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WOMA 2026: Where Will Australian Wind Be in Five Years?
Recorded live at the Wind Operation and Maintenance Australia 2026 conference, Allen, Rosemary, Matthew, and Yolanda are joined by Thomas Schlegl for a panel discussion on where the Australian wind industry is headed over the next five years.
Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
Alright, let’s get started. This is the, the final event of this three day marathon. Uh, where will we be in five years? And I have, uh, pretty much everybody from the Uptime podcast and Thomas Schlagel from eLog Ping. Uh. Uh, Rosie and I had a big argument before we all came about what we were going to be in five years, and Rosie’s and my opinion differed quite a bit just on, that’s, uh, that’s what led to me suggesting the personality test because yes, and that was, that’s actually a really good suggestion.
So I know something about myself now, but, uh, I, I think talking to people here, watching the presentations. And having an American slash European perspective on it. I think every, everybody can chime in here. Australia’s probably on a better pathway than a lot of places. Yeah. Well, I know I’ve been back in Australia for about [00:01:00] five years, five years.
Before that I was in Denmark. I left Australia. Because I was so like in despair about the state of renewables and also manufacturing and just doing smart engineering in Australia. Um, so yeah, when I came back five years ago, I was a bit shocked at how different things were in Australia. And I was also, you know, like I will say that it, we were, we were behind like way less mature than other, um, markets in terms of how we operated our wind energy assets.
Um, and it’s changed so much in five years, so like a half day, if I’m making predictions for where we’ll be in five years time, I have to, you know, like use that as a, it, it’s probably gonna be more than you would think in five years, just based on how far we’ve already come in, in five years. Um, so yeah, I think that five years ago people were trusting a lot more in the full service agreements.
Um, definitely there’s very few people who are still naive that that’s just, you know, um, a set and forget kind of thing that you [00:02:00] can do and not worry about it. Everybody’s now aware that you need to know, um, about your assets and we’re already to the point where there are like a lot of asset managers know so much, um, and, you know, have become real experts and really wasn’t, wasn’t the case five years ago.
So. I’m hopeful for that. Um, you know, that it, it will continue and yeah, probably at a faster pace than, um, what we see elsewhere. I think Australia is a really attractive market, not just for developing new wind projects, but also for developing all of the kinds of supporting technologies, which is, you know, like a lot of the people here either using or developing those kind of technologies.
And some of our challenges here make it the perfect place to, yeah, develop new text because. Things are, it’s really expensive to do repairs here. Um, the operating conditions are harsh and so things wear out and it just means that it’s, you can put together a positive business case for a new tech here much sooner than you could overseas.
So I’m really [00:03:00] hopeful that we see, you know, like a whole lot of innovation, um, in, in those kinds of technologies that are gonna help wind energy get a lot more mature. And even hearing some of the answers from last year to this year, you see that shift. Uh, I was really shocked last year how much reliance there was on.
The FSA and now I hearing a lot more discussion about, all right, we need to be shadow monitoring. We need to be looking at the, the, the data coming off, trying to hack, break into the passwords to get to the SCADA system, which was new, but I feel like very Australian thing to do. Matthew, you’ve been in the small business in Australia for, for several years in the wind business.
What do you see? I mean, you’ve been in it like for five years now. Plus actually more than that, uh, I actually did my first wind farm around 20 oh 2001. Okay. Or 2002. Um, that was from a noise perspective. So I, I’ve seen things, you know, the full cycle. Um, you know, there were many years of [00:04:00]despair, the whole, um, stop these, stop these things.
I’m actually featured, I was featured on Stop these things. So, um, don’t, don’t Google it. It was pretty horrible. So, um, we did a lot of work around infrasound and noise impacts and so there was many years which were, were pretty horrible. Um.
Over that time, I sort of relate to my daughter. My daughter’s turning 21 soon. She is a beautiful girl, turning into an adult, a wonderful adult, and it’s, I think the wind industry is really growing, maturing, growing up, and you know, is wonderful to see. And I think we are, we’re only gonna get better, stronger.
And I think one may, one note I made here is that now they’ve got wind, solar batteries. I just think it’s unstoppable, so I’m super optimistic that we’re only gonna keep, you know, raising that bar. Well, if you look at where Australia is compared to a lot of the places on the [00:05:00] planet, way ahead, in terms of renewable energy.
I mean, you’ve got basically $0 in electricity for, because of how much solar there is, plus the batteries are coming in and, and the transmission’s coming online. And I’m talking to some people about, uh, what these new developments look like. If you’re trying to develop some of these projects in the United States, you’re not gonna be able to do them.
There’s, there’s too many regulatory hurdles, and it seems like Australia has at least opened some of the doors to explore. Uh, people in America, the companies in Europe are gonna be watching Australia, I think in, in terms of where we go next. Because if Australia can pull off pretty much a renewable grid, which is where you’re headed, others will follow because it’s just a lower cost way of running a, running an electricity grid system.
Yeah. Now I need to perform my, um, regular role of being a Debbie Downer. Um, I, I think that there’s, there’s big challenges and it’s definitely not, um, a case of [00:06:00] the status quo now is good enough to carry us through to a hundred percent renewables. Um, there are some big, big problems that need to be solved.
Like, uh, solar plus batteries in Australia is, is going amazing and it’s gonna do a lot. It’s not gonna, it will be incredibly hard to get to, you know, a fully renewable grid that way. The problem with wind is at the moment, I mean, it’s getting more expensive to install wind now and we don’t only need to install new wind farms, we’ve also got existing wind farms that are retiring.
