<LIFE11 ENV/IT/000036>

“Low Resources Low Energy”

Technical Report

Project Data

Project location ITALY

Project start date: 01/07/2012

Project end date: 30/06/2014

Total Project duration

(in months) 24 months

Total budget € 2.207.166

Total eligible budget € 1.921.366

EU contribution: € 960.683

(%) of total costs 43,53 %

(%) of eligible costs 50 %

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1. Executive Summary

Objectives

The main project objective was to drastically reduce the use of non-renewable resources in the

manufacturing of a new family of ceramic-tile-like wall and floor coverings. The main

objective was to implement a process capable of recycling waste which is typically difficult to

re-use due to its quite heterogeneous composition. Such waste has been converted into

coverings using an innovative waterless recycling practice of glass-based waste, lime and

natural stone cuttings. As a matter of fact, currently the complete glass waste recycling is

hindered by the extreme variability of glass compositions and to the higher and higher

content, in collected glass, of more refractory ceramic or glass-ceramic materials.

The new process for recycling undifferentiated glass-based waste, exhausted lime and stone

cuttings follows the same process currently used for ceramic tiles manufacturing, except for

the milling phase, which is conducted without any water, and thus it doesn’t require any

further atomization of slurries. This allows the reduction of water and energy consumption in

coverings manufacturing.

Another objective of this project, was the realization of a pilot plant which demonstrates the

feasibility on a larger scale of the results obtained by tests already performed and that its final

products can maintain the excellent technical features found on the products obtained from

these tests.

Description

The project started as envisaged on 1 July 2012.

The first phases implemented concerned the management and general organization of the

various activities, the confirmation of the decision-making hierarchies and of the timing and

manner of communicating between partners. Several meetings and contacts took place in the

first weeks, mainly using digital means, between the project managers of the various partners

to define, right from the start, the decision-making flow and to carefully evaluate each aspect

of future activities. The following has in fact been organized: project management, flow of

information that must circulate between partners for the correct management of the project

and monitoring of the progress of the various actions through monitoring sheets which have

been prepared and distributed.

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Action A.1 was started immediately. The search for stable sources of glass-based waste, stone

cuttings and other materials had an immediate positive outcome thanks to the work of the

University of Modena, a project partner, which supported MammaRosa in the achievement of

this important objective. New important sources have been added to those already known

before the start of the project, guaranteeing a satisfying stability of the supplies over time.

This has been achieved thanks to the knowledge of the territory and the contacts that the two

partners have provided for the project. The action has been completed.

Action B.1 started as soon as the first supplies of raw materials and waste were available. In

September 2012 we had the first results of the grinding tests after some initial technical

adaptations. The action continued until March 2013 with various grinding tests, varying the

grinding units, grinding speed as well as the inside and the walls of the special mill, to prevent

the residues from “dirtying” the raw material mixtures. At the end of the action and after the

various tests and the necessary technical and mechanical modifications all the materials taken

into account were ground to the necessary fineness and at the same time the mixtures of the

materials were finely milled ready to be pressed. Multiple grinding operations are required

due to the different types of material to be ground. Thanks to the work carried out, with the

same instrument it is possible to grind the harder materials, the fragile ones and then mix

everything with binding components such as clay or bentonite. After each grinding operation

sieving guarantees the necessary fineness; the material which is not suitable is reintroduced in

the system for the following grinding operations. The tests to define the actual energy

consumption of the mixing system are underway and the objective of 30% of consumption

saved should be reached.

Action B.2 started at the beginning of 2013, even if some pressing tests had already been

carried out previously, in relation to action B.1, to confirm certain mixing parameters and

characterize in the best way some of the ground mixtures. Thanks to the help of external

suppliers, some of the best in the world as regards instruments or similar for the ceramic

sector, the parameters are being defined for the correct operation of the presses for the new

materials. We have obtained excellent results.

The moulds used are made of steel and measure 50x50 or 33x66 cm. They are amongst the

largest in use in the ceramic sector. Once the adaptation of the forming system has been

completed we have assessed whether increasing the size of the moulds is profitable, as well as

possible, in economic terms.

