Annual Report 2011-12

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2011/ 2012 Annual Report

Contents

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Impacts and Case Studies

Executive Summary

KCMC’s role in the UK Innovation Landscape

Foreword

Connect...faciliate and deliver

Feature: Sensors

Feature: Hartree

KCMC Metrics

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Just as a thriving manufacturing sector is vital to the health of a well balanced UK economy, so materials and the chemistry to create and develop them are key to manufacturing. In turn, collaborative innovation in materials chemistry is a major driver for the High Value Manufacturing (HVM) which the Technology Strategy Board supports.

The many and diverse links between manufacturing and materials chemistry are nowhere better illustrated than in the breadth and depth of the successful collaborations which KCMC has forged between industry and academia. In its first three years, KCMC has continually delivered and contributed ahead of expectations – achieving a conservatively estimated Gross Value Added (GVA) of ten times its original combined government and university investment of £15m.

These collaborations have been created by single point access to multi-disciplinary research partnerships across key sectors including energy, health and sustainability.

The contribution of the KCMC link is further reinforced by the

Foreword …..materials chemistry in High Value Manufacturing innovation

fact that despite the challenging economic climate there has been strong year-to-year growth in the number of collaborations KCMC has enabled. In 2011/12 it made first-time introductions to the research partners of no fewer than 82 companies, with over 50 projects formally contracted and 250 industry engagements progressed.

KCMC has also highlighted the importance of a flexible approach to companies wishing to access leading edge expertise, while reflecting distinctly different sectoral approaches to innovation.

Crucially, what many of these collaborations share and reflect is the resultant inward flow of skills and trained staff needed to support high growth companies in the manufacturing sector.

As it transitions towards a new role in the UK innovation landscape for 2013 and beyond, KCMC stands as an impressive model for collaborative innovation.

In 2011/12 KCMC made first-time introductions

to the research partners of no fewer than 82

companies, with over 50 projects formally contracted and 250

industry engagements progressed.

Malcolm HannabyLead Technologist -

High Value Manufacture, Technology Strategy Board.

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Connect, facilitate, deliverMaterials chemistry is vital to key technologies for sustainable solutions for society and industry, especially in energy, health and in developing replacements for scarce raw materials.

KCMC uniquely connects and networks academia and industry, facilitating collaborative R&D that can help companies to deliver accelerated innovation-to-market timescales.

Executive Summary

Key highlights of KCMC achievements in the year to 31 March 2012 included:

2011/12 saw first time company introductions to the four university partners – of which 50% were SMEs…

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By the end of its third full year, KCMC had delivered a GVA projected impact of ten times original combined

investments started in late 2008 by government and the university partners...£15m

25050 new projects were formally contracted and industry engagements progressed last year – taking total engagements since KCMC start-up to beyond 500…

companies have now benefited from multiple interactions with the KCMC research partners…

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of post-outline agreement projects proceeded successfully…

87%The Solvay/The University of Manchester materials development research programme announced during the year was a major success story for KCMC…

£1.4m

Knowledge Transfer (KT) research income grew by an impressive

50%in 2011/12…

Majority of key five-year project targets

have been matched or exceeded within KCMC’s

first three years.

… net year-on-year KT income growth was delivered even with the Solvay/UOM programme excluded…

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KCMC’s mission is to enable companies to enhance and accelerate their innovation through collaborative R&D in materials chemistry.

KCMC is a virtual centre hosted by Chemistry Innovation Ltd and provides highly flexible access to multi-disciplinary academic research by its partners - the Universities of Manchester, Liverpool and Bolton and the Science and Technology Facilities Council (STFC) at Daresbury.

Dedicated resources deliver competitive advantage for businesses in industrial timescales with reduced business risk.

KCMC catalyses innovation across applications in energy, health, personal care, ICT and sustainability. It offers companies single-point access to the research partners, rapid project start-up via dedicated scientists and ready access to support grants.

KCMC at a glance

KCMC Leadership TeamDr John Conti-Ramsden, KCMC DirectorProfessor Mike Turner, University of ManchesterProfessor Matt Rosseinsky, University of LiverpoolProfessor Elias Siores, University of BoltonDr Paul Sherwood, STFC

materialschemistry.org

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Impacts and Case Studies:

In 2011/2012, a further 82 new companies were introduced to the four KCMC research partners and a high proportion of these (50%) were SMEs. Total engagements since project start-up have now passed 500. More than 100 scientists from KCMC and the surrounding region have now been trained in the state-of-the-art applied research capabilities of KCMC with 497 training units completed. A further two project scientists have taken their KCMC skills on to other roles in industry and academia.