So we need to either extend those or we need to, um, you know, build new wind farms in their place. So we do need to get better there. And then I think that the new technologies, like, you know, I’m the blades person and the bigger blades are bigger problems like, like dramatically. I don’t think that your average, um, wind farm owner or wannabe wind farm owner is aware, like actually how many more problems there are with big blades compared to smaller ones and.
I think that, like I said earlier, I [00:07:00] think Australia’s a great place to get those technologies, um, you know, developed. But we, we need to do that. That’s not like a nice to have and oh, everything will be a little bit better, but if we can’t maintain our assets better and get more out of them, um, we also need improvements with manufacturing.
But it’s not really an o and m thing. I won’t talk too much about it. But yeah, I think that like we can’t be remotely complacent. Well, I think in, in Europe, uh, Thomas, you actually spent several months in Australia, and you’re obviously from Austria, so it’s an Austria Australian connection. Do you see the differences between the Austrian market, the German market, and what’s happening here in Australia?
What, what do you think of the comparison between the two? So, what I, what really was fascinating from was the speed of, um, improvements we see here in Australia. It. Um, just for me, wind industry in my young industry, sorry, was always rather slow in Europe and [00:08:00] like not really adopting. Um, and here, sorry.
For example, last year you asked the question how many. Of the audience to use sensors for shadow monitoring and no hand was raised right. It was zero silence. And uh, this year we even had a few percentage on, on sensors on the, on the cido. So you see only within a year like this gradually graduated, improvements are happening and I think that makes such a, um, speed in, in improvements and that will.
Close to the rescue again.
Thank you. And that, um, that will bring Australia to a big advantage. Um, especially I think overtaking, uh, at a certain point, and it would be great to see in five years from now, um, maybe Europeans, Austrians, uh, coming to Australia to. [00:09:00] To learn and not the other way around. Yeah, and, and especially with Yolanda working for the biggest energy company in Denmark, uh, in America, you see how Americans react to change and, and the reluctance to move forward on some of the things we talked about this week, which are, do seem to be moving a little bit quicker.
There is more an acceptance of CMS systems here. And on in the States, it seems like you have to really fight. A lot of times to get anybody to listen, to do something because it’s all, it’s financially driven in some aspects, but it’s sort of like, we don’t do that here, so we’re not gonna listen to it.
What’s been your experience being on a, this is your first time in Australia, what, what has been your experience this week and what have you learned? I was very pleasantly surprised by just the amount of collaboration that everybody really wants to have here and the openness to, to do so, and to learn from each [00:10:00] other, um, and to accept just, you know, if you’ve seen an issue and or someone else has seen an issue, then you can really learn from each other.
And it doesn’t necessarily mean that you have to silo yourself as much as, as you typically do in the United States. I mean, it is a different culture, right? And so it’s just. Honestly, hats off to, to Australians for, for being able to, to work with each other, so, so well, yeah. The discussions out at the lunchtime and the coffee area were uniquely different than what we generally will see in the United States.
And Matthew, you’ve been around a lot of that too, where it kinda gets a little clique. But here, I mean, obviously, I mean, not just human nature, but on some level I felt like, oh, there’s a lot of interaction happening and it’s really loud. So people are engaging with one another and trying to learn from one another, or at least connect.
And I, I think in a lot of times in Europe, there’s not a lot of the connection until the, the drinking starts, you know, at about 10. Uh, but. Uh, Matthew, did you see that too? [00:11:00] Like I was really pleasantly surprised. That was a good thing to see here. Yeah. And in my former life as a consultant, I dealt with, you know, construction, uh, road rail, you know, I mining a whole range of industries.
And, um, one of the reasons why I’ve stayed in wind is ’cause I, you know, I love the people, you know, I love you all. So, or, um, but no, I think, um, the. The collaboration, the willingness to talk, um, the willingness to share ideas. And I think, I think I’ve been super, super, super happy about the way the panels have run, you know, everyone’s willing to share.
Um, yeah, I’m, I’m just stoked. Yeah, Rosie, this is all your fault, honestly, because Rosie was always the, the contrary opinion. So I would say something and Rosie would feel obligated to say something as the opposite. But when, when we all started this discussion about, uh, a, a wind turbine conference, you had been to a bad wind turbine conference in Australia and I had been to a really bad one in the States and we were just, okay, that’s enough.
And the movement [00:12:00] toward, let’s get some information, let’s everybody interact with one another. Let’s, we will give all the presentations to people at the end of this so you can access data. You’re not spending a ton of money to come. That was a, a big part of the discussion, like, I’m spending $5,000 to listen to sales presentations for three days.
I don’t want to do that anymore. We try to avoid that in this conference. Hopefully, if you notice that and, and, and. I guess the conference board is up here right now. Are we gonna do Woma 2027? Are we gonna decide that today? Or. Yes, yes, the website is live.
Um, I also wanna take this opportunity to, um, thank the, the sponsors of the event. And I hope that you’ve noticed that it’s not like these aren’t the sponsors of normal events where they’re like, okay, we’ll give you a bunch of money and then we’re gonna stand up and talk at you for half an hour about our new product launch or whatever.
Like these sponsors haven’t, they haven’t got back [00:13:00] in the traditional way that you, you would with a kind of, um, event. So I’m really grateful for the very high quality sponsors that we’ve got. And, um, yeah, I just, I, I dunno if I’m allowed to share a little bit about the, the economics of this event. Um, if we didn’t have the sponsors tickets would cost twice as much.
So, um, that’s one thing. But then the other key thing that we. Really couldn’t do it without sponsors is that we didn’t, our event didn’t break even until about a week ago because everyone buys their tickets late. Um, so yeah, the, the, we would’ve been having heart attacks, um, months ago about our potential, you know, bankruptcy from running the event if it wasn’t for, um, yeah, the, the great sponsors.
