Pioneering Sustainable Building Solutions!
Samsara Materials is dedicated to revolutionizing the construction industry via a sustainable building material made of plastic waste.
"Samsara" is a term rooted in ancient philosophy, representing a circular journey of existence marked by challenges, learning, and transformation, through which one ultimately attains liberation or enlightenment.
Our True North
Samsara is committed to creating high-quality products from waste materials while ensuring environmental integrity and sustainability.
How We Started
In early 2022, during the pandemic, Frank Pho and Alexis Liu were alarmed by the growing piles of plastic waste in their neighborhoods due to suspended garbage collection. The sheer volume of plastic—food containers, packaging, bottles—made them realize the magnitude of the global plastic crisis.
Seeing the waste, they had an epiphany: "This wasn’t just a temporary problem but a long-term environmental disaster." They decided to act despite the lack of prior operation experience in waste management, relying on their prior involvement in clean tech projects. Frank and Alexis wanted to contribute to a circular economy where plastic waste could be transformed into valuable, sustainable materials.
They began experimenting in their garage, conducting countless trials to convert plastic waste into bricks. To refine their approach, they consulted Prof. Tony Bi, an expert in chemistry and clean-tech at University of British Columbia, who provided critical insights that shaped their experiments and accelerated their progress.
By the end of 2023, they had a clear understanding of the process and formulated their blueprint. They visited Asia, discussed with industry leaders and potential Original Equipment Partners (OEM) to complement their global market research in order to evaluate the related market size and its competitive landscape.
In early 2024, they officially founded Samsara Materials, Inc., driven by their passion to combat plastic waste and create a cleaner, more sustainable future.
Introducing EcoBrik™
EcoBrik™ is a durable, low-carbon alternative to traditional building materials, offering strength and durability comparable to conventional materials, a significantly lower carbon footprint, scalable production methods, and compliance with or exceeding industry standards.
Samsara Mission
Trusted by Our Partner
"Flexible plastics packaging is a difficult material to handle as it is both lightweight and comprised of a wide variety of multi-laminated plastics. As Recycle BC continues to increase its collected tonnage, it is imperative that we partner with organizations such as Samsara Materials to find alternative and viable solutions for recycling this material." – Recycle BC
Tackling the Global Plastic Waste Crisis
Despite recycling efforts, conventional methods are not a complete solution. Much plastic waste remains non-recyclable or is downcycled into lower-grade products that return to the waste stream. This crisis is further fueled by plastic waste from agriculture, commercial industries, and manufacturing, creating a heavy burden beyond residential sources.
Addressing this complex, large-scale problem requires immediate, innovative, and collaborative solutions that go beyond single-use bans and traditional recycling. We need comprehensive strategies rooted in circular economy initiatives and sustainable material innovations, such as transforming plastic waste into resilient, reusable building materials, to mitigate environmental damage and create a truly sustainable future.
The Key Challenges
While the concept of transforming plastic waste into eco-friendly building materials has long been explored, a widely adopted, proven, and scalable product solution remained elusive.
Recycling and repurposing mixed plastic waste into building materials is a complex challenge because it involves a range of interrelated material, processing, and economic hurdles. These challenges have been significant barriers to the successful commercialization of turning mixed plastics into building materials at scale.
1. Separation Challenges:
Effectively separating mixed plastic waste streams is a major hurdle:
- Visual Similarity: Many plastic types look alike, making manual sorting prone to errors.
- Labeling Inconsistencies: Lack of standardized labeling complicates identification, hindering accurate sorting.
- Multilayer Packaging: Products made of multiple layers of different plastics are especially difficult to sort and recycle.
2. Material Incompatibility:
Different plastics have varying chemical compositions, leading to incompatibility during recycling:
- Degraded Quality: Mixing incompatible plastics results in recycled materials with inferior mechanical and physical properties.
- Contamination: Residues from one plastic type can contaminate others, affecting the purity and performance of the recycled product.
3. Processing Challenges:
- Melting Point Variations: Plastics have different melting temperatures, making simultaneous processing difficult.
