Bringing a Creative Idea to Life

Innovation in Foul Release:
… more about Doing, less about Dreaming
“Bringing a Creative Idea to Life”
Presentation Outline
Introduction
The Key Discovery
Technology
1980’s: “A Product looking for a Market”
1990’s: “A Market looking for a Product”
2000’s: “Product + Market = Success”
2
Some background History of Foul Release
• 1950’s: The first Patent for a silicone Foul Release system
to control fouling was taken out in 1955.
• 1970’s: “Silicone RTV rubbers are ideal materials for
coatings surfaces to provide a thin, inexpensive anti-stick
layer” (JAC Watt, “Silicone Liquid Rubbers”, Chemistry in
Britain, 6 (12), December 1970).
• 1990’s: “About 40 patents have been registered but only a
few products are available on the market” (B. Watermann,
Biofouling, 1997).
Lesson 1: Patenting is not Innovation
3
4
Woods Hole: “The History of the Prevention of Fouling”
“Even as late as 1872, Robert Mallet, in presenting the
Institute of Naval Architects with a catalogue of British
shipbottom patents, stated that the majority of them were
useless or worse, and that the best were mere palliatives.”
(Chapter 11, p 216)
5
Woods Hole: “The Invention of Protective Devices”
“A large fund of information concerning the methods
proposed as an answer to the fouling problem is to be found
in the patent literature. It is true that many patented ideas are
nonsense, due largely to a misunderstanding of the problem.
This is because many inventors are enthusiasts rather than
experts.” (Chapter 12, p 224)
6
The Key Discovery
• In the late 1960’s TBTO (Tributyltin oxide) was starting to
be used in antifoulings, and companies were seeking
ways to best utilise its potency.
• Goodrich, who made rubber tiles for protection of Offshore rig legs, wanted to see whether these tiles could
have TBTO incorporated in them, to provide additional
antifouling protection.
• Goodrich prepared a set of square tiles, with various
levels of TBTO incorporated, and sent them to IP to test
the a/f properties.
7
The Key Discovery
• The person involved in this testing was
Alex Milne, and he decided to test these
panels on the company rafts at our test
site near Plymouth.
8
The Key Discovery
• In order to fix the Goodrich tiles to wooden boards for raft
testing, Alex decided to use a silicone sealant around the
edges, to secure them in place.
• The boards were then inspected after immersion and
although the tiles were found to be heavily fouled (had the
TBTO all leached out ?) the silicone sealant around the
edges was not fouled.
9
The Key Discovery
• Instead of ignoring this “accidental observation” (which
was not connected with the original purpose of the
experiment at all) Alex then contacted the manufacturers
of the silicone sealant (Silcoset 105 ex ICI) and started a
programme to test a range of different silicone polymers
and additives, for their antifouling effect.
• In this way a liquid/paint formulation was developed, that
could be applied by brush, roller or spray, rather than as a
thick elastomeric compound applied from a caulking gun.
• Equally important was finding a suitable primer, to enable
the “non-stick” finish to adhere to a range of substrates.
1
0
Original Panel Trials
Silicones
Controls
Silicone + TBT
18 months immersion, UK
(Immersed 8th April 1971)
11
Original Panel Trials – 10 years immersion
Lightly Sanded
1972 – 1982 (72202)
12
Patents
• AM was granted a GB Patent (GB1 470 485) in 1976 for the
Finish coat. The “inventive step” in this Patent was the
addition of a low molecular weight Methyl Phenyl Silicone
fluid (up to 5%).
• He found that the low Mol. Wt. MePh fluid significantly
reduced the adhesion of fouling organisms, and this effect
has been reported in many publications subsequently.
• Contrary to popular myth, substantial levels of the MePh
fluid remain in the film after extended periods.
13
MePh Fluid content vs Time
Vessel Name
Applied Inspected Years
-
% KS1927 Comments
0
6.8%
2001
8
5.4%
2003
10
4.2%
2005
9
5.5%
Maersk Merlion Jul-96
Jul-05
9
2.2%
Test Patch
Jul-00
Jul-05
5
4.1%
Test Patch
2.8%
Control sample of fresh
Intersleek had 3.0% KS1927!
Tropic Lure
Summer Bay
USS Defender
1993
1996
Jul-99
Mar-05
9
Analytical Report No A3/3414/1
Nada V
Dec-00
Apr-05
4.3
3.0%
Control sample of fresh
Intersleek had 3.0% KS1927!
USS Sentry
Sep-96
2005
9
4.2%
Large Flake
1993
2005
12
4.6%
Barium method for analysis
Aug-00
Mar-06
2.5
5.0%
Finish coat only
NWB1290
Polar
Discovery
14
MePh Fluid content vs Time
% KS1927 Remaining
7.0%
6.0%
5.0%
4.0%
3.0%
2.0%
1.0%
0.0%
0
2
4
6
8
10
12
14
Years in service
15
How the MePh Fluid works
Note: This is Alex
Milne’s handwriting
1
6
What happened next?