So thanks to everybody that did that. Um, and everybody that attended consider buying a ticket earlier next time. Um, I, I’m the worst. I often buy my ticket the day of, of, of an event. So it’s, you know, like it’s a pot calling the kettle black. But, um, yeah, that’s just a bit of the, [00:14:00] the reality. And we have a number of poll questions.
Uh, let’s get producer Claire back there to throw ’em up on the screen. So while we’re doing that, we should really thank Claire. Claire has been amazing. Yeah. Thank you, Claire.
So the emojis are from Claire. Claire, clearly here. Uh, how do you feel about the, the current state of the wind industry?
Hopefully there’s more smiley faces after this week. Well, alright, we’re a hundred percent rosemary.
We had to put the one with the, yeah. And for me personally, um, I used to feel a lot more optimistic when I worked in design and manufacturing. And then when I come into operations, that like automatically makes you feel a bit more pessimistic. And then me specifically, like I only get involved when really bad things are happening.
And so sometimes for me, like it’s easy to think. [00:15:00] When technology is just not good enough and, you know, I need to find a new industry to move into. So, uh, it is good to talk, talk to other people and, you know, like bring my reality back to a kind of a midpoint. And I, I just like to say, I, I think, I mean maybe there’s been a bit of OE em bashing here maybe.
Um. Um, however, we need really strong OEMs, so I just wanna put a shout out to the OEMs and say, yeah, we absolutely need you. So just keep doing it. You will keep doing better, so thank you. Yeah, it’s a difficult industry to be in and we put a lot of demands on them and they, they’re pushing limits, so yeah, they’re gonna run into problems.
That’s fine. Let’s just find solutions for them. Alright, uh, next question, producer Claire. What is the best thing you learned at Woma?
This is not multiple choice. You can write whatever you want. Stealing passwords. [00:16:00] Did any of us learn anything? Unexpected
contracting? Oh yeah. Get the contract right? Oh yeah. Yeah. Dan was really good. Yeah, Dan was great about contracting, looking on the other side of that fence. Cybersecurity is not that big of an issue in Australia. That’s some big thing in Europe, so yeah, it is. I was surprised by the environmental factor in Australia.
I was surprised about the birds. Yeah. Everyone who wasn’t in the birds workshop yesterday, Alan was freaking out about, about how Australian wind farms have to manage birds and um, you have to freeze a bird for 12 months. I don’t, where do you have to freeze it for a bird? I don’t know. But that, it just is a little odd, I would say.
Yeah.
All right, Rosemary, you gotta take away Rosemary’s phone. Alan’s personality test. Yeah, there we go. That was not me. Wind farm toilets was a good one. Thank you, Liz, for, for raising that. [00:17:00] Yeah, I know when I worked in, um, Europe and Canadian wind farms, I would have to strategize my liquid intake for the day.
Balancing out tea will help keep me warm, but on the other hand.
Did everybody meet up with someone who had a solution? That was part of the goal here is to put people with solutions in the room with people with problems and let you all sort it out. So hopefully that was one of the things that happened this week. Or if you haven’t connected here, be able to connect with over LinkedIn or over coffee later.
And the networking on the app and networking page on the website. Right. So you can actually use that now that’s all live. Yeah. So you can, you can connect through there if you’ve selected to. To keep your contact information open. Yep. You can connect through there so it’s easy to, if you need somebody to find my or Matthew’s email, you can just find it right there and we’ll upload the presentations, as you said.
Right. The presentations we uploaded. But you have to select into that, Matthew, is that right? Also, the speakers [00:18:00] have to approve them as well. Right. And the, and all the speakers, you know who you are. Can let us know if we can use your slide decks to public size them. I didn’t see anything there that looked highly classified, so I think that would be fine.
Alright. This is really interesting. Convince OEMs to install better pitch bearings. That’s very true. Okay, thanks you for that. Claire, what’s the next one?
What do you wish you learned more about? So Matthew did a tour before the conference several months ago. And, and went to a lot of the operators and said, what would you like to hear about? So the things that were, uh, the seminar or the different workshops and all that were the result of talking to each of the operators about what you would like to see.
So hopefully we covered most of them. Uh, obvious There. There’s some new things. Gear boxes. Yeah. I figured that one was coming. Tower retrofits. Okay. Good, good, [00:19:00] good. ISPs? Yeah. Life extension. Yeah. A lot of life extension. I agree. Well, we’re gonna run into that to the United States also. Asbestos. I’ve read some things about that in Australia.
Okay. Which leading protection work by name. I do, I do have, well, lemme see. I do know that answer, but you’re gonna have to talk to Rosemary to get the, the key to the vault there. I I also think that you can’t assume that it’s gonna work in Australia. I think that, that like really seriously, I, I wouldn’t, um.
I wouldn’t replace my entire wind farms leading edge protection based on what worked well in Europe and America. So, um, I would highly suggest, um, getting in touch with me and or bigger to get involved in a trial if you, that’s a problem for you. Yeah, definitely get involved in the trial. Uh, more data is better and if you do join that trial, you will have the keys to the castle.
They will tell you how all the other pro uh, blades went. Uh, trainings and [00:20:00] skills, obviously that’s a, that’s a international one. When does ROI really happen? Yeah. Yep. We hear that quite a bit. Needs have proven good products for leading edge erosion. Yep. Okay. Yeah. So the que I guess one of the questions is, is that we did not on purpose, did not have any vendor things.