- Additives and Colorants: The presence of various additives and pigments can interfere with recycling processes.
- Equipment Limitations: Most recycling equipment is designed for specific plastic types, not mixed streams.
- Environmental and Health Impacts: Toxic additives in certain plastics and emissions during processing pose environmental and health risks.
4. Quality Control Issues:
- Inconsistent Properties: Mixed plastic waste streams produce recycled products with unpredictable mechanical and chemical properties.
- Contamination Risks: Cross-contamination between different plastics compromises the safety and durability of recycled materials.
- Regulatory Challenges: Lack of standardization and difficulty in meeting safety standards limits the use of recycled plastics for high-demand applications.
5. Economic Viability:
- Lower Market Value: Recycled materials from mixed plastics often have lower market value due to quality concerns and limited applications.
- Higher Processing Costs: Sophisticated sorting and processing technologies are required, increasing operational expenses.
- Logistics and Infrastructure: Collecting, sorting, and transporting mixed plastic waste is costly, particularly in areas with inadequate recycling infrastructure.
- Premium Pricing Pressure: Many consumers and businesses are reluctant to pay the premium necessary to offset increased processing costs.
The EcoBrik™ Project
While the concept of transforming plastic waste into eco-friendly building materials has long been explored, a widely adopted, proven, and scalable product solution remained elusive. Samsara is committed to developing sustainable construction solutions that not only address the plastic waste crisis but also meet the growing demand in the construction market, aligning with the principles of Better Buildings.
Our project is focused on developing durable, energy-efficient alternatives to traditional materials, promoting a circular economy and helping to redefine construction practices. We are working hard to advance standards for sustainability, resource efficiency, and the creation of healthier, more resilient communities.
Strong Construction Market Demands
The global bricks market, valued at $250 billion in 2023, is driven by demand for both traditional and sustainable bricks used across various applications, including residential, commercial, and infrastructure projects. Bricks are widely applied in building walls, facades, pathways, and landscaping due to their durability and versatility.
Offering Sustainable Building Solution
The Better Buildings trend is transforming construction by prioritizing sustainability, resilience, and community well-being. Driven by climate concerns and resource scarcity, it promotes environmentally responsible practices like using recycled materials, reducing carbon footprints, and integrating renewable energy.
This movement aims to create adaptable, efficient structures that support both ecological and social goals, setting new standards for sustainable, community-centered construction.
EcoBrik™ Features
Performance and Compliance
EcoBrik™ meets ASTM (American Society for Testing and Materials) requirements, ensuring its performance and quality align with the standards required for traditional building materials. Rigorous testing, including assessments of compressive strength, durability, and resistance to environmental factors.
Advancing the Circular Economy
EcoBrik™ promotes sustainable resource use and aligns with modern construction practices that prioritize resilience, eco-friendliness, and community well-being, setting a new standard for sustainable and responsible building practices in the industry.
A Practical Solution for Eco-Builders
EcoBrik™ is 45% lighter than traditional bricks, reducing transportation costs and minimizing wrist and back injuries during installation, leading to lower overall labor costs.
By choosing EcoBrik™, you're not just opting for a building material – you are contributing to a sustainable future.
A Low-Carbon Alternative to Traditional Bricks
In response to the rising demand for eco-friendly building materials, EcoBrik™ stands as a superior alternative to traditional bricks. Conventional brick production is energy-intensive and a significant contributor to carbon dioxide emissions. EcoBrik™, however, is designed with a low-carbon production process that significantly reduces emissions without compromising strength or durability.
Our product line features two innovative and sustainable solutions: EcoBrik™ Paver and EcoBrik™ Cladding, each designed to meet diverse construction needs while promoting eco-friendly practices.
EcoBrik™ Paver
Specifically engineered for eco-conscious outdoor applications, EcoBrik™ Paver is ideal for creating walkways, land pavements, garden paths, and driveways. Its lightweight yet durable design ensures easy handling and installation, while offering superior strength and resistance to weather and wear.