• AM had made the discovery, patented it, and
demonstrated that it worked …. so why was it not an
instant success?
• Answer: TBT SPC!
The silicone Foul Release system could not compete
with the TBT SPC system that had arrived at virtually
the same time, and was proving a real success,
commercially.
Lesson 2: Markets can only accomodate one
innovation at a time!
17
Keeping the Technology alive
• In the 1980’s Lab work continued at a low level of
investment (involving a recently retired consultant) to try
make a more practical system, optimising the primer and
tie-coat.
• Simple screening trials were carried out using Mussels
byssus threads. Panels with the various formulations
were placed in sinks, along with a handful of mussels.
• Once the mussels were firmly attached, the panels were
inverted, and the adhesion quantified by attaching
weights to individual threads, increasing the weights until
detachment occurred.
18
Dr Sandy Christie (IP A/F Technology Manager, 1980)
• “At one time we produced a
fine graph showing a good
straight line relationship
between byssus adhesion
and antifouling performance.
• On our very best silicone
elastomers the byssus
threads could not even
attach.”
19
The 1980’s: “A Product Looking for a Market”
• During the 1980’s attempts were made to find niche
commercial outlets for the technology:
Aluminium boats
Yachts
Fish Farms
Water-treatment works
20
The 1980’s: Aluminium boats
• The US Coastguard started commercial applications in 1988, but
static performance was not good, and damage was a problem:
12 months in-service
21
The 1980’s: Aluminium boats
2
2
The 1980’s: Yachts
• In 1987 the company had
two yachts, based in Ocean
Village in Southampton, on
which trials were carried out.
• The slime fouling was
deemed by the skipper (the
UK Sales Manager) to be
unacceptable, and the trial
was terminated after 1
season.
23
The 1980’s: Yachts
24
The 1980’s: Fish Farms
• Long rolls of Nylon were “blade” coated with Intersleek, at
a textile factory near Dundee (owned by Courtaulds, who
had purchased International Paint in 1969).
• First the Primer was applied, followed by the Finish.
25
The 1980’s: Fish Farms
Failure!
26
The 1980’s: Fish Farms
27
The 1980’s: Water treatment plants
28
The 1980’s: Offshore
Buoy (Bahrain)
Offshore Rig Leg “wrap”
29
The 1980’s: “A Product Looking for a Market”
• None of these various attempts in the 1980’s to find a
suitable market for the technology was commercially
successful.
• The installation cost was high, and the results were not
good enough to justify this cost.
Lesson 3: Innovation is 99% Perspiration, 1%
Inspiration!
30
Technology Development (1) “Make it Tougher”
•
The perceived wisdom in the early 1990’s was that the
silicone finish was “too easily damaged” (largely based on
laboratory small panel data) .
•
So R&D were asked to “toughen up” the silicone. This
was achieved by incorporating a second cross-linking
mechanism (polyurethane) into the films.
•
Tests on small panels showed this to be a much tougher
system, and so this was then applied to the UK Navy
nuclear submarine, “HMS Vanguard”, in 1993.
31
“HMS Vanguard”
32
“HMS Vanguard”
• This was unsuccessful: the coating lost gloss during sea
trials, and rapidly succumbed to weed fouling at the waterline.
• Divers were employed to clean off the weed and this
damaged the coating even further.
• Repairs only made the appearance worse, with the fresh
glossy finish in stark contrast to the aged matt coating.
• So the “toughened silicone” approach was abandoned, and
it took nearly 20 years before the UK Navy was to use
silicone coatings again!
33
Technology Development (2) “Make it Simpler”
• A simpler Tie-coat was developed in the USA in the 1990’s
and then applied to an LNG in Japan, in early 2001.
• After only a short time (1 month) detachment was observed!
34
Technology Development (2) “Make it Simpler”
The vessel had to be dry-docked and re-blasted ($0.3m), and the
system re-applied.
Lesson 4: There will be failures along the way!
35
The 1990’s: “A Market Looking for a Product”
• 1993 was one of the most significant years in the eventual
success of the innovation.
• The first full ship application took place in April/May. This
was achieved by:
Externally: Finding a ship-owner in the USA who was
interested enough to take the risk with the new
technology (“early adopter”).
Internally: Persuading senior management that the
market existed, and was worth the investment.
• In September a full-time Business Manager was appointed
to focus on the commercialisation of the technology.