I haven’t mentioned my product once this week. I, because I don’t want to, you know, that’s not the point of this conference, but should we. I don’t know. I mean, that’s a, should we have people standing up and I don’t know if it’s standing out there, but able to, to trial things. Yeah. Yeah. I agree. I agree with what.
I, I don’t, I don’t want that. Oh, yeah. No, I don’t want that. But it’s not my conference. Right. It’s, it’s everybody who c comes and wants to participate. What do you wanna see? Do you wanna see 10 leading edge products out in the hallway or, I didn’t mind that people were putting like stickers and like little knickknacks out on [00:21:00] tables.
That was fun. Rosemary’s got a, a satchel full of them. Alright, Claire, is that the last one? There’s one more. All right. Hang on for one more. What’s your biggest takeaway from Woma? That you’re gonna buy your tickets early for WMA 2027, hopefully, and you’re gonna sponsor. I had a lot of people come up to me and say they would like to sponsor next year.
And that’s wonderful. That will really keep the, the cost down because we’re not making anything off of this. I’m losing money to be here, which is totally fine ’cause I think this is a noble effort. Uh, but we will keep the cost as low as we can. We have an upgraded venue from last year. If you attend last year we were at the library, which was also a very nice facility, but this is just another level.
Mm. Um, and the website has the ability to register interest in sponsorship. Yeah. Yes. Yeah. Yeah. I’ve already got, uh, Jeremy’s already shook my hand. He’s already committed. Yeah. [00:22:00] Uh, I think we’ll have a lot of three pizzas on, on sponsorship for next year, and that’s good. Uh, that tells you there’s some value to be here and, and, uh, connect stickers, Rosemary stickers.
There you go.
I like whoever put calories up there. That’s funny. Yeah. You know the thing about, uh, this city is you can eat and it’s so dang good. You can’t do that in the states. You can’t just walk around in a random. Downtown like Detroit, Chicago. There are places you can eat there, but every place you walk into in this city is really good food.
It’s crazy. Yeah. It’s, it’s uh, sort of addictive. I’m gonna have to go home on Saturday or not gonna fit in my seat. Um, alright. This is great. Yeah. We really love, um, constructive feedback. I think we’re all, or at least. Vast majority of us are engineers. We like to know about problems and fix them. So, um, most of us can’t have our feelings hurt easily.
So, you [00:23:00] know, be very, very direct with your feedback. And, um, yeah, I mean the event should be different every year, right? Like, we don’t wanna do the exact same thing every year, so, um, it will change. Yeah. Yeah. And there is a survey going out as well, so Georgina will send out a survey. All right. So those surveys go to who?
Matthew, are they going to you or are they going to all attendees and go? I think it goes back to Georgina, but we’ll, okay. Yeah. Great. So if you do get a, a form to fill out, please fill it out. That helps us for next year. Are we gonna be back in the same city? I say Yes. Yes. Yeah, this place is great. Sydney is also lovely.
I spent an hour there at the airport. It was quite nice, but it was long enough. As I learned from people from Melbourne that Sydney is not their favorite place to go. So I guess we’re, we’re here next year. Is there anything else we need to talk about? Um, no. I mean, I’ve just been, uh, my favorite thing about this event is like the, the size of it and that people, uh, like very closely related in what we’re interested in that.
It’s not like a, [00:24:00] you can put any two random people together and then we’ll have an interesting conversation. So I’ve really enjoyed all of the, you know, dozens of conversations that I’ve had this week. And, um, yeah. So thank you everybody for showing up with a open and collaborative, um, yeah. Frame of mind.
It’s, yeah, couldn’t be done without everybody here. We do have a little bit of an award ceremony here for Rosemary, so we actually put together. A collage of videos over the last, um, five years. Uh, this is news to me. What? Yeah. Surprise. All right. Let it roll. Claire.
Champion Rosie Barnes is here. Everybody.
Climate change is a problem that our politicians don’t seem to be trying. Particularly hard to solve. This used to frustrate me until I realized that as an engineer, I have the power to [00:25:00] change the world, and unlike some politicians, I choose to use my powers for good.
So I made a gingerbread wind turbine, I mean, a functional gingerbread, wind turbine, functional and edible. Everything except for the generator is edible. Alan, what were some of your takeaways from our talk with, uh, with Rosie? Well, I just like the way she thinks she thinks in terms of systems, not in terms of components.
And I, I think that’s a, for an engineer is a good way to think about bigger problems. On today’s episode, we’ve got, well, some exciting news. Number one. Rosemary, uh, Barnes will be joining us here today as our co our new co-host. Yeah, thanks. Thanks so much for having me. So, you know, one wind turbine with, um, wooden 80 meter long wooden blades.
Yeah. Like, that’s so cool. What a great engineering challenge or, you know, craftsmanship challenge, um, there, but, you know, I’d like to see one [00:26:00]wooden wind turbine blade, but not, not more than that. It’s a, it’s a cool, it’s a cool novelty. And then burn it, right? If you burn it, then you’ll catch the carbon. We need someone within the Australian wind industry to start up a, a better conference.
Um, you know, it should be allowing you to kind of put your finger on the pulse and figure out, you know, what, what’s the vibe of wind energy in Australia at the moment? Um, what are the big problems people are having and then, you know, some potential solutions, some people talking about things that are coming up that you might not have heard about yet.
I just think that it’s much easier to get a good value conference from a, like a, a small organization that is really dedicated to the, um, topic of the, of the conference. So as part of the Uptime Wind Energy Podcast, Rosemary,
the YouTube ci, these little gold plaques. So this is actually, this is your first gold plaque, but you have two [00:27:00] silver plaques also. ’cause engineering with Rosie reached a 100,000 subscribers. Uh, the uptime also reached a hundred thousand subscribers a while ago, but we reached 1 million. This is the first time I, we’ve been in person, but I could actually hand you this award.