A KCMC economic impact review at the end of the Centre’s third full year operation concluded that return on the original £15m investment by government and university partners has - conservatively - generated a GVA return using standard metrics of approximately ten times that amount.

Diverse examples of materials chemistry-related innovations in KCMC’s generation of value include:

At a glance: ACAL Energy is developing a new fuel cell engine utilizing patented liquid catalyst chemistry. Flow Cath® technology will represent a key milestone in delivering affordable, durable fuel cell power.

ACAL Energy

Affordable, durable fuel cell power:

Timeline: Commercialisation is well advanced. Evaluation and field assessment began in Q4 2011, with demonstration and product/packaging development scheduled for 2013/14.

KCMC support: KCMC catalysis modelling projects at Daresbury have been complemented by catalysis development at The University of Manchester and high-throughput synthesis/screening and electrochemistry at Liverpool University.

Benefits: The technology has class-leading durability and reduces platinum levels by 75%. Together with plant simplification this brings fundamentally lowered cost, with instant power availability.

Approach: ACAL’s virtually platinum-free FlowCath® cathode liquid technology meets key cost and durability challenges. A proprietary chemical solution is reduced at cathode to produce electrical power, with regenerated solution flowing back into the stack.

Challenge: With its efficiency and low environmental footprint, electric fuel cell technology is a multi £billion global opportunity – notably for the auto and stationary power markets... But with their high platinum content, conventional PEM fuel cells are too expensive – with poor durability and slow response.

At a glance: A market leader in colour-change materials for laser coding and marking (consumer products, packaging and labels), Datalase is focused on developing digital print solutions that are scalable across multiple platforms, media and applications.

Challenge: To develop “next generation” materials for Datalase Infinity full-colour, in-line digital printing – especially with regard to heat driven or activated colour change reactions.

Approach: (1) Study by The University of Manchester and STFC Daresbury of polymorphic properties of Infinity materials, including material analysis and molecular modelling. (2) Univeristy of Liverpool study of reduced indium tin oxide NIR absorbers (r-ITOs) to assist

Datalase “Next generation” digital printing:

r-ITO design for highest efficacy in Datalase applications and to underpin IP generation.

Benefits: Clarity on the presence of low energy unreactive and reactive configurations and ability of a molecule to convert from unreactive to reactive form. Data feed into R&D programmes.

KCMC support: Identified molecular modelling partners; facilitated engagement and provided financial assistance. Assisted in application for support of PhD Studentship to study sustainable metals for NIR absorbers. Provided networking, fundraising and business development guidance.

Timeline: The KCMC-supported 2011/12 programme is being used to steer in-house molecular engineering R&D.

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Byotrol Award-winning clean technology:

At a glance: Byotrol is a branded anti-microbial barrier technology, licensed to numerous major names across the global household and consumer markets. Products include cleaners, sprays, sanitisers and wipes that have a wide range of applications across the domestic, personal and healthcare, food and beverage sectors.

Challenge: Initially Byotrol was found by serendipity. Hence there was a real need to understand how the technology worked and how best to optimize what the technology could deliver. This then led on to exploring how to build the next generation.

Approach: Physical structure studies have included work on surface tension, AFM and phase separation. Also identification of new polymer candidates. Surface studies have been carried out at Sheffield University.

Benefits: Collaboration has raised further market opportunities for Byotrol’s technology - including from Biofilm studies at The University of Manchester (OMIC).

KCMC support: KCMC has facilitated R&D on next generation hygiene technologies, notably for health and personal care.

Timeline: Award-winning, Byotrol’s consumer division has enjoyed notably rapid expansion across international markets for surface care. Just recently (Summer 2012) a global deal with Kimberley Clark has been announced. Current forward focus is on developing next generation technology.

At a glance: Auxetic (flexible) material advantages in biomedical devices - including hip prosthesis - are being assessed. The new auxetic mesh artificial hip implant provides for optimal fit, device life extension, bone in-growth capability and reduced stress-shielding.