36
1993: The first Full Ship Application
“Tropic Lure”, Jacksonville, Florida,
May 1993
Lesson 5: Finding a willing
customer partner to do the
early “proving trials” was
crucial
37
The 1990’s: “A Market Looking for a Product”
• The second large-scale application to a Navy
vessel was to the submarine “HMAS
Collins”, in Adelaide in 1993. This followed a
successful trial on a small RAN workboat in
1992.
38
The 1990’s: “Intersleek 425”
• Performance on “HMAS Farncombe” and “Tropic Lure”
were deemed successful, so in 1996 the decision was
taken to formally launch Intersleek 425.
• The focus was on two niche market segments, where the
“customer perceived value” could justify the high
installation price, and the risk of failure was low:
Navy
Fast Ferry
39
Intersleek 425: Navy
In 1996 “USS Scott” (DDG) was coated,
along with the Mine Counter Measures
vessel (GRP) “USS Sentry”.
4
0
Intersleek 425: Fast Ferry
• The first Fast Ferry test patch was on a large Aluminium
catamaran, “Stena Explorer”, newly built in Finland.
• This patch showed much better performance than the
conventional antifouling being used alongside, and so Stena
decided to apply Intersleek 425 to the whole ship.
41
Intersleek 425: Fast Ferry
“Stena Explorer”
(1996 - 1998)
42
Intersleek 425: Fast Ferry
43
The 1990’s: How to expand into the Deep Sea market?
• In order to produce convincing evidence of the product
benefits a collaboration with Newcastle University, which
had been dormant for some time, was re-started.
• Dr Townsin suggested Towing Tank trials, and Prof Atlar
found a brilliant PhD student (Maxim Candries) to do the
work. Significant advances in understanding the
hydrodynamics of Foul Release surfaces were made.
Lesson 6: Academic support gives credibility
and impetus!
44
Newcastle University Towing Tank tests
45
Newcastle University Towing Tank tests
46
Newcastle University Towing Tank tests
CEHIPAR, Madrid, Spain (320 m, 8 m/s)
47
Newcastle University
Journal of Fluids Engineering Copyright © 2005 by ASME
MARCH 2005, Vol. 127 / 1
48
The 1990’s: Expanding into the Deep Sea market
Two full commercial ship applications were carried out in 1996:
• “Norway” (Cruise Ship), Sept 1996, Southampton
• “Summer Breeze” (Reefer), Dec 1996, Amsterdam
49
The 1990’s: Expanding into the Deep Sea market
• Getting full Deep Sea ship applications required:
The Sales team to find the “early adopter” ship owners
Manufacturing to correctly scale-up the products
Distribution to get them to the right place, on time
Technical Service to ensure correct application
Commercial to agree the financial arrangements
Lesson 7: It’s a team effort: “No one can be a
hero on their own”
50
It’s a Team Effort!
Name
Alan Pratt
Andrew Rayner
Andy Maidment
Andy Billington
Bijan Askepour
Brian Thoms
Carol Charlton
Caroline Shilton
Catherine McGurk
Cathy Stephenson
Clive O'Leary
Clutch Coverdale
Colin Watson
David Tan
Derek Banks
Dick Higgins
Gordon Stephenson
Ian Hawkins
Ian Reilly
Jim Brown
John Hinchley
John Kelly
John Millett
John Sinclair-Day
John Smith
John Wilsher
Jon Bradley
KJ Kim
Mark Morris
Michael Friis
Ole Friis
OS Kang
Paul Marzocca
Peter Barlow
Richard Towns
Richard Vali
Robert Hall
Simon Parker
Sylvain Fillion
Tom Doleski
Tom Taylor
William Tsang
What did they do?
Tech Service control for the applications in China, especially Leif Hoegh Car Carriers
Strongly supported the sale of Intersleek 700 to the German market
Master Class training and many applications supervised
PC Lab - Armawrap
Took the risk to push Intersleek with Qatar Gas, resulting in a significant breakthrough into the LNG sector
Carried out the first RAN Dive Boat application. Managed the Felling factory production for many years.