So congratulations Zi. Very, very well done.
Thank you. This is treasured and, um. Yeah, added in. Nothing like that has ever happened to me before, so I’m bit overwhelmed. I, I’m interested to know, we got that Wheel of Fortune footage from, ’cause I thought that was lost. Lost forever. It’s over. It’s on YouTube. Sadly. It is. It’s 24. All the episodes Rosemary competed in the Wheel of Fortune.
She was on four times. Six times. Six times. Sorry. There’s only four available on the internet. You may have white scrub tube. I wanna massaging Lazy Boy.
Is that your husband? He made me get rid of it. He is like, that thing is hideous. And [00:28:00] it was, yeah. Thank, thank you so much. And I mean, yeah, this is the, the uptime wind energy. Um. Yeah, podcast achievement. It’s, um, it’s crazy how, how popular that, um, it’s in insanely popular since we crossed the 1 million mark that was a while ago.
We’re up to 1.6 million right now. We’ll cross 2 million this year. I know it’s, it’s clear Claire’s reason. It mostly clear and it honestly is. Uh, but wind energy is a big part of the energy future, and as I’m realizing now, uh, when you start to reach out to people, you realize how important it is for the planet and for individual countries that wind energy is part of their electricity grid.
So the, the information we exchange here this week is very valuable and reach out to others. I think that’s part of this wind industry and Matthew’s pointed out many times, is that we share. So unlike other places, uh. Wind energy likes to work together. And that’s great to hear and it’s great to participate in.
So I wanna thank everybody here for attending, uh, this conference. Thank you to all the sponsors. Uh, you [00:29:00] made this thing possible. Uh, as Matthew has pointed out, we’ll be at WMA 2027. The website is live. So, uh, listen to Rosie. Please register now. Uh, and uh, yeah. Thank you so much for, for being with us. And we’ll see you in February right here.
Thank you.
Renewable Energy
Plaswire’s Blade Recycling Breakthrough
Weather Guard Lightning Tech

Plaswire’s Blade Recycling Breakthrough
Andrew Billingsly, CEO at Plaswire, joins to discuss how the company recycles wind turbine blades into construction materials, timber replacements, and utility products. Plus carbon fiber recovery, zero-dust cutting technology, and plans to license blueprint factories worldwide.
Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
Andrew Billingsly: Exactly.
Allen Hall: Are we good?
Andrew Billingsly: I’m truly impressed with this great operation you’ve got. You really moved this forward, isn’t it? That’s great. We try. Yeah.
Allen Hall: Yeah, we try. We’re not
Andrew Billingsly: trying. You do.
Allen Hall: So I, I will put an intro to this episode when we get back to the states. So I’m just gonna say, Andrew, welcome to the show.
And then we will start talking.
Andrew Billingsly: Where do I look
Allen Hall: here?
Andrew Billingsly: Right? Just, just here.
Allen Hall: Yeah. Don’t worry about those. We’ll figure that out later. That’s,
Andrew Billingsly: yeah. A bit of AI in that. Yeah.
Allen Hall: Yeah.
Andrew Billingsly: And you’ll see as well. Andrew, welcome to the program. Thank you very much, Alan. Joe, really great pleasure to be here today.
Allen Hall: So we’re here to learn about PLA wire and all the great things you’re doing in Northern Ireland because you’re involved in a lot of recycling efforts in wind, outside of wind.
You’re doing very novel things, which I think the world needs to hear about. Let’s just back up a minute, because not everybody. And particularly [00:01:00]in North America has heard of PLA wire, even though you, you’re all over LinkedIn. What does PLA wire do? What is this basic fundamental of PLA wire?
Andrew Billingsly: Basically, we’re a processor of polymers.
Okay?
Andrew Billingsly: So that’s how we see ourselves, that’s how we frame ourselves. We’re a polymer processor with a waste management license. Uh,
Joel Saxum: I think the important thing here, and this is why I wanted to have this conversation, you and I have been talking in the background for a few years, is. The rhetoric around a lot of the world is we have this problem with recycling blades.
We can’t figure it out. Nobody’s got any solutions. Um, and if they do, it’s very agricultural as we say, right? They’re just grinding them up, using ’em in this, that, and what I tell people is like, no, no, you’re incorrect here. There are people doing this. There is, there is solutions out there. It just needs to be, we need, we need to talk about it.
We need to put it out there.
Andrew Billingsly: Absolutely. Uh, I fight very hard to tell the true story. Of course, there’s a [00:02:00] lot of greenwashing in every sector of every industry in the world, and those who do it right have to defend themselves. I mean, unfortunately, that’s what we have to do. Fortunately, mostly we’re able to do that if we work hard at it.
For us, we do not have a problem in general, dealing with wind farm waste. Wind farm waste is for us blades. Because we’ve taken a pragmatic approach to it. We have to look at how we deal with any waste coming into our, uh, process to ensure it’s environmentally handled, that it’s handled correctly, environmentally, that it meets a price point so that whatever we do with it, we can sell that product, ensure that it’s sustainable in how we operate, and it’s fully circular.
So that’s how we’ve addressed wind blades. We were invited into the industry and we worked out what was needed in the industry. But [00:03:00] before we went all full on with it, we had to make sure we could make products that was saleable, that was usable, and could be utilized within the industry wherever possible.