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Action B.3, which has the objective of optimising the firing curve by modifying the burners

started at the beginning of April 2013 and was completed without particular problems in

September 2013.

This action was jointly carried out by technical staff at Majorca, Mammarosa and professors

from the University of Modena.

Several tests were carried out to achieve the objectives and the modification was designed to

obtain maximum results at minimum cost.

Changes were made to three parts of the kiln considered strategic:

� configuration and adjustment of the burners to obtain a constant and flame that

extends transversally across the kiln;

� modification of the firing curve to fire the new materials at temperatures below

1000° C;

� adaptation of the conveyor system, in particular the rollers, whose speed has been

modified so it is compatible with the firing time, which is slightly different from the

traditional time required.

The most complex part that required different test was the one concerning the achievement of

the right firing temperature.

After having obtained the optimal base and carried out various tests we found the right

compromise of 900/920°C for 60 minutes (10/12 minutes only in the firing area).

Action B.4 began regularly in July 2013 and was completed without encountering particular

problems in late April of this year. A semi-continuous demo line was initially started up,

which could produce 500 sq.m/day of product with a content of recycled material (glass,

natural stone, spent lime) of up to 82%.

Demonstration sets of the new products with low environmental impact were then developed

and used for both wall and floor coverings.

The final product was characterized at the laboratories of the University of Modena and

Reggio Emilia; the data processed by the University of Padua for the LCA was jointly

collected.

Action B.5, which began in January and was completed in mid-May has allowed us to identify

the best product laying conditions; duration field tests were carried out and allowed us to find

the right solution to produce demonstration coverings.

Action B.6, carried out by the University of Padua, made it possible to develop, thanks to the

data collected the study of the LCA and the mass and energy balance of the project.

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An excellent dialogue between the partners and the definition, right from the start, of the

decision-making process and of the tasks assigned to each partner is guaranteeing the correct

progress of the project and of the management and monitoring of the project activities.

Dissemination activities started immediately thanks to the visibility given to the project in all

the offices, plants and laboratories involved, which has attracted the attention of suppliers,

customers, technicians and visitors in general. The final event was organised on 24 May 2014

at the Department of Industrial Engineering of the University of Padua, where the results

obtained were exhibited; it was an important opportunity to engage in networking activities

with other proponents of LIFE projects on similar topics.

The project environmental and social-economic monitoring activities have been implemented

by the partner University of Padua.

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2. Introduction

Environmental Project addressed

The environmental problem is the current enormous consumption of non renewable resources,

raw materials of natural origin in primis, used to manufacture ceramic coverings, like wall

and floor tiles. Considering that the high quality tiles (porcelanized stoneware) that the EU

production exceeds the 700 millions of square metres, it is evident that such kind of

manufacturing activity absorbs huge quantities of valuable materials like sands, feldspars,

alumina, zirconia, mullite, clays, not to speak of the water used during processing.

Regarding raw materials, it must be taken into account also that the manufacturing of high

quality tiles requires special raw materials, whose provenience can be from extremely distant

sources. Also water plays an important role, water requirement is of 8-18 m3 to mill raw

materials required to produce 1000 m2 of tiles; 7-15 m3 to prepare the enamels to glaze such

surface, and 800 m3 for cutting, grinding and polishing. This becomes a particularly high

consumption considering that it occurs in well defined regions.

Hypothesis verified by the project

The project has a demonstrative scale able to produce approximately 500 square metres of

coverings per day, equivalent to the recycling of 8 tons per day of glass based waste and 0.1

tons of exhausted lime from filters. A smaller scale would not have been representative of the

real conditions, since milling is a discontinuous process, and it requires a minimum quantity

to operate at the maximum efficiency. Nevertheless, the proposed demonstrative line size

allowed to reach the equipment steady state, a condition required to assess the energy, mass,

and environmental balance. The demonstrative line allowed to quantify the raw materials and

water savings, the energy consumed, the recycled and new raw materials used, to estimate

transportation environmental costs, and, together with the definition of end of life recycling

procedures, allowed to obtain a preliminary LCA.