EcoBrik™ Cladding
Our EcoBrik™ Cladding is perfect for vertical applications, providing a versatile and attractive solution for retaining walls, landscaping projects, and sustainable housing developments. With excellent durability, EcoBrik™ Cladding offers both functional and aesthetic benefits, making it an ideal choice for incorporating sustainability into designs.
Carbon Footprint Reduction
Long-Term Carbon Storage
Each EcoBrik™ is made up of nearly 50% waste plastic by weight, containing approximately 2.2 kg of CO2 equivalent. By storing plastic waste in a stable, non-degradable form, EcoBrik™ helps prevent the release of CO2 and methane that would otherwise occur as the plastic degrades.
Avoidance of Cement-Related CO2 Emissions
Prevents roughly 0.63 kg of CO2 emissions by substituting cement. EcoBrik™-based construction reduces or eliminates the need for cement, avoiding the significant CO2 emissions associated with cement production.
Reduce
Transportation Emissions
Compared to a regular concrete brick of the same size, an EcoBrik™ weighs only 1.55 kg, making it approximately 50% lighter, which contributes to lower emissions during transportation.
Improve Project Efficiency
Lightweight EcoBrik™ improves work efficiency, shortens construction time, and reduces labor costs, all while lowering CO2 emissions by requiring less energy for on-site transport and installation. Its ease of handling also minimizes worker strain and injury risk.
Our Path of Development
Our journey in developing sustainable building materials has been guided by a commitment to environmental responsibility and high-quality standards. Each phase—from material preparation and compounding to forming and testing—has been carefully crafted to meet industry demands while minimizing environmental impact. Below is an outline of our process, showcasing our dedication to advancing sustainable construction.
Material Preparation
Our approach to material preparation is rooted in environmental sustainability, high product quality, and competitive mass production. This phase requires careful planning and calibration, addressing aspects like pre-treatment, mixing ratios, and filler selection. These elements are part of a carefully designed "recipe" that lays the foundation for optimal performance, with numerous parameters that influence both the material's structural integrity and its environmental footprint.
New Composite Materials
The compounding stage integrates materials using precise heat transfer parameters and mixing methods to achieve a uniform blend. Our development process explores multiple combinations to balance durability and efficiency, addressing challenges like high energy consumption and greenhouse gas emissions while minimizing VOC (volatile organic compound) release for a safe, environmentally responsible outcome. This iterative approach enables us to tailor the composite to meet rigorous standards while maintaining an eco-friendly profile.
Forming & Scale-up
Forming is a crucial step in transforming composite materials into high-quality, mass-producible components that achieve optimal strength performance, productivity efficiency, and zero waste. At the heart of our efforts is a production platform designed to seamlessly integrate the composite material while minimizing environmental impact. This approach ensures that each component meets rigorous quality standards, supporting both productivity and sustainability in every production cycle.
Tests & Improvement
Although industry regulations for bricks made from plastic waste are still emerging, we have proactively developed stringent testing protocols to meet anticipated standards. Our emissions testing, conducted by Powertech Lab in Canada, and strength performance testing, completed by SGS Lab in Taiwan, demonstrate highly positive outcomes. These tests confirm the environmental and structural integrity of our products, reinforcing our commitment to sustainable, high-quality building materials.
Evolution of EcoBrik™ Prototypes
The development of the EcoBrik™ prototype showcases Samsara's advancements in sustainability, durability, and production efficiency. Extensive research and testing have guided each iteration, enhancing key performance metrics and advancing toward a green manufacturing platform that achieves zero waste, minimal gas emissions, and optimal productivity. The latest EcoBrik™ prototypes embody industry-leading performance and a scalable design for mass production, aligning with circular economy principles for sustainable building solutions.
Innovative Solutions
Our green manufacturing system is the result of extensive innovation and development, created to tackle the environmental challenges facing modern industry. Central to this system is our commitment to sustainability, which is reflected in the advanced engineering and proprietary techniques we use to transform waste materials into valuable resources.
Our flagship product, EcoBrik™, is a direct result of comprehensive research and iterative development, addressing multiple industry needs while adhering to strict environmental responsibility standards.
As we explore new composites and products, we will develop our SAIS (Smart AI Systems) to accelerate our R&D processes, reducing development time while maintaining our focus on innovation and sustainability.
Low Emission
The heat transfer process keeps emissions within safe limits, as recommended by National Institute for Occupational Safety and Health (NIOSH) standards, ensuring safety and adherence to regulatory guidelines for workplace air quality and environmental health.
Versatility
Accommodates a broad spectrum of plastics, ranging from rigid to flexible types, including PET, HDPE, LDPE, PP, PS, and even PVC. All material is processed under distinct handling protocols to ensure optimal quality and compliance with environmental and safety standards.
Compounding System
Features high shear mixing for uniform dispersion, temperature-controlled zones to prevent thermal degradation, low residence time, degassing for improved material quality, energy efficiency with reduced power consumption, and stability for consistent output.
Zero-waste Process
Our system processes 100% of all incoming materials, ensuring nothing goes to waste. Any spoilage or scrap generated during the process is efficiently recycled back into production, contributing to a closed-loop system.
Smart Manufacturing
Integrates IoT monitoring for real-time tracking and data-driven adjustments to enhance performance, while robotic arms automate heavy tasks, improving precision, speeding up the process, and reducing labor strain.
Meet Our Team
A dynamic group of professionals dedicated to addressing the plastic waste crisis and leading the advancement of sustainable waste management practices.
Frank Pho, CEO
With over 35 years of experience in venture capital, operational management and advisory roles with in start-ups, Frank has a proven track record of success. He was a member of the Canada-China Cleantech Joint Working Group, representing Canada to explore cooperations between two countries. As a VC he had impressive exits, with one exceeding 11x returns. As an operator, he successfully turned around several multi-million dollar operations. Frank is a Chartered Accountant with a B. Com and Diploma of Accountancy from Concordia University.
Alexis Liu, COO, VP. R&D
Over 3 decades of executive experience in high-tech enterprises in Canada and Asia, with proficiency in executing ESG-centric projects such as Energy-as-a-Service, Hybrid microgrid systems, Net zero building material solutions and Smart agriculture. Alexis holds a B.Sc. in Bio-environmental Systems Engineering from National Taiwan University and M.Sc. in Computer Engineering from University of Massachusetts, and attended the Ph.D. program in Neural Science from Boston University.
Enzo Casal, Senior Manager, Operation
With more than 5 years of hands-on experience in the waste and recycling sector, Enzo also manages his own consultancy, serving clients such as Recycle BC, CleanFarms, Lichens Recyclabilité, and is working alongside others such as Circular Materials in Ontario and Éco Entreprises Québec. He has previously supervised three transfer stations where he coordinated various material streams in Metro Vancouver. Additionally, he is overseeing the operations for the BC agricultural plastics collection pilots in Northern BC. Enzo holds a Honours B.Sc. Biology and an MBA from UBC.
Lisa Bate, ICD.D, FRAIC, LEEDap BD+C, Architecture Advisor
Globally renowned sustainability executive, certified Board Director and Architect with extensive experience in ESG issues. Board Chair leadership roles at CarbonCure, WorldGBC and CaGBC. Passionate thought leader in high-performance sustainable and resilient design. Extensive knowledge of Net Zero Carbon Design, Specifications and CleanTech solutions for Buildings and Infrastructure as supported by a vast portfolio of global built work.
Tony Bi, Ph.D., Technology Advisor
Director of Clean Energy Research Center and Professor in the Chemical and Biological Engineering Department at University of British Columbia, Fellow, Canadian Academy of Engineering, recipient of the CIESC Engineering Thermochemistry Award in 2023, BC Bioenergy Sector Award in October 2022, and the CSChE Industrial Practice and Design Award in October 2020, with a portfolio boasting 12 patents and provisional patents across USA and Canada.
Sarah Gray, P.Eng., CAHP, Engineering Advisor
Principal, Senior Building Science Specialist at RDH Building Science Inc. Sarah has been in the engineering and building science field for nearly 25 years. She holds a B.Sc. in civil engineering from University of Cincinnati and a M.Sc. in historic preservation from University of Pennsylvania. Her work is focussed on heritage building rehabilitation, existing building condition assessment and deep retrofits, and building enclosure consulting for new construction. Sarah has served on various industry boards and committees for 15 years.
Kirthi Roberts, Ph.D., P.Eng., Environment & Sustainability Advisor
Partner at Fasken Martineau DuMoulin LLP, a corporate lawyer with over 30 years’ experience in advising companies, underwriters, and venture capital, private equity and other investors on a broad range of transactions. He has advised on the negotiation, structuring and implementing of M&A, financing and other transactions involving some of the world’s largest technology companies.
Iain Mant, LL.B. Legal Advisor
Kirthi has 25 years of industry experience, across five different industry sectors in Canada. The former Director of Environment at Vancouver Airport Authority, Manager of Sustainability at Vancouver School District, and co-chair of Metro Vancouver Regional Engineer’s Advisory Committee’s (REAC) Climate Action Sub-committee, is an advocate for systems-thinking and closed-loop circular economy solutions. Kirthi is a licensed Professional Engineer in BC (Engineering Physics) and holds a Doctorate in Resource Management and Environmental Studies.
Together We Are a Team
We collaborate with a network of industrial partners who support our efforts to develop EcoBrik™,solutions in line with industry standards
Recycle BC, a not-for-profit organization responsible for managing the recycling of residential packaging and paper products throughout British Columbia, plays a crucial role in diverting significant waste from landfills and advancing sustainable waste management practices. They contribute not only financial resources but also provide access to valuable waste streams and facilitate partnerships within the recycling ecosystem. This support is vital for driving innovation and collaboration in the pursuit of more sustainable recycling solutions.
Powertech Labs, a wholly owned subsidiary of BC Hydro, is made up of around 200 scientists, technicians, engineers, and specialists, making it one of North America’s most advanced testing and research organizations. Powertech plays a vital role in ensuring that all tests are conducted in strict compliance with industry standards and regulatory guidelines. Powertech also provides essential support in designing detailed test protocols, ensuring Samsara's innovations consistently meet the highest standards of quality and reliability.
SGS, headquartered in Geneva, Switzerland, is a global leader in inspection, verification, testing, and certification services. The SGS Taiwan branch provided crucial support to Samsara by designing comprehensive testing protocols and conducting rigorous strength tests on its product prototypes. This partnership was essential in ensuring that Samsara's products not only met stringent industry standards but also achieved the highest levels of safety, reliability, and durability.
Two industrial leaders from Asia partnered with Samsara to co-develop a manufacturing process and equipment. These OEM partners brought extensive expertise in plastic waste management and advanced production techniques, helping to refine and optimize Samsara’s approach. They played a key role in testing and fine-tuning the process to ensure both efficiency and scalability. Additionally, these partners were instrumental in producing initial samples, enabling Samsara to validate the quality and performance of their materials.
Founded in 2000, MaRS (Medical and Related Sciences) has since broadened its scope, becoming a prominent platform for research, commercialization, and collaboration. MaRS supports Samsara by offering vital resources for research, commercialization, and sustainable growth. Through its network, MaRS connects Samsara with experts in cleantech and circular economy initiatives, providing guidance on scaling sustainable solutions.
News & Updates
Join us in building a sustainable future, one EcoBrik™ at a time!
We’re transforming plastic waste into sustainable building materials, paving the way for a greener future. If you're a builder, architect, or developer passionate about sustainability, let’s collaborate to create impactful solutions together. Together, we can build structures that not only stand strong but also protect our planet. Connect with us today and be part of the change!
info@samsaramaterials.com
Samsara Innovations transforms plastic waste into sustainable building materials, revolutionizing construction with EcoBrik™ for a greener future.
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