But you thought outside of the box
Allen Hall: quite a bit because the way I think the wind turbine blade recycling efforts have gone is to say, well, we’ll, just like Joel was saying, we’ll just grind them up. You’re taking polymer outside of the wind blade world that you’ve been using in aerospace and other industries and saying the valuable part of the wind turbine blade is the fiber and the resin, whatever remains there.
If I combine that with other polymers, I can create products with a lifetime that can replace other more expensive items, metal items, cement items. That is the, the, the wisdom that went into what you have done. How did you come up with that?
Andrew Billingsly: I think I was born outta the box. Frankly. I’ve been told that several times.[00:04:00]
We’re a solution orientated company. Uh, I was talking recently to somebody about how we built our first factory in Northern Ireland that went up in 10 weeks. That’s 20,000 square feet. And because the pressure we were under, we had that factory erected and in operation in 10 weeks. And that’s just a fact.
That’s a recorded fact. And I looked back only two years later and said, heck, what did we do there? Yeah, because we had to do it. So we did it. Yeah. We looked at the problem with the wind blade and we thought, we’ve gotta get a good solution for this. And we’d done that years before with aviation. We were presented with the challenge to deal with plastics arising from the manufacturer’s seating.
Now the US produces all the plastics for that sector. It comes into Europe for manufacturing seats, a lot of it local to where our factory is, but nobody had a solution. I have to put my hands up now. I broke a few rules here. I filled two [00:05:00] barn up with this material chopped up and ready to sell, but I actually couldn’t sell it, but I knew there was a solution.
So I worked on that for perhaps 18 months and then it worked. And today we are the main, uh, processor of this plastic that comes out of aircraft seating manufacturing, possibly. We still are the only one doing that.
Allen Hall: So you actually take the plastics from the manufacturer of seating and there’s a lot of scrap that’s involved in that.
Andrew Billingsly: Yep.
Allen Hall: You take all that plastic waste, you bring it back into your facility, you recombine and pelletize it again so that it can be reused somewhere else.
Andrew Billingsly: Yes, that material goes into, uh, an extrusion process with another company now. Okay. Wow.
Joel Saxum: But, but that’s the same thing you’re doing in wind right now, right?
The making it circular, but you’re adding or you’re, you’re adding other second use plastics to it.
Andrew Billingsly: Yeah. So our outta the box thinking was looking back in 2018, how do we grow our business [00:06:00] because recycling plastics within the extrusion world and the injection molding world. What’s getting more internal companies getting better at dealing with their own waste and putting it back into the circuit.
So what’s the waste? Nobody wants. It’s the really mucky stuff. It’s this material that comes out of, for example, bio digesters that take the supermarket garbage, the yellow label food that people don’t buy because it’s really is in a bad state. And that goes for digestion and they pull outta those biodigester 10% plastic waste.
Hmm. That is a really difficult product to deal with. And not only that, you also find a similar volume of waste coming maybe 24 tons a day, in some cases, sometimes more from the municipal waste processing centers as well. All this waste plastic goes for incineration. Nobody knows how to economically recycle that.
So we took on that challenge and produced what we call [00:07:00] RX polymer, which is. Hm, going through pattern now. I got the number only yesterday incidentally for it. And, uh, this enables us then to combine plastics that would not normally combine. So think about polyethylene, polypropylene. Yeah, they mix, but then add in nylon, adding polyester.
PET, add in styrene, adding up to 8%, uh, PVC materials. It’s an unknown for a polymer engineer, but we did that. And we cooperated with the university in Ireland to prove it. Uh, this is the technology Uni University in Shannon, and we still have an extremely good relationship with them. So we have this polymer.
Along comes COVID, we worked with it. We did the deep dive. We went out to find out could we make product with it, could we make a product people wanted, and could we sell that product because what’s the point otherwise? And then after COVID. [00:08:00] We went out into the market, met with aviation, had a very substantial and transformative almost meeting with Paul Bella, director at Boeing.
So by the end of the year we’d worked out along with some discussions with Air Airbus and with Tarmac Aero serve, how we could help them with their composite wastes as part of our RX polymer January, 2023. We got sucked into a, into the wind sector.
Allen Hall: Mm-hmm.
Andrew Billingsly: January, 2023. We got sucked into the wind sector with a significant phone call from Ted.
We had a meeting and agreed to take their first blades. We went out bo more land and that was start of a journey.
Allen Hall: Okay. So it just calls you up and says, Andrew, I need you to start recycling our offshore, mostly offshore or all offshore blades.
Andrew Billingsly: These were initially on shore blades. On
Allen Hall: shore blades. Okay.
Andrew Billingsly: And they said, did we know how to do it? Could [00:09:00]we do it?
Allen Hall: Okay?
Andrew Billingsly: And we said, yes.
Allen Hall: You said that? Yes. Without really knowing if the answer is yes.
Andrew Billingsly: Yes.
Allen Hall: Okay. I, I think that one of the things, I’m gonna back up just for a minute here. One of the things about Northern Ireland that people in the states don’t really realize is plastics and ejection molding are a focal point for Northern Ireland.
Roy, which is the big plastic comb. Brush manufacturer is based in Northern Ireland, so there’s a tremendous amount of plastic knowledge, injection molding knowledge sitting right in the same area. So hearing your story just makes me think, yes, this all starts to make sense now that, that the whole region is a, uh, epicenter in it, so to speak, of how to think about plastics working with shorts and bombardier and all the now Airbus and Boeing.
Those people are brilliant and you’re cut off the same limb of the tree. Right. [00:10:00] Where are these products now being used? So you now you’re getting blade from Wared and you, well, let’s talk first.
