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Recycled PP Bests Plywood in Marine ApplicationsRecycled PP Bests Plywood in Marine Applications

The Supersede Marine Board has superior structural integrity compared with traditional plywood, is more cost effective, and is sustainably crafted using recycled plastic waste.

Stephen Moore

October 3, 2024

2 Min Read
SupersedeBoard on steel background
Image courtesy of Supersede

Phoenix-based Supersede may be located some distance from the ocean, but that’s not stopping it from developing the world’s first 1:1 marine-grade plywood replacement for boatbuilding and other applications. The Supersede Marine Board is a hollow-core, engineered extruded sheet crafted from polypropylene waste enhanced with proprietary additives to meet specific performance standards.

The cost-effective sheet is 100% recyclable, water- and rot-proof, and does not splinter or split. Beginning with the boat manufacturing industry in key components such as decks, transoms, and stringers, Supersede will also provide its innovative solution to manufacturers of modular homes, recreational vehicles (RVs), and trailers.

Plywood market ripe for transformation

Supersede’s product launch comes as traditional plywood prices remain one-third higher than they were in 2019, following pandemic-related supply chain challenges. Additionally, boat manufacturers are increasingly facing a rise in plywood warp, rot, splinter, and performance issues because of changes in moisture levels. Further, marine-grade plywood is processed using harmful chemicals that are known to pose possible health, safety, and environmental hazards. While marine-grade plywood has been in use for decades, the unreliability of its supply chain, its nondurable nature, and the potential risk to human and environmental health make the plywood market — valued at $31.5 billion in the United States alone — ripe for disruption.

“Boat manufacturers and their insurers have more experience than almost anyone with the headaches of plywood — from the persistent challenges associated with inconsistent performance, warping, and splinters, to extensive maintenance, high cost, and little peace of mind,” said Supersede CEO and co-founder Sean Petterson. “We have created the first modern breakthrough addressing these issues with the Supersede Marine Board, a true 1:1 replacement for marine-grade plywood that has all the attributes boat manufacturers look for — a durable, reliable, and affordable solution that is non-hazardous, environmentally sustainable, and always consistent. This isn’t just an upgrade to the legacy plywood industry — it’s a long overdue leap forward.”

Scrap buyback program

A core focus at Supersede is reducing plastic waste in oceans and landfills by giving recycled plastic a long-lasting, sustainable use. In its Phoenix facility, the company regrinds and reuses all offcuts from the production process. Additionally, it partners with customers to purchase their leftover trimmings, which are then reprocessed to create new products, further closing the loop on plastic waste.

Capacity at the outset is more than 250,000 sheets annually, with plans to scale production as demand grows. Hollow-core plastic extrusion technology transforms plastic pellets into finished sheets in under 120 feet of production line length — dramatically reducing the manufacturing footprint compared with traditional plywood production.

Saving trees and time

The potential environmental impact of the Supersede Marine Board is also substantial. For every 72 sheets of ½-inch displaced plywood, one tree is saved, according to Supersede. Additionally, its manufacturing and engineering process removes VOCs and adhesives from the equation. Supersede also eliminates time-consuming steps, such as sanding, sealing, and drying, from the manufacturing process.

About the Author

Stephen Moore

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and a proud dachshund owner.

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