Case studies

Case Study #1: Building Sector

Challenges

Conventional window frames made from Polyvinyl chloride (PVC) often contain potentially harmful additives and have a low recycling rate. The production of PVC and its steel reinforcements are major environmental hotspots.

Objectives

The goal was to develop a recyclable, bio-based polyurethane (PU) alternative that improves insulation properties and durability while reducing the use of hazardous substances and the overall carbon footprint.

Achieving Recycling Loops

The project developed recyclable PU materials using vitrimer chemistry, which allows the thermoset material to be reprocessed. This strategy aims to achieve at least three recycling loops with minimal loss of material properties, a significant improvement over conventional PU and PVC.

Case Study #2: Transport Sector

Challenges

Metal parts used in trains are heavy, leading to high energy consumption during the use phase, which is a major environmental hotspot. Traditional epoxy composites are lightweight but are typically non-recyclable and can contain hazardous, halogen-based flame retardants.

Objectives

This case study aimed to design a fire-resistant, intrinsically recyclable epoxy-vitrimer composite to replace metal parts. The key targets included a significant weight reduction (>30%), compliance with strict fire safety standards (EN45545-2), and 100% recyclability through vitrimerization.

Advances in Sustainability

The developed lightweight composites offer significant operational cost savings over their 25-year service life due to lower energy consumption. While the manufacturing of carbon fiber remains a hotspot, the design successfully replaced potentially hazardous flame retardants and introduced a viable chemical recycling route using environmentally friendly solvent.

Case Study #3: Packaging Sector

Challenges

Conventional multilayer food packaging films are often not recyclable due to their complex structure, which includes incompatible polymers. This leads to most of this material ending up in landfills or incineration.

Objectives

The goal was to design a fully recyclable MultiNanoLayered (MNL) film by creating a simpler structure (PE/EVOH or PE/PA) and optimizing the use of compatibilizers.

Advances in SSbD

• The formulation and process optimization (MNL, supercritical CO₂) provide an ideal balance between technical performance (barrier, mechanical, and optical properties), and sustainability.
• The innovative solution reduces raw material consumption while optimizing costs and limiting environmental impact.
• The Safe and Sustainable by Design (SSbD) approach highlights improvements across most of the evaluated criteria.

Recommandation

• Ensure compliance with customer requirements for the entire set of specifications (transparency level, NIAS migration, etc.)
• Further investigate the feasibility of industrializing processes with low technological maturity (low TRL)
• Strengthen the efficiency of collection and sorting of flexible packaging in order to increase their recycling rate

Lessons Learnt

The practical application of the SSRbD framework across the three case studies generated valuable insights that are now embedded in this digital infrastructure. The key lessons include:

• The Need for a Guiding Methodology: A structured, holistic approach is essential to navigate the complexities of SSRbD.
• Importance of System Definition: Clearly mapping functionality requirements and identifying a reference product (baseline) are crucial first steps to define the system boundaries and target improvements.
• Interdisciplinary Collaboration is Crucial: Effective SSRbD requires co-creation within a diverse team of experts, including toxicologists, material scientists, chemists, and processing experts, to ensure an efficient innovation process.