Andrew Billingsly: You have other customers besides Wared now you have some big names there. Oh, absolutely. So we do work with Airbus.
We do work with Boeing on the aviation side, but we’re talking wind today. Uh, so we have Sted, we work with Eola, Scottish Power Renewables, work with GE Verona. RWE uh, a host of them actually just goes on and on, you know, and it’s very important to serve these companies as best we can. Uh, we’ve recently started working with EDF and taking first fleets from a lot of these first fleets of blades from these companies.
We have a contract with BNM, which is in partnership with Ocean Wind for the future. BNM is B and Owner one of those great stories of a dirty company in the sense of producing. Fuel for, uh, households from Pete, which is extremely smoky and so forth, transforming to being the best [00:11:00] when it comes to, uh, renewables in Ireland.
Wow. Wow. Yeah,
Joel Saxum: I didn’t even know you could do that. Make fuel out of Pete. I just knew you made whiskey out of it.
My knowledge is not as good as your, your knowledge. Uh, but so questions for you. Then you have all these other customers coming in. You’re bringing in plastics from other areas and other sectors. How many right now as it sits, how many wind blades can you guys run through, you think? What does a yearly put throughput look like?
So
Andrew Billingsly: when we get to capacity as we grow the business, we’ll be able to process up to 11,000 tons of blades on our site.
Joel Saxum: Okay.
Andrew Billingsly: Whoa. Which is a good size capacity. Yeah. Uh, far, far in excess of what we expected, but that was to do with development. We moved from putting 10% blade into our finished product to 30%.
Joel Saxum: Yeah.
Andrew Billingsly: It was a big step. We achieved that in March this year, and it was just a. Happy days. And,
Joel Saxum: and when we talk product, right, we’re talking the RX polymer, but what is the end product? What can that be used for?
Andrew Billingsly: So the end product, uh, we can directly [00:12:00] replace virgin plastics in certain situations in the construction industry.
Things like protection board, shuttering board and that type of thing. For, uh, precast concrete, there’s a lot of precast concrete products are manufactured because it’s easy to do with, uh, concrete and to use virgin plastics. It’s just not even thought of doing that. But with our RX polymer and the combination of a fiber base in it, we can produce precast concrete products, which outperform concrete versions.
We’ve now got a polymer version, which won’t crack through temperature, variation through vibration, through wet and dry cycling, that type of thing. Wow. It’s kind of no brainer in a sense. And then on the timber replacement,
Joel Saxum: scour protection, offshore wind.
Allen Hall: There’s certain, well being in Northern Ireland, there’s a lot of wind and rain and sea and all the above.
Oh yeah. It’s
Andrew Billingsly: plenty of all of those. There it is. Definitely. It’s just wet and a bit like Glasgow, plenty of rain, you [00:13:00] know, and or Seattle’s not so different actually. It’s sure. Very similar. It could be quite similar. Yeah. So, and timber replacement is a big thing because the supply of timber cannot meet demand.
Yeah. To try and accelerate the supply of timber. They accelerate the growth of the trees using hydrocarbons in the form of fertilizers. And it’s not really gonna go anywhere in the right way. But to be able to put out product now, which outperforms timber for the utilities is a logical step for us. And that’s what we’ve done.
Producing poles and posts, which are fiber reinforced, which outperformed timber for the utility companies. Just one design by one utility in the UK consumes 33,000 tons a year. It is madness. I know. But we can offer them a product which lasts a minimum of 30 years certified versus a timber version that because of the regulations regarding, uh, preservatives, it could only last between eight and 10 years.
Allen Hall: Oh, [00:14:00] sure. Well that makes a lot of sense. So you’ve, you’ve broken through the barrier of blade recycling into now almost consumer products, industrial products, construction products. Uh. What’s next? Where are you going next? You gonna start making airplanes and cars out of this material or
Andrew Billingsly: no? That I fell outta the box actually bumping my head so I can’t go any further.
Um, where do we go from this Look, we are always going to be looking to be better at what we do, so on the blade side, we have great cutting technology that everybody should look at and consider doing something at least similar. So no dust. Very important, and we are moving sometime next year. We haven’t got a date for this yet, where we’ll have a robotic cutting system with absolutely no ze, no dust at all.
Zero dust. That’s amazing. Yeah.
Joel Saxum: That’s a, that is a, that’s a big problem in like the states for plane recycling. The, the [00:15:00] regulations around dust and um, and how close you can be to residential areas and siding and all those kind of things.
Andrew Billingsly: If you’re making dust and it’s landing on the ground, it’s gonna be there forever.
So don’t make it.
Joel Saxum: There you go.
Andrew Billingsly: That’s the fact. Um, the idea of the robotics is also to be able to recover the carbon fiber, stay in the center of the blade.
Joel Saxum: Yeah. ‘
Andrew Billingsly: cause carbon fiber is heading towards being a shortage product. And we have the opportunity to preserve that and re reuse that product effectively.
If you see the carbon fiber in a blade and the big blades, 70 meters and so forth, you go, wow, it’s pencil thickness. You don’t want to see that getting weight.
Allen Hall: Right.
Andrew Billingsly: So using expensive
Allen Hall: too. Yeah.
Andrew Billingsly: Using, yeah, it’s very expensive. Get more so, you know, we are using carbon fiber for novelty. Things like fass in cars and so forth, right.
Or wrongs and other matter. But it’s utilizing a product that needs to be going into better applications. No doubt about it. So we’re going in that way to improve the cutting technology. And then [00:16:00] another area is a recyclable blade. So we are talking with the developers of the original recyclable Blade technology about should we be working with them to operate a facility to enable that future technology to become operable.
