Zero Waste Day: discover HaDEA-managed projects reducing waste and promoting sustainable production

Every 30 March, we celebrate Zero Waste Day, an occasion that highlights the importance of reducing waste and promoting sustainable production. EU-funded research and innovation projects managed by HaDEA are working tirelessly to support this vision, by delivering cutting-edge technologies and processes that enable the transition to a more circular economy. Discover some of these pioneering projects, which are making significant strides in achieving zero-waste and zero-defect manufacturing, and paving the way for a more sustainable future in various industries.

COMPASS is developing a data-supported remanufacturing process for sheet metal and composite parts in the aerospace and automotive industries, focusing on creating a digital component passport that stores data throughout the product's lifecycle. This innovative approach aims to increase the efficiency of recycling and remanufacturing processes by remanufacturing components at the level of sheet metal and composite panels, rather than converting them to secondary raw material. By leveraging digital tools and a digital component passport, the project aims to optimise the quality of remanufactured output parts and reduce costs. 

The COMPASS project has the potential to initiate significant private investments in technology development and implementation, with the overall goal of enabling the remanufacturing of approximately 30% of sheet metal parts and thermoplastic composite panels. The success of this endeavour could lead to reduced waste, increased efficiency, and lower costs in the aerospace and automotive industries.

PLATFORM-ZERO is developing a self-learning, modular, and customisable in-line process monitoring platform for the third-generation photovoltaic (PV) industry. The platform employs non-destructive inspection methods and Industry 4.0 Artificial Intelligence (AI)-based tools to enable early detection, correction, and prevention of pre-critical production faults. By reducing defects and waste, the project aims to increase the overall quality and reduce the cost of high-tech PV devices, making the EU's PV industry more competitive and contributing to Europe's transition towards climate-neutral energy generation. 

The platform will be demonstrated in four functional demonstrators in different PV and PV-related manufacturing lines, including roll-to-roll, sheet-to-sheet, and line flow PV manufacturing lines. The project's success could lead to improved manufacturing control, reduced environmental impact, and enhanced competitiveness for European PV manufacturers.

The FLASH-COMP project is developing a digital hybrid twin platform for the manufacturing industry, utilising advanced technologies such as AI, physics-driven modeling, and digital twin technology. The platform's Decision Support Tool (DST) enables workers to make informed decisions, reducing waste and increasing efficiency in composite manufacturing. 

Key features include non-destructive inspection and monitoring instruments, an online Defect Severity Estimation Tool, and a decision support system. The project will be validated through a test bed and two industrial use cases, ensuring future replicability. A comprehensive training program will also be provided to enhance operators' skills.

By optimising the composite manufacturing process, FLASH-COMP aims to contribute to the European transition towards climate neutrality, aligning with the Green Deal's goals. The project's human-oriented solution will help reduce waste and increase efficiency in strategic sectors such as energy, aerospace, and automotive, ultimately promoting a more sustainable future.

TURBO is working on a zero-waste manufacturing process for wind turbine blades, aiming to reduce defect formation through better process simulation, monitoring, and control. The project is developing new methods of non-destructive testing (NDT) and introducing novel repair strategies in composites and coatings. 

By achieving zero-waste turbine blade production, TURBO could lead to improved recyclability, reduced environmental impact, and a more circular economy in the wind turbine industry. The project is utilising advanced technologies such as digitalization, artificial intelligence, and the Internet of Things (IoT) to optimise the manufacturing process and improve quality control. With its comprehensive approach, TURBO has the potential to transform the wind turbine industry, promoting sustainability, efficiency, and innovation.