Did the paper-work for the Queens Award submission. Produced much of the sales support material for Intersleek 700. Did the Hull Roughness reports for most of the Intersleek 700 ships
A/F Lab - Speed vs Performance data
Crucial R&D support in the period leading up to, and immediately after, the launch of Intersleek 700
Helped with the sales support material for Intersleek 700, including the Internet version of the Focus Product Pack
Helped develop the Hull Roughness Penalty Calculator. Progressed the sales training and marketing packages, and customer presentations
Was the TSR on the first Cruise ship "Norway" (Sept 1996)
Helped develop the Application Procedures Manual when in TOD. Ironed out the application issues, especially NB in Korea, when in the lab
Helped develop the Technical Service protocols to ensure successful applications
Auditing the Application Procedures Manual, and implementing the strict application controls
Early Tie-coat development
Carried out the Rubber Tile trials, when in the R&D lab, to enable the RAN submarine applications to take place
Provided "Silicone Expertise" to the fledgling Intersleek R&D team
Formulation of Epoxy Adhesion Promoter, used by PC for many years
Arranged some of the original Test Patches and trials in early 1990's. Essential Marketing Services for the launch of Intersleek 700
Assisted MM in the management of the Islk 700 marketing programmes
For many years supported Intersleek trials with the US Navy and USCG
Did the first submarine applications in Adelaide in the early 1990's. Strongly supported and promoted Islk 700 throughout Asia-Pacific, in both Marine and Yacht
Supported the development of an Intersleek R&D team, and recruited Ian Hawkins
Development of Intersleek 700 for the NB market in Korea
Inspected the first Intersleek Test Patch ("Esso Pacific") in 1987 (?). EMEA sales support
When Gen Manager in USA, supported the "Tropic Lure" application
Arranged two big customer events at sequential KorMarine exhibitions
Arranged some of the original Test Patches and trials in early 1990's. Managed the March 1999 launch at Miami Cruise Show. Managed the Marketing Programme from 2000-2004
Sales support in the Middle East
Took the risk to push Intersleek with AP Moller, resulting in a significant breakthrough into Containers
Strongly supported the sale of Intersleek 700 to the NB market in Korea
Brokered the agreement with Miami Divers to import Mini-Pamper into the USA from UMC, for the Cruise market
Tech Service control for the applications in Dubai
Sterling R&D work to solve some of the Fast Ferry adhesion problems
When Marine Manager in Sweden, arranged the first Linkcoat application on "Don Carlos" despite pressure not to do so.
Strongly supported the sale of Intersleek to the Cruise industry in the USA
Strong sales support, initially in UK and then throughout Europe
Developed the 2-pack Tiecoat, used in the USA from 2000 - present day. Did the testing to prove the Linkcoat worked
The key person to push Intersleek on Propellers, with a view to then getting the complete ship
When VP-Sales in Houston took the risk to do the first full ship trial "Tropic Lure" (1993)
Dealing with the Guarantee issues, when in WWM Commercial
51
The 1990’s: Expanding into the Deep Sea market
The ships were followed closely, to assess speed and fuel
consumption. Not only was the product found to give long-term
fouling control, but there were also fuel savings:
“Tropic Lure” (1998, 5 years)
“Summer Breeze” (1999, 3 years)
52
The 1990’s: Intersleek 700
Confidence in performance increased to the extent that a full
commercial launch for the Deep Sea market took place in March 1999,
at the Miami Cruise show, for any vessel operating from 15-30 knots.
Note: The 15 knots “lower limit” came from the successful
performance on “Tropic Lure”, after 5 years in-service (1998).
“Tropic Lure” (1993 - 1998)
53
Intersleek 700 and Intersleek 425
• Having different brand names enabled:
Different “customer expectation”
Differential pricing
• This required considerable “internal training” in order to
make sure the sales team understood the key differences.
54
The 2000’s: Product + Market = Success
It wasn’t until 2003 that sales started to take off:
Full Vessel Applications
200
180
160
140
120
100
80
60
40
20
0
55
The 2000’s: Product + Market = Success
There were two significant events that greatly helped :
1. The large increase in the price of fuel – exactly as it did
for the TBT SPC system in the 1970’s!
2. The ban in TBT applications from 2003, leading to the
complete ban on any ship in 2008.
Lesson 8: Timing is everything!
56
The 2000’s: Product + Market = Success
57
The 2000’s: Product + Market = Success
• New opportunities were also explored, to expand into
previously untested areas – propellers.
• Doing this required “breaking some eggs to make the
omlette”! The fear of failure makes big companies put
control measures in place to minimise risk, and IP is no
different
• Only by finding innovative salesmen, and innovative
customers, was this achieved.
Lesson 9: There will be internal resistance to
overcome!
58
The 2000’s: Product + Market = Success
59
What does all this teach us about Innovation?
60
Lessons in Innovation
•
Patenting is not innovation
•
Markets can cope with only one innovation at a time
•
Innovation is 99% Perspiration, 1% Inspiration
•
There will be failures along the way
•
A willing customer partner(s) is crucial
•
Academic support gives credibility and impetus
•
It’s a Team Effort – “No one can be a hero on their own”
•
Timing is everything
•
There will be internal resistance to overcome
6
1
A final quote from Alex Milne
“Remember Bessie Bighead in Dylan Thomas’ “Under Milk
Wood”, who was kissed once by Gomer Owen when she
wasn’t looking, and never kissed again, although she was
looking all the time? Research is a bit like that. We were
kissed by SPC and Intersleek and fell in love.”
(14th July 1989 memo on “Fluorine in Non-Stick Antifoulings”)
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The next perfect wave?
6
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