Technical/methodological solutions

- setup of a supply chain of candidate waste materials used for the manufacturing of the new

covering and selection of the waste material sources.

- installation of demonstrative high energy milling equipment and subsequent mixing and

homogenization station with lime powders, feldspars, pigments and clays.

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- forming station: construction of new large (> 1 square metre) dies, definition of binder

additions and moisture corrections, modification of pressing cycle to account for the lower

plasticity of the new mixture containing less than 10% clay.

- Modification to firing kiln: realization of fast firing cycles in roller kiln with maximum

firing temperature <1000°C and final slow cooling to avoid residual stresses in the tile.

- Demonstrative line startup and manufacturing of testing and demonstrative sets of the new

coverings, for both floor and wall application; complete characterization of the obtained

coverings and definition of the new product specifications; demonstrative floor and wall

covering installations at the proposer’s show room, both indoor and outdoor, for

dissemination activities and field durability tests;

Definition of end of life procedures, energy and mass balance of the new process using ECO-

Audit tools and LCA studies.

Expected results and environmental benefits

- Reduction of non renewable raw materials resources up to 82% weight compared to

conventional ceramic tiles, this led to savings of up to 11.2 million tons of raw materials, most

of them glass-based, i.e. complete recycling of the whole glass production:

- Setup of a demonstrative line for conversion of glass-based waste, exhausted lime and

natural stone cuttings into low-temperature fired coverings, able to process 500 square metres

per day.

- Substitution of currently used natural or synthetic raw materials, having a high embodied

energy and CO2 footprint, with others having much lower environmental indicators.

- Reduction of energy consumption during firing of the coverings: currently 1.16 kWh are

required to fire 1 kg of porcelanized stoneware at 1250°C, while the new process requires less

than 0.8 kWh/kg. This amounts to a reduction of more than 30% of the energy consumption.

- CO2 emissions lowered, quantifiable in 0.063 kg CO2/kg of the new coverings fired.

- Reduction of energy consumption in milling operations, since the 50-80% glass-based

content enriches the mixture of brittle materials.

- Complete recyclability of the product at its end of life, with possibility of re-milling and

reintroduction in the same original manufacturing process, depending on the glazes used.

- Lower manufacturing cost of coverings, thanks to the use of low cost recycled materials,

faster milling, rapid drying and firing, the latter at temperatures lower than 1000°C, and final

finishing operation using dry cutting techniques. The potential manufacturing cost reduction

can be estimated in 40% less.

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- Possibility of obtaining curved shapes (for instance to cover columns) by hot bending of the

tile, under an applied pressure.

Expected longer terms results

The main expected results of the project in the long term is the industrialization of the line and

the transfer of the technology to other tiles and coverings manufacturing companies. If this is

implemented as expected (involving a consistent number of companies) the results will

contribute significantly to: better managing wastes, decrease CO2 emissions, energy use

efficiency and natural resources improved use. Many legislations and policies are involved

and the positive results obtained will foster the modifications of regulations which will favour

the uptake of the technology developed.

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3. Technical part per action

ACTION A.1 - Setup of supply chain of candidate waste materials

The aim of this action was to find possible sources of glass-based waste, stone cuttings and

other alumina silicate waste that would provide a constant flow of raw materials and to verify

their suitability for the manufacture of new ceramic tiles.

Mamma Rosa was responsible of the activity with the fundamental help of the University of

Modena (department of engineering) which has strong connections on the territory, in

particular: local and national industries, universities and research centres and public

companies. Majorca has given a support as well in the implementation of the action, storing

some waste at its premises. The university of Modena was in charge of contacting suppliers

based on environmental and technical aspects, while Mamma Rosa was responsible for

milling and mixing materials.

