World Environment Day

Circularity, recycling and reuse

A new line of shoes made with recycled blades

Acciona Energía and El Ganso have announced the launch of a new line of sneakers made with recycled blades from a wind farm currently undergoing repowering: Tahivilla in Cádiz (Spain). The company is replacing 98 old turbines with 13 modern, more powerful and efficient Nordex turbines, which will optimise the wind farm’s performance and increase its renewable energy output by 72%. With this initiative, Acciona Energía repurposes dismantled wind turbine blades at the end of their useful life into a new product, while advancing the development of blade recycling solutions, one of the main challenges for the wind energy sector as thousands of turbines approach the end of their operational life. While around 90% of a wind turbine can be recycled through well-established processes, blades–made from complex materials such as resins, fibreglass and/or carbon fibre–require specific solutions. The main challenge lies in developing sustainable and scalable recycling methods at an industrial level. At the same time, Acciona Energía is developing an industrial-scale wind blade recycling plant in Lumbier (Navarra), to process 6,000 tonnes per year and convert them into new raw materials for sectors such as automotive and construction.

The R3wind project promotes the circularity of wind turbines in Ireland

R3wind – repair, recycle and reuse being the 3 Rs – is the name of a new project involving Irish composites manufacturer ÉireComposites Teo and the Advanced and Sustainable Manufacturing and Materials Engineering (ASMME) department at the University of Galway in Ireland. Supported by the Sustainable Energy Authority of Ireland (SEAI), the project aims to strengthen circularity in the Irish wind energy sector by developing robust wind turbine blades that are optimised for disassembly, repair and recycling. The use of more easily recyclable resins such as Arkema’s Elium thermoplastic resin or vitrimers, which can soften under the effect of heat, will promote repair methods that extend the life of blades and reduce downtime and maintenance costs. These processes can be applied in both onshore and offshore environments. During the development of R3wind, demonstrators will be manufactured and full-scale structural tests will be carried out. In addition to reparability, the project will also focus on the development of recycling techniques for out-of-service blades.

FIBIAS++: How recycled thermoplastic composite is revolutionising the automotive industry

The aim of the FIBIAS++ project, led by IRT Jules Verne, is to develop thermoplastic composites based on recycled materials for use in the automotive industry, where reducing vehicle emissions and weight has become crucial. Can we produce a more environmentally sustainable composite, and integrate it into an environment of metal parts, while maintaining sufficient mechanical performance to meet strict safety requirements? This is the central question that FIBIAS++ is seeking to answer. The FIBIAS++ project is the continuation of an initial research project that focused on developing technologies for processing thermoplastic composites. This second phase adds an environmental dimension, with the aim of developing composites with a low CO₂ footprint and incorporating recycled materials, while maintaining high performance for semi-structural and even structural automotive applications.

The European Circular Composites Alliance (ECCA) unveils its letter of intent

The ECCA, created by EuCIA in partnership with JEC, aims to build a sustainable value chain for composites at European level. Here it presents its letter of intent: “Objective : Building a sustainable European value chain for composites

The European Composites Industry Association (EuCIA) is launching the European Circular Composites Alliance (ECCA). ECCA is a new collaboration between key stakeholders in the European composites industry, committed to building circular and competitive value chains for composite materials in Europe.

The Alliance will promote circular use of composite products through lifetime extension strategies such as repair, reuse and remanufacture. Also, it will set targets for the recycling of existing products that, for different reasons, are not suitable for further lifetime extension strategies, so they can be used in new products […].”

Natural materials and fibres

Bcomp and Siux release a sustainable padel racket

Swiss cleantech company Bcomp has collaborated with Siux, a leading Spanish padel brand, to develop the GEA racquet, an advanced level racquet that contains Bcomp’s ampliTex™ flax fabrics in its front and back. The natural fibre reinforcements offer high mechanical properties, and therefore high resistance to breakage, while also helping to preserve the environment, as flax fibres are a natural, CO₂-neutral raw material. The structure of the flax fibres integrated into the racket also gives it damping properties that reduce vibrations and give better ball control. What’s more, the composite material composition makes the racket lightweight yet durable.

A bio-based wood and bamboo Imoca for low-carbon sailing at the Vendée Globe

Marc Thiercelin, a famous skipper and environmental defender, has launched an innovative project: a truly low-carbon Imoca sailboat, using wood and bamboo, designed to meet today’s needs for sustainability and decarbonisation. Marc Thiercelin’s project aims to combine high technological performance with environmental considerations by using bio-based materials. Wood, which is being reintroduced into shipbuilding, will be used as the core of the sandwich composite parts. The skins, meanwhile, will be manufactured using bio-based resins and bamboo fibre reinforcements from Cobratex, thereby reducing the environmental impact. By using these innovative materials, the sailboat will emit 70% less CO₂ during its construction while reducing production costs by 45%. This ambitious project proves that sustainable solutions are not only possible but also viable for the marine sector.