It’s okay to sell the product, but are you recycling it afterwards?
Allen Hall: Right. Can you break it down and get the fiber out of it? Yeah.
Andrew Billingsly: So they’re early discussions and we’d like to progress those over time and achieve a success for everybody there.
Joel Saxum: So Audi, the, the, the facility in Ireland, you’re doing a lot of process improvement.
You’re getting better and better and better, but you can, you can process a certain amount of tons there per year. Are you looking at mainland Europe, US South America? Are you, are you moving around yet or,
Andrew Billingsly: yeah. You are a mind reader, aren’t you? I think. Come on now. Look. So we are working with the crown estate.
I don’t know, how do you know about the crown estate? Very, uh, influential party, uh, regarding offshore wind [00:17:00] and onshore wind. Okay. And we are working on a feasibility study with them to create a blueprint factory and put up a new facility in the United Kingdom in Scotland. Where we put, that is still under negotiation at the moment because it depends whether or not there’s gonna be a blade manufacturing facility there.
Blade manufacturing waste has to be dealt with. Oh yes, it has to. And it’s been ignored and it has to be dealt with and we align to be doing that.
Allen Hall: So you would set up shop next door to the blade manufacturing facility.
Andrew Billingsly: That’s the optimal thing to do.
Allen Hall: Sure it
is.
Andrew Billingsly: Yep. And there’s various discussions taking place with more than one manufacturer about putting a facility into Scotland, but I’m not privy to discuss those things.
And then in England, working with a consortium to put up a facility there which will support the offshore wind as it decommissions.
Allen Hall: Oh sure. Wow. See, we have a lot of plans. Yeah. For
Andrew Billingsly: the future. Yeah. And we real, we will realize them. Uh, the beauty of all of this [00:18:00] is the carbon saving because we are diverting products away from incineration.
And if you take a blade and put into cement kilt, you’re still producing CO2.
Allen Hall: Sure. It
Andrew Billingsly: has to. And we know that’s not a long term solution because when you melt glass, glass sinks to the bottom of the furnace and one by one cement kiln say, we’ve had enough of this and it seems to affect the refractory bricks as well.
Which causes deterioration and another cost for the cement companies. So we can prevent between 2.7 and 2.9 tons of CO2 production. For every ton of waste we divert from this generation.
Allen Hall: Wow. That’s tremendous.
Andrew Billingsly: That’s tremendous. Yeah. And then the products we replace in the market, the virgin plastics, the precast concrete replacements, the, the timber replacements all have high carbon numbers, but now that’s finished.
Right. Yeah. So we can net up to 1.7 tons of CO2 offset saving, [00:19:00]whatever way you want to put it, for every time we process. That’s quite fantastic. Well, now we never knew these numbers. As I say, we were pulled into this industry and then we started to look at what are we doing here? And whoa, we didn’t realize.
Joel Saxum: Fantastic.
Allen Hall: Well, for, for everybody who’s listening today that deals with blades and that, that’s a vast majority of our relationship has to do with blades somewhat during their life cycle. And I’m wondering what the next generation of recycling actually looks like. It’s PLA wire and they need to get a hold of you, Andrew.
How would they do that? To learn more?
Andrew Billingsly: Yes. Well, we are talking with potential partners. Our way to grow is really through a licensing system.
Allen Hall: Okay.
Andrew Billingsly: A reasonable licensing system. So our intention is to put out this blueprint factory, which can be manipulated to suit the market. It can be smaller, it can be larger.
The equipment for it is standard. It’s a lot of standard machines joined together in a particular way. The keys and the process and so forth. [00:20:00] So for example, we can offer a blueprint to a company and they equip it with US machinery or Mexican machinery or whatever, machinery. Sure. Yep. So they can control the cost of that.
So we sell that design, sell them the engineering work to it. Work with ’em on their market surveys in advance to make sure they’re not going into a world that’s not gonna produce revenue for them. Everything has to be profitable. Assure them of the markets for the finished products, and then work on a license fee with them.
Allen Hall: Okay. And they can do that by going to the website PLA wire. You can just Google PLAs Wire,
Andrew Billingsly: Google. Yeah. So you’ll find me at andrew@plaswire.com, which is easy enough for everybody, I believe. Yeah.
Allen Hall: P-L-A-S-W-I-R-E. Dot com.
Andrew Billingsly: That’s correct, Alan. Yeah. Thank you.
Allen Hall: Yeah, it’s a, it’s a really interesting website and Andrew, I’m really glad we had the time to sit down and to discuss your business because it is fascinating.
It’s next generation on recycling, and it’s good to spread the word a little bit. So thank you for [00:21:00] joining us today,
Andrew Billingsly: Alan. Joel. It’s been really good for me too. It. I’m so pleased to be able to do this. Yes. And you know what you want the most fantastic podcast to listen to, I have to tell you that. Yeah.
Allen Hall: Well we need to have Yon Moore. So
Andrew Billingsly: yeah, I’ll be very happy and love to be able to share our progress as we develop and just, we are always gonna be a changing organization, but always for the better. And you’re gonna understand, I guess we’re quite passionate about what we do.
Allen Hall: Yes.
Andrew Billingsly: Yeah.
Allen Hall: Yes.
Congratulations and thank you for joining us.
Andrew Billingsly: Thank you very much. Yep. Perfect. Cool. Wonderful. Wow. So easy now.
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If humankind is forced to migrate to Mars because it’s too stupid to fix the catastrophes it’s created here on Earth, and also stupid enough to believe that taking our criminal insanity to another planet will effectively address our problems, I can’t think of a better name.
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