Finite Element (FE) modelling by Bolton University’s Institute of Materials Research and Innovation (IMRI) has assisted development of hip stem designs.

Challenge: Total hip replacement (THR) implants are stiffer than the skeleton and carry greater weight load - known as stress shielding. The upper thighbone is unloaded and more fracture-susceptible.

The challenge is to overcome limitations of current biomedical device materials.

Approach: THR structure stress analyses, using the ANSYS FE code, show lower levels of stress shielding for auxetic stem devices than for conventional devices.

Rapid prototyping is being used to manufacture devices for testing.

Benefits: Auxetic stem device diameters can be increased or decreased, leading to operational flexibility and faster rehabilitation.

The porous auxetic component promotes new bone in-growth and has greater energy absorption for improved comfort.

KCMC support: Testing of rapid prototype devices using videoextensometry.

Timeline: Completion target - Spring 2013.

Smart medical devices from auxetic materials:

At a glance: Due to superior hardness/corrosion resistance, electroplated chromium is the most popular coating layer for decoration and engineering components. But replacement of toxic hexevalent Cr-plating solution is clearly desirable. The University of Bolton has developed nickel and copper nanocoatings with much improved hardness, wear and corrosion resistances. They reduce cost and eliminate use of toxic Cr-plating solution.

Challenge: To develop composite Ni or Cu coatings, or combination structures, with much improved hardness, wear and corrosion resistance.

MSC Ltd Bolton’s cleaner, harder, tougher coatings:

Approach: Incorporation of a small percentage of nanoparticles such as TiO2 and carbon nanotubes (CNTs) in electroplated layers can drastically reduce cracks, and improve hardness, wear and corrosion resistance.

Coatings performance can be maximized through optimization of the plating condition and the type and concentration of nanoparticles.

Benefits: Compared with the pure nickel layer, corrosion resistance of Ni-nanocomposite coating technology has increased by up to 100%, and wear resistance and hardness by up to 70%.

KCMC support: Involved in the project from the beginning, KCMC helped to make the plan of development, schedule of delivery and implementation of tasks.

Timeline: Ongoing joint development with MSC Ltd.

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At a glance: A leader in development, manufacture and supply of semiconductor quantum dot (QD) fluorescent nanoparticles – which have unique optical and electrical properties - NANOCO has a long-standing relationship with KCMC and its research partners.

KCMC connections are aiding NANOCO’s innovation across their key markets in LED lighting and displays, solar cells and bio-imaging.

Challenge: Extension of QD lifetimes, with retained optical performance.

Approach: Modification of nanoparticle structure and related process development.

Benefits: Substantial improvement in product lifetime, with no reduction in light conversion efficiency.

KCMC support: The focus in a series of major projects has been on using novel nano scale processing. The experience and capabilities of KCMC research partner the University of Liverpool have been key to the collaboration.

NANOCO Extending QD lifetimes:

Timeline: Ongoing. Currently, NANOCO is engaged in phased production scale-up and planning of further major investment.

At a glance: Energy-saving glass is key in reducing heat loss from buildings and fuel consumption. The PROMISE project is seeking new coating materials and manufacturing processes for “next generation” energy-saving glass.

SAFC Hitech and Pilkington have collaborated in adaptation of atomic layer deposition (ALD) to put energy saving layers onto window glass. The University of Liverpool (Centre for Materials and Structures) has a key role in this extensively TSB-funded programme.

Challenge: To develop and manufacture new ultra-thin coating materials that will keep heat in without compromising the transparency of architectural glass.

Approach: Adaptation of precision ALD coating technology – associated with computer chip production – to meet EU regulations for energy saving glass.

Benefits: Process compatibility with energy-saving glass manufacturing would enable seamless integration of ALD into glass production.

Pilkington Energy saving glass for homes:

KCMC support: Continuation of established working relationship between KCMC partners SAFC Hitech, Pilkington and the University of Liverpool, and has made extensive use of KCMC purchased equipment.

Timeline: Ongoing. Next step is process scale-up – to manufacture thin films on glazing-size substrates. The University of Liverpool has secured EPSRC funding to develop pilot plant.

Through discovery and development of innovative new materials and the new materials technologies needed for next generation products, KCMC is uniquely positioned to drive innovation in high value manufacturing in the UK.