The main suppliers identified are: Emiliana Rottami, Sasil CoReVe, Ecolamp, stone and

sandstone quarries such as Borghigiana or certain areas of extraction in Carrara; the material

derived from ceramic tile processing is available from all the ceramic tile district of Modena

and Reggio Emilia, of which the coordinating beneficiary are part.

One of the aims of the present action was to identify suppliers able to provide 120ton per

month of the required waste; thanks to the collaboration between partners it has been possible

to select suppliers able to supply such quantity and even more if needed. Moreover another

objective consisted in the identification of suppliers in a given area in order to minimize the

environmental impact of their transportations. Also this objective can be considered achieved

since all suppliers are established within 200km from proponent’s plants and from the places

in which the project is carried out, guaranteeing a fast supply, low environmental impact and

reduced costs.

Finally, the last result to be achieved consisted in the identification of recovered materials not

excessively variable in terms of composition which allow us to achieve homogeneous semi-

finished powders which can be perfectly pressed following suitable processing to adapt the

particle size. Tests conducted by Mamma Rosa and the University of Modena showed that

such hypothesis was confirmed leading to a perfect pressing after appropriate processing

of particle size adjustment.

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More technical details can be found in the deliverable “A.1. Waste material supply chain

description”

Thanks to the actions implemented, partners have been able to set up an entire and

functioning supply chain for waste materials to be used for the manufacturing of new

products. The activities have been carried out without facing particular problems and they

have been completed within the timeframe foreseen.

Partners have been able to identify optimal sources of waste within the timeframe foreseen. In

particular some of the companies from whom waste is purchased are: Emiliana Rottami, Sasil

CoReVe, Ecolamp, Borghigiana and Calcium Carbonate from marbles mining. For what it

concerns the ceramic waste material, partners don’t have problems getting it from other

companies working in the ceramic district; some of the companies they have set up an

agreement with in this sense are Ceramica Alta and Ceramiche Gardenia Orchidea. All

suppliers are located at a maximum distance of 200 km from the company, so that CO2 linked

to transportation is limited.

ACTION B.1 - Installation of demonstrative high energy milling equipment and

optimization

The present action started as soon as action A.1 was completed and waste materials and tests

on them available. The main objectives of action B.1 were:

• Set up of a demonstrative line with a productivity of 500 m2/day;

• Design a system able to homogenize the granulometry and bring it to the desired

values via dedicated grinding.

• Reduction of energy consumption in milling operations, since the 50-80% glass-based

content enriches the mixture of brittle materials

In order to achieve the before-mentioned goals, it has been designed and built an innovative

milling equipment made of balls and internal walls made of particular shape blocks.

The particular shape and the use of circular grinding bodies, avoids the use of blades, at the

expense of a slight extension of the milling time which, however, is still widely compatible

with industrial production and the initial objectives. The demonstration system developed, in

fact, including the mill and the movement system able to change the speed and rotation, is

able to grind different compositions of raw materials and to separately treat fragile waste

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(glass-based materials) and more complex waste (stone cuttings, fired tiles) and mix the

powders obtained with binders such as clays and bentonite, as well as with dyes or additives

and thickeners such as sand.

This semi-continuous equipment is able to treat more than 8 tons per day of material and

therefore, despite the technical changes mentioned and slight extension of the operating time,

the initial goal of an overall load of 120 tons of material and waste per month is widely

respected. So far we can therefore confirm a productivity of the final demonstration line of

500 square meters per day.

The equipment developed is also able to homogenize the grain size and bring it to the desired

values through the use of dedicated grinding. Grinding takes place separately for different

classes of waste materials, fragile or more complex. All grinding is dry and the system is able

to vary speed, rotation and processing times according to the characteristics of each grinding

cycle; the most common materials used are: vitreous material waste, unfired ceramic waste,

natural stone waste and salvaging ceramic sludge.

Also the energy reduction objective has been achieved; results showed that energy

consumption decreases by approximately 30% and increasing the processing time (when

possible) would lead to further savings.

Partners have been able to achieve all objectives connected to action B.1. without facing

particular problems, for more details information on the action and the results achieved,

please refer to deliverable “B.1. photography of the new demonstrative milling plant”,

enclosed to the inception report.

Suppliers and consultants have been contacted immediately after the start date of the project

in order not to lose time for simple actions. Suppliers and consultants have been selected

following the procedure of private treaty and best value for money. The first progress

indicator has been achieved by the end of August 2012.

Also the other indicators of progress have been achieved in advanced compared to the

foreseen schedule. No particular problems have been encountered therefore the first milling

tests have started in September 2012. The anticipation of the first activities gave partners the

possibility to spend more time on functioning tests and on the improvement of the system.

The action therefore continued as scheduled until March 2013 with grinding tests and many

other different kinds. All progress indicators can therefore be considered achieved.

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ACTION B.2 – Modification to forming station by uniaxial pressing

Action B.2 was started as foreseen with some pressing testing aiming at confirming the

mixing parameters and to characterize a number of ground mixtures. The effective

modification of forming station by uniaxial pressing started the first few days of 2013. The

main objectives of the present actions were:

• Realization of a demonstrative pressing system, equipped with large moulds, to form

the new coverings in formats up to 1 square metre;

• Optimization of pressing, drying and enamelling parameters;

• Preparation of a set of pressed tile-like materials, to be tested in roller kiln firing.

Thanks to the help of external suppliers, a number of technical changes to existing systems

have been performed in order to achieve the expected results, in particular: weight range

given under pressure has been increased, the loading system of dies has been modified and

pressing times were adjusted in relation to the weight applied.

Also dies have been modified in order to adapt them to the new composition of raw materials

waste; The dies employed are made of steel and of size 50x50 or 33x66 cm and they don’t

show evidence of higher wear if compared to wear that normally occurs.

A number of punches and die boxes to be inserted into the dies have been created or adapted

for the project based on the composition of the treated materials and possible wear or

undesired reactions of the materials.

The system presents also a further innovative aspect which consists in the ability to add

binding agents or moisture corrections directly via the press loading system to vary.

Once the entire system has been built, tests were performed in order to identify parameters to

be optimized. The results obtained were satisfactory in terms of resistance to flexion and with

regard to the tests of surface and depth abrasion, however some modifications to the pressing

station were needed for optimize the treatment of mixtures composed of waste with low clay

content and to deal with humidity level of mixtures.

The best level of humidity identified was 7%.

After modifications several other tests have been carried out, thanks also to the help of the

University of Modena which realized also a mechanical characterization of the pressed

materials. Results obtained showed that physical and aesthetical characteristics of products

were equal (and in some cases better) than state of the art products, therefore action B.2 can

be considered concluded, having achieved all the expected results.

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The moulds and dies suppliers they also helped partners to design and realize new dies and

moulds. Subsequently partners have built the demonstrative forming line and tested it. Results

confirmed the expectations and parameters have been studied to obtain the best performances.

In particular it was found that the ideal pressing force is 420 kg/cm2 and 7% humidity content

is the best solution to achieve great results.

ACTION B.3 – Optimization of firing curve and burners modification

The present action started and was concluded as foreseen in the project’s demand without

facing particular problems.

The present action started from the results obtained in action B.2 and aimed at:

• Build a demonstrative roller kiln, modified in order to perform the low temperature

(<1000°C) of the new covering;

• Optimization of the demonstrative roller kiln parameters;

• Preparation of a set of fired coverings;

• Reduction of energy consumption (0.8 Kwh/kg) and CO2 emissions (0.063 CO2/Kg).

The first activity implemented was the modification of burners so that they can operate at

lower temperatures, before modifying the whole firing kiln. Such actions have been

implemented jointly by Majorca and the University of Modena. Other modifications have

been: optimization of the firing curve and adaptation of the conveyor system, in particular

rollers.

Tests have shown that the right parameters are 900/920°C for 60 minutes (10/12 minutes only

in the firing area). Considering that today the ceramic tile companies that produce porcelain

stoneware use a temperature of 1180/1220°C for 50/60 minutes, we can state with satisfaction

that we have lowered the firing time while maintaining the characteristics of the finished

product in line with the classic mixture products present on the market

This firing process, characterised by a lower temperature, significantly reduces the wear of the

kiln, increasing its life cycle.

In addition to the satisfying technical results, positive results in environmental terms were

also achieved: thanks to a 'low' firing temperature there is a 30% reduction in energy

consumption, which goes from an energy consumption 1.16 kWh required to fire one kg of

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porcelain stoneware at 1250°C to less than 0.8 kWh/kg. The reduction in energy consumption

during firing of the new material results in a reduction in CO2 emissions (0.063 CO2/Kg).

At the end of the action a set of demonstrative coverings has been prepared and used for

dissemination activities and on field testing.

The present action can be considered concluded since all objectives have been achieved

obtaining optimal results.

For more details about the present action, please refer to “Deliverable B.3 - photos of the

roller kiln and graph of the firing curves”.

Burners have been modified, decreasing the flow of gas inside each burner, the firing curve

which appeared optimal was 900/920°C for 60 minutes which determines a decrease in the

use of energy and CO2 produced. Finally roller kilns have been modified in order to

adapt the flow velocity to the actual speed of the plant (firing). The demonstrative line has

been then used to produce samples and test their properties. Products showed that new

products have nothing to envy to state of the art coverings and that they can be easily

considered perfect substitutes.

ACTION B.4 – Demonstrative line start-up and manufacturing of testing and

demonstrative sets of the new coverings

Action B.4. started regularly in July 2013 and was completed without problems in April 2014.

The present action aimed at:

• Setup of a demonstrative line for conversion of glass-based waste, exhausted lime and

natural stone cuttings into low-temperature fired coverings, able to process 500 square

metres per day;

• Manufacturing of sets of 100 square metres each of the new coverings, to be dedicated

to demonstrative installations.

The importance of action B.4 is evident since it represented the connecting step for the actual

obtainment of a complete functioning line. The equipment developed in previous actions had

to be assembled in one complex line, for this reason the focus of action B.4 were on auxiliary

systems such as conveyors and AGV systems to convey the unfired material.

Once the semi-continuous line was assembled, the result deriving from the firing in a kiln at a

temperature around 900-920° was connected to the quality control of the new coverings

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produced in order to assess the result and promptly take action if the results were not those

expected.

Thanks to the efforts of all partners and the perfect completion of previous actions,

beneficiaries have been able to obtain a perfect functioning system with a daily productivity

of 500 m2 of coverings per day which allow to decrease energy consumption and CO2

production.

Results have been achieved without facing particular problems. For more detailed information

on the present action, please refer to “Deliverable B.4. – Demonstrative line description and

pictures” of the final report.

The demonstrative line has been completed adding connections and auxiliary systems which

make it able to work autonomously. The entire line has been tested and samples have been

produced. Samples produced have been used both for indoor and outdoor applications. Finally

demonstrative installations were made at Majorca and Mamma Rosa’s premises.

ACTION B.5 – Demonstrative floor and wall coverings installations

Action B.5, started regularly on 1 January 2014 and ended as scheduled in the project

application on 31/05/2014.

The main objectives of the present action were:

• Demonstrative installations of the new coverings, for both indoor and outdoor case, as

wall or floor coverings;

• Definition of installing procedures and adhesives and sealants to be used for this

purpose.

It resulted particularly important the definition of the sealant and adhesive to be used for the

product implemented. For this purpose a preliminary study has been implemented which

started from a comparison of the parameters and data deriving from the characterisation of the

new products and of traditional porcelain stoneware: the results reduced the choice to a small

number of adhesives and sealants.

After testing it has been individuated as best adhesive a series of highly thixotropic powder

adhesives composed of high-strength cement, quartz of selected size, synthetic resins and

special newly conceived additives. Such adhesives allowed installations both indoor and

outdoor, both for ground applