Student’s experiment sees him put crisp packets to novel use

Crisp packets are annoying; they’re noisy, they’re never actually full, and they can’t be easily recycled. But what if crisp packets could be re-used for something cool?

Garreth Smith, a past pupil of Galway Technical Institute, realised they could be used for something more than crisps – skateboards. Yep, skateboards.

While studying in Dublin, he entered a project design competition with the task of identifying types of waste and creating something of value.

While walking through campus one day, he was handed a free packet of Doritos and he got an idea. The packets reminded him of his childhood where his parents would shrink them in the oven – “they used to shrink down considerably but they’d be much firmer to the touch”, he explains.

He began experimenting with the material and methods for about six months and the first object he made was a stool for the competition.

Garreth thought more could be done and so, he took it on as his final year project and, as a big skateboarding fan, he decided to use this opportunity to make something he loves.

The 24-year-old began his research and found that due to the foil in crisp packets, the only way for them to be recycled is to take that foil off.

“But it takes a lot of effort and energy, so there’s no economic incentive to do it and, so, the packets end up in landfills,” says Garreth.

Traders in India were the only example he could find of people using a method like this and they would weave the material into colourful ropes. Garreth felt as though he “stumbled upon a goldmine because it’s such a popular material” and not a lot was being done with it.

Keogh’s Crisps gave Garreth five or six large bin bags filled with the waste from production, such as bags which weren’t printed right or bags which didn’t seal correctly.

It takes around 500 packets to make one skateboard and the process isn’t quick either; the packets all have to be cleaned manually and are shredded. Garreth started shredding them by hand but he realised it wasn’t the way to go and, so, invested in a shredder.

The shredded packets then go into clear halogen ovens for an hour to 90 minutes to shrink. Small amounts go in at a time as Garreth explains they wouldn’t melt or mould properly otherwise.

This produces “two blobs” which are kneaded together and put into a mould. “They’re like really hot and sticky piles of plastic,” laughs Garreth. Pressure is put on the mould using a press and after 20 minutes it’s popped out of the mould.

From there, any excess material is taken off and wheels and grip tape are applied, and there you go – a Bruscair Board. It can take three to four hours to make for one person to make a single board.

It took trial and error but Garreth’s perseverance resulted in a successful Bruscair Board. He also designed and did the 3D work for the wooden mould used for the boards. “That was probably the hardest part of the project,” he admits, “it took an incredible amount of time.”

Bruscair Boards haven’t been available to buy as Garreth explains that “they would never have come close to the safety standards that skateboards currently have to adhere to.” However, he is hopeful that he can work at the boards and make them function in the future.

There are three of these boards in existence at the moment but Garreth laughs as he says that he has broken another five through testing, “they can support your weight no problem”, but he explains that if the board lands from a height of one or two feet then it can snap.

Garreth has since finished college and, although he is from Valentia Island in Kerry, he decided to move back to Galway and his sights are set on bigger and better projects using his original idea. “You could possibly apply this material to a wall; it could be used as an insulator for houses,” he suggests.

The Vault, a new indoor skate park and rock-climbing facility coming to the city later in the year, will play host to Garreth and his inventive skills. He hopes to do workshops teaching kids about recycling and will plan his role there more in the coming months.