Using a powerful combination of dedicated knowledge transfer experts and flexible research resources in its research institution partners, KCMC links expertise and specialist capabilities within industry and academia to deliver collaborative research to industry timescales.

KCMC collaboration themes are formed by an internationally competitive group of chemistry-using companies and academic experts. They provide a bridge to connect the leading edge science of the research institution partners and UK industry’s commercial market needs and opportunities.

The KCMC business model for collaborative research directly addresses major challenges to maintain and enhance innovation in the UK economy.

KCMC’s role in the UK Innovation Landscape:

KCMC is notably aligned towards:

Networking, facilitation and grant funding support for access to leading edge materials chemistry skills and capabilities.

Addressing societal challenges in energy, health and sustainability.

Creating innovative new materials:For electronics, photonics and sensors; formulated products; biologically relevant materials; multi-functional materials; enabling new manufacturing technologies.

Sustainable products and processes:Reduction and replacement of critical raw materials, bio-sourced materials, materials recycling and reuse.

Supporting SMEs and bridging the innovation gap “valley of death”.

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Following the early 2011 launch of the KCMC National Incentive Scheme,

KCMC has continued to engage actively with UK chemistry-using

companies both across and beyond the UK.

From many hundreds of informal contacts, more than 250 industry

engagements progressed in 2011/12. A substantial proportion of industry

engagements (43%) progressed to project scoping involving 40+ academic experts from the four

research partners. Pleasingly, once a project outline was agreed, a high

proportion (87%) of industry projects proceeded successfully.

Connect …For the SMEs (numbering 67 companies), a majority of the interactions in the period were an introduction or a single point interaction on a specific topic. Notably though, and with a small group of SMEs where there is a particularly strong alignment of capabilities between the KCMC research partners and company need, there have been sustained ongoing relationships involving multiple interactions and projects, often involving several of the research partners.

There are eleven SMEs in this group with their respective business focus in chemicals & materials (5), energy & environment (3), health (1), and electronics & photonics (2). Fewer than half these SMEs (5) are based in the NW UK – the rest come from the Southeast, Midlands, Scotland and Wales - reflecting the increasingly national scope of KCMC.

As in previous years the number of industry engagements has

been approximately split evenly between UK SMEs, larger UK-owned

companies and foreign-owned enterprises (Figure 1). 82 new

companies have been introduced to the KCMC, with roughly half of these

(40) being UK SMEs.

Overall, industry sectors supported are led by chemicals and materials companies working across a broad range of end application areas, but in aggregate the largest number of

companies supported are specialised in other industries eg in energy,

health, fast moving consumer goods and electronics (Figure 2).

Figure 1: KCMC Collaborators

by Company Type

Ten UK SMEs have now been identified with potential to grow more substantial research links with KCMC based on strength of business plan, fit with KCMC themes and match to research partner capabilities. Applications covered include chemicals and materials (2), clean water (2), energy efficiency and storage (2), health (3) and sustainable composites (1).

For larger enterprises, there is a group of 19 companies with multiple interactions with the KCMC research partners where KCMC has raised awareness of academic capabilities and connected up the relevant experts. These companies span chemicals & materials (8 companies), energy (2), health (1), fast moving consumer goods (2), food & drink (2), electronics & photonics (2), construction (1) and engineering (1).

Foreign owned - overseas link

Foreign owned - UK R&D

UK SME

UK other

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Figure 2: KCMC Industry Support

Chemicals & materials

Energy & Environment

Engineering

Health

Electronics

Construction

Food, drink & agrochem

Fast moving consumer goods

Transport

Other

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Delivery from the KCMC project pipeline has strengthened substantially in 2011/2012, with 50 projects contracted during the year.

There have been strong contributions from both medium and large sized projects. A high proportion of projects - by both number and value - are repeat business, with many building on the flexible resourcing approach of KCMC. A major project success of 2011/2012 was the agreement between Solvay and The University of Manchester of a research programme for the development of new materials with an investment of £1.4million spread over four years.

An increasing focus for new project generation in 2011/2012 has been European projects funded in the FP7 programme, with examples of projects won including Phast-ID and COMMONSENSE , both profiled in our features section, and InnoMatNet - a project jointly awarded with Chemistry Innovation on the networking of materials innovators and product designers.

The range of project sizes has shown the power of the KCMC flexible approach to project resourcing. The great majority of projects employ flexible resources for projects and short term support of less than one year’s duration (42 out of 50 projects). The average size for flexible projects (ie more than one week and less than one year’s work) was one third of an FTE experienced post doctoral researcher, or £34,000.

KT research income has grown impressively, by more than 50%, since the end of 2010/11. Indeed, net year-on-year growth has been delivered even after the contribution of the research programme between Solvay and The University of Manchester is excluded.

...Facilitate and Deliver KT research income per annum is shown to the right in figure 4 for the first three and a half years’ operation of KCMC.

The split of KCMC projects against industry sectors is similar to that of the industry engagement data shown to the left in Figure 2. Against the societal trends and challenges where materials chemistry can make an impact, the projects contracted by KCMC broadly align with the Industry Steering Group themes highlighted in the 2010/11 Annual Report.

These include: Sustainability (strategic raw materials, bio based products, carbon based electronics); Energy (new sources of energy, renewable energy, energy saving) and Health (aging population, quality of life, healthcare economics). Other key themes embrace Security and Secure Food Supply, with a number of new materials technologies offering potential impacts across a range of challenges (“divergent science”). For a few smaller support projects it is not possible to assign them in this precise way (“NA”).

Figure 4: KCMC Research Income

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4000

3500

3000

2500

2000

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1000

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arc

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2008-10Corr

2010-11 2011-12

Industry Income

KT grant income

Figure 3: KCMC Project Resources

Short termsupport

Flexible project

Major >1 year

Programme

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28

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,00

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£1

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Project Value

Number of projects

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Research at The University of Manchester is focusing on the discovery and development of novel materials to deliver specificity and detection of a range of target molecules in a number of platform technologies for sensor applications.

The technologies notably include thin film transistors utilising organic semiconductors andphotonic devices.

Sensors Sensor technology development at The University of Manchester:

The programme is lead by Professor Michael Turner in UOM’s School of Chemistry, with major contributions from Professor Roy Goodacre (Chemistry) and Dr Leszek Majewski (Electrical and Electronic Engineering).

Professor Turner has a wide ranging portfolio of collaborative R&D projects with universities, companies and other organisations both within the UK and across Europe. Three diverse examples are:

Phast-IDSaving people from pancreatic cancer:

The PHAST-ID project is researching how photonics could help in detecting pancreatic cancer at a much earlier stage than is possible with current techniques.

Every year 70,000 people across Europe are diagnosed with pancreatic cancer - a disease with a 90% mortality rate. As current technology only detects this type of cancer at a very advanced stage, fewer than 10% of those diagnosed are still alive five years after diagnosis.

PHAST-ID has developed photonics crystal based sensors that can measure changes in the blood molecules of a patient before the pancreas tissues are affected. This technology could save many lives as the early detection of the cancer potentially increases survival rates. The University of Manchester’s role within the project is in developing new materials to provide selectivity in the sensors.

The project is co-ordinated by the Tyndall National Institute in Ireland and other universities, research centres and companies in Germany, Sweden and the UK. It is funded by the EU Seventh Framework Programme with €2.68 million (total project cost of €3.55 million). It started in September 2010 and is due for completion in August 2013. www.phastid.eu

CommonSenseGreater protection for EU citizens:

The purpose of the CommonSense project is to provide greater protection to EU citizens from threats posed by the use of improvised explosive device (IED) manufacturing facilities in urban environments by criminal, terrorist and other organisations - but without using intrusive surveillance and tracking techniques.

The partners will develop a series of different sensors for detection of chemical explosives and radioactive materials, together with chemometric data processing algorithms to recognise trace amounts of explosives, and differentiate them from other interfering compounds. The University of Manchester contribution to the project is the development and characterisation of new materials for the selective detection of chemicals in the sensors.

www.fp7projectcommonsense.eu/index.html

Working in collaboration with Solvay, Professor Turner’s research team is developing new materials and devices for application as low cost sensor systems to monitor environmental contaminants and biomarkers of disease. The project offers a major opportunity to take the leading edge research from the R&D bench into commercial products.

Key UOM contacts are: Professor Michael Turner - michael.turner@manchester.ac.ukDr Mike Holmes - mike.holmes@materialschemistry.org

Collaborative R&D Project with Solvay SA:

Features

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Moves to ensure that UK scientists and businesses can be at the cutting edge of growth and innovation R&D are being fuelled by a £158m government investment in e-infrastructure - data storage, faster networks and large, high performance supercomputers.

KCMC’s heartland of chemistry and material science (predictive modelling and chemical and physical properties) has been identified as a key sector that will benefit from one of the moves triggered by the government’s investment.

A £30million share of the programme has been awarded to the Science and Technology Facilities Council (STFC) Daresbury Laboratory at the Sci-Tech Daresbury national science and innovation campus, to support research into the latest product development software. Its new Hartree Centre – with IBM as lead collaborator - is a modelling and simulation initiative designed to focus on the needs of industry and industry innovators.

Using STFC’s highly-skilled software developers, the Centre will write applications for today’s supercomputers - and new applications to take advantage of the supercomputers that will come on-line in research-led organisations over the next five years.

Chemistry and material science is one of six sectors on which Hartree will concentrate. Others include engineering, life science and environmental (weather and climate/ocean modelling).

KCMC-related projects featuring STFC’s powerful modelling capabilities include the current Datalase project for next generation digital print solutions (see case study p6). Another standout example is STFC’s work with Unilever in developing new software tools to serve product and process innovation in formulated personal care products.

STFC has a strong history

Sensor technology development at The University of Manchester: Hartree Speeding chemistry and materials modelling

in computational science and engineering, with 30 years’ experience in writing parallel codes for science and engineering applications - and a track record of delivering codes that scale to the largest supercomputers.

Modelling and simulation has become an essential component in several UK market sectors and its incorporation into the design process can shorten development times and cost.

However, in order to make use of increased integrated circuit density on computer chips, software needs to be written to be able to use multiple processor cores in parallel. The Hartree Centre will address this ongoing challenge by reconnecting the speed of hardware to the software which runs on these parallel systems.

Hartree will also act as a focal point to bring together leading technology hardware and software providers, the academic community and application end users in the business community.

Additional project partners to date include DataDirect Networks (DDN) - the world’s largest privately-held data storage infrastructure provider, OCF - a UK high performance server and storage cluster integrator, and Intel - a world silicon innovation leader.

The new UK e-infrastructure programme was triggered in Summer 2011, when BIS Minister for Universities and Science David Willetts invited discussion towards its establishment.

A ten-year strategic vision - including recommendations around software, hardware, networks, data storage and skills - emerged in a roadmap for advanced computing, data and networks by Professor Dominic Tildesley, published in November 2011.

The Hartree Centre is one response within many of the report’s key recommendations now being taken forward.

Key STFC contacts are:Dr Michael Gleaves - michael.gleaves@STFC.ac.uk

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* there was a separate requirement for growth in knowledge generation grant funding which was exceeded in the previous reporting year and no longer monitored as not directly relevant to collaborative research.

KCMC Metrics

In preparation for the closure of the regional development agency, all

project funding arrangements were terminated in the first quarter of

2012, one quarter earlier than the original business plan. A final report

of KCMC finances has been carried out by independent auditors and

received and accepted by the NWDA. A funding strategy was agreed with

the key institution partners for the current financial year (2012/2013), pending the transfer of KCMC to a

sustainable business model for 2013 and beyond.

Reporting and metrics

In the 2011/12 reporting period strong progress has been made against all key metrics, and in some cases five- year project targets have already been exceeded. The achievement of remaining project targets and the agreement of revised goals is currently under discussion as part of the development of a sustainable business model for the KCMC.

Output MetricProject Goal Sept 2013 (5 Years)

Actual April 2012 (3.5 years)

Comment

New Company Engagements (NW)

Business Engagements

Industry Income

Joint Projects

150 164 5 year target exceeded

5 year target exceeded

Ahead of plan

Changed approach to reflect business needs

350 >500

£6,360,000 £4,816,000

40 10

Grant Income* – Knowledge Transfer

Number of adults undertaking work based training (NW)

Total number of training instances (UK)

Commercial Opportunities

Jobs Created

5 year target exceeded

5 year target exceeded

5 year target exceeded

5 year target exceeded

Ahead of plan

£3,895,000 £5,954,000

90 103

350 497

41 26

17 19

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