Currently, the use of bio-composites is limited to less critical applications that do not have significant requirements in terms of mechanical performance. However, the use of synthetic composites made from carbon or glass fibre has several difficulties in terms recycling and in terms of dependence on third countries. About 98% of these synthetic composites still end up in landfills and about 80% of the raw materials are currently manufactured outside of Europe. To improve this situation, the project addresses the challenges of using bio-composites for structural parts and aims to increase the range of applications in which bio-composites can be used. This will be achieved by developing an accurate draping process to control fibre orientation, by creating material models that capture the natural variability of the material and by integrating nano-structured, bio-based sensors for load monitoring. Through the increased accuracy and additional control loops in the manufacturing process the consortium expects to achieve predictable properties and constant quality. Within the project use cases from wind energy and boat-building will be investigated, aiming at the manufacturing of a full size rotor blade and a ship hull to demonstrate the technical feasibility and achieving TRL7 for the manufacturing technologies. In addition to the end users, the consortium consists of partners from automation, machine building, measurement technology, material manufacturing and simulation software to cover all aspects of the developments. Based on the predicted growth of the bio-composites market, which is expected to increase by a factor of 2.5 by 2030, the consortium expects a market potential of about 100M€ by 2030.

European industries remain a significant source of pollution (51% of GHG emissions), with unsustainable production processes impacting adversely on climate change, natural resources availability, air/water/soil quality, ecosystems services and biodiversity. Thus, a transition to a sustainable and strong bioeconomy is one of the European main priorities as part of the EU Industrial Policy Strategy, the European Green Deal, the 2030 Climate Target Plan and the Bioeconomy strategy. CALIMERO will analyse bio-based sectors industrial case studies provided by partners (construction (ECIA), woodworking (CESEFOR), textiles (TECHTERA, EREKS), pulp & paper (ESSITY) and biochemicals (BIMKEMI)) to find feasible solutions to improve their environmental performance while considering also economic and social aspects. A deep analysis and improvement of the bio-based sectors sustainability performance by sustainability experts (CTA, WELOOP, LIST, IVL NEOVILI), followed by the simulation and modelling of relevant case studies through bio-engineering expertise (DTU) will be conducted to improve current Life Cycle Sustainability Assessment methodologies, based on the Product Environmental Footprint (PEF) guide. To that end, missing characterization factors to assess biodiversity loss, impacts to ecosystem services and toxicity effects of sector-specific substances will be developed. The allocation methods of biotic circular systems will also be improved and the time dimension for lifecycle carbon footprint assessment will be considered. Material criticality and socio-economic indicators will also be included to cover the three pillars of sustainability. The improved methodology will be applied via a Multi Objective Optimization framework that will optimize industrial simulations with sustainability criteria. Finally, guidelines and recommendations addressed to industry, policy makers and scientific community will be developed for industrial sustainable development and monitoring.

SOLSTICE aims at demonstrating 4 replicable systemic solutions for the territorial deployment of the circular economy (CEC) for the major industrial sector of textiles (62Mt produced/year). All steps of waste prevention and management will be included in a 5R strategy: Refuse/Reduce, Reuse, Repair, Repurpose, Recycle. The solutions developed can be replicated and cross-linked with the plastics value chain. SOLSTICE will: • Develop tools and strategies to implement the 5R approach: oFor the 4R Refuse/Reduce, Reuse, Repair, Repurpose: - Engage the different stakeholders (industrial companies, local authorities, citizens) to revise their supply chains / behaviour, and become more sober, circular and sustainable. - Scope and map current state, carry research on and analysis of relevant circular interventions per territory, - Create a methodology and blueprints of CEC interventions to be tested/piloted - Define circular guidelines and indicators oRecycle: Demonstrate innovative chemical recycling technologies, able to treat efficiently part of the major streams of polymers in textiles and plastics (PET, elastane, polyamide, polyurethane) in mild conditions. The technologies allow to recycle multicomponent and bio-based materials, complex streams, and to recycle textile into textile or coating into coating (closed-loop) or into added-value applications (open loop). They are easily adaptable and allow a local recycling. • Set-up a traceability system based on a Digital Product Passport and designed in relation to existing initiatives. The demonstration will take place in 4 EU representative and complementary territories. Knowledge-transfer and cooperation between the cities and regions involved, and with CCRI and other stakeholders and projects, will ensure an optimised development and deployment of the new circular concepts, as well as the replicability of the concept and a maximal impact. The deployment of SOLSTICE could save 4.3-10.8 Mt GHG emissions/year by 2030.

Each year about 110.000t of carbon fibre composite parts and 4.500.000t of glass fibre composites are used. 98% of these parts end up in landfills at the end of their life. To address this problem the MC4 project aims at establishing a multi-level circular process for carbon and glass fibre composite. Multi-level means that processes will be developed for short-term implementation with immediate impact and for the longer term with a wider impact on industry. Carbon and glass fibre have substantially different costs and the project takes this into account by developing economically feasible procedures that are based on chemical matrix/fibre separation for carbon fibre and on a new type of resing for the direct re-use of the composite for glass fibre. Quality grading of the recycled material will be a key element to ensure a proper use in the different domains. Within the supply chain investigated in the project the goal is to achieve a recycling rate of at least 60%. As an additional benefit, the project will enable European material manufacturers to develop their own, patented processes for manufacturing of recycled material. Currently, 80% of the manufacturing of virgin carbon and glass fibre is taking place outside of Europe and the manufacturing technologies used inside of Europe are often licensed from foreign countries. MC4 puts particular emphasis on the design and manufacturing of best practice examples of parts made from recycled materials. For five different domains, including automotive, aerospace, sports equipment, boats and urban furniture, composite products will be manufactured, with the aim of demonstrating the use of recycled material and enhancing the demand side for recycled material in the different domains. The consortium includes process developers, material manufacturers and SME end users, who manufacture composite parts. It covers the whole value chain and thus enables the creation of real circular process for composites.