4 architectural projects using natural fibres

As the global construction industry turns towards sustainable solutions, flax and hemp are emerging as high-performance, low-impact alternatives for a new generation of bio-based architecture:

1. University of Stuttgart’s ITECH Research Pavilion 2024 program in Germany : 2 extraordinary lightweight structures have been created using filament-wound flax fibres, demonstrating the material’s strength and design flexibility
2. French manufacturer Temca completed 880 lightweight shading panels using Bcomp’s ampliTex™ flax fibre material for the Cité Scolaire Internationale Jacques Chirac business school in Marseille. The system uses RTM-moulded ampliTex™ combined with UV-resistant gelcoat and fire-rated resin, providing a nature-inspired, energy-efficient solution with drastically reduced weight and hardware requirements compared to traditional materials
3. In collaboration with Alliance member Procotex and material partner Nabasco, Dutch composite innovator NPSP has delivered striking façades across Europe, including the vibrant green cladding of Amsterdam’s NEMO Science Museum, designed by Renzo Piano. Nabasco® Natural panels offer both design freedom and top fire safety standards, paving the way for bio-based façades in modern urban design
4. Demgy, a leader in recyclable moulded composites, has partnered with green roof experts Plantika to introduce Flaxcomp® sandwich base panels for rooftop garden modules. Replacing aluminium with perforated flax composites, the solution enhances water drainage and aeration while reducing environmental impact

Clean energy

Eel Energy boosts its biomimetic tidal turbines with Exel Composites profiles

French start-up Eel Energy has turned to Finnish pultruded and tensile-wound composite manufacturer Exel Composites to reinforce the undulating membrane of its hydrokinetic generator. That biomimetic technology harnesses the kinetic energy of water currents to generate electricity. This method, which does not disrupt aquatic ecosystems, is based on a patented undulating membrane inspired by the movements of fish tails. The subsea environment is particularly demanding, requiring materials capable of withstanding extreme stress and pressure. Exel has used several layers of discrete flat carbon profiles, the same as those developed for wind turbine applications. These flat carbon fibre profiles are stacked to create beams integrated into the membrane. Three bars have been placed across the membrane at 50, 80 and 100% of its length. This arrangement avoids bulging, which significantly reduces the efficiency of energy capture, and limits overall deformation, ensuring the structural integrity of the membrane and its optimum performance.

Owens Corning to reduce emissions by 80% at its Sweden plant

An estimated 10 to 20% of the EU’s building CO2 emissions comes from their construction, renovation, deconstruction, demolition and wider supply chain. In response to statistics like these, Owens Corning is transforming its operations across Europe. As a case in point, in August 2024, the company embarked on a multi-year project to replace 2 coke-fired cupola furnaces with 1 electric melting furnace at its Paroc Hällekis insulation plant in Sweden. When completed in 2027, the new furnace has the potential to reduce the plant’s Scope 1 and 2 emissions by an estimated 80% compared to 2023, as well as its Scope 1 and 2 emissions by 20% for stone wool, an insulation material made from volcanic rock. The electric melting furnace will make Owens Corning more competitive, both on the market and with new talent, reinforcing the Hällekis plant’s reputation as a prominent regional employer and one that values sustainability.

SMM Composites contributes to the relocation of wind energy in France

French wind turbine designer, manufacturer and operator Poweend is relocating its production to Hauts-de-France (northern France). The company has turned to composite mould maker SMM, based in Lanester in Brittany (France), to design its Eole5 wind turbine moulds, which it now manufactures in Carvin in the Hauts-de-France region. Formerly produced in Asia, the blades of the 1 MW wind turbines are now part of a process of reindustrialisation and support for employment. SMM Composites has drawn on its expertise in the production of large composite moulds, in particular using mechanised welding, infusion and the integration of heating systems, to develop a set of 6 moulds, including the one for the outer shell of the blade, of very large dimensions, incorporating a complex turning system, a heating device and recycled fibre, a first for the company. Currently producing one blade a month, Poweend hopes to gradually ramp up production, aiming for 2 blades a week within 3 years. By 2030, the aim is to have 100 wind turbines in service.

Cover photo: image by Sergio Cerrato – Italia from Pixabay