Renewable energy and water-saving technologies 3) Locally sourced, non-toxic, sustainable materials 4) Excellence in indoor air quality, acoustics & lighting 5) Innovative and inspiring architectural design
ACASA Values
41
www.malamacomposites.com
7756 St. Andrews Avenue, Suite 117 San Diego, California 92154
