AD-CORSSI | Automation and digitalisation of a production line for recycled composites

Region:

Wallonia

Financed by

Towards a circular economy for thermoset composites

The AD-CORSSI project addresses a pressing challenge in industry: the sustainable and efficient management of thermoset composite waste. Thermoset composites are used in many sectors (transport, construction, industry), but are still difficult to recycle. AD-CORSSI aims to show that they can be repurposed on an automated production line and reused in applications with high safety requirements, taking their place in a completely circular economy.

Context

The repurposing of thermoset composites is hindered by technical, economic and logistical obstacles. Existing processes are mostly manual, hard to reproduce and insufficiently digitalised. This results in inconsistent performance and limited traceability – unsuitable for critical applications. In addition, companies have limited access to reliable data and few decision-making tools for designing or manufacturing with recycled materials.
AD-CORSSI aims to overcome these obstacles by developing a pilot automated production line, generating standardised data on the performance of recycled composites and showing that they can be used in demanding industrial environments.

Objectives & results

AD-CORSSI’s objective is to turn thermoset composite waste into an industrial opportunity by boosting the manufacturing sector’s recycling capabilities.
Specific objectives include:

Automating a production line for recycled composites
Optimising RTS (Reprocessed ThermoSet) formulations for improved mechanical performance (fatigue, elasticity, impact resistance)
Developing a digital twin of the process in order to monitor, anticipate and optimise production
Developing a durable industrial speed bump that is designed to withstand heavy traffic and meets cost, performance and environmental impact criteria
Carrying out a complete LCA (Life Cycle Assessment) of the material, product and process

Approach

WP1 – Administrative, technical and strategic project management.
WP2 – Formulation and optimisation of a recycled composite material.
WP3 – Development of a digital model to simulate the material’s behaviour.
WP4 – Development of a new product based on recycled material.
WP5 – Automation of the production line and integration of control systems.
WP6 – Development of moulds and refinement of the manufacturing process.
WP7 – Creation of a digital twin for process monitoring.
WP8 – Evaluation of the product’s technical and economic performance.
WP9 – LCA: environmental assessment of the product and process.
WP10 – Valorisation: exploitation, dissemination and preparation for market launch.

Target group

The project is primarily intended for industrial manufacturers seeking to make use of their waste, as well as manufacturers of safety equipment (signage, street furniture). Ultimately, it will be beneficial to companies in transport, construction and logistics – sectors that need materials to be easily traceable and durable.

Benefits are also expected for:

The automotive sector (an end-of-life solution for lightweight structural parts),
The building and public works sector (signage and protective items),
Local authorities (management of recyclable safety equipment).

Questions about the project or its relevance to your business?

Get in touch with our expert Didier Garray to explore what’s possible for your company.

Contact Didier Garray

Funding

Funding agency: Walloon Region
Project type: Grant within the framework of the Greenwin and MecaTech competitiveness clusters
Contract number: Agreement No. 8511 + Addendum (12-month extension)
Funding level: €2,221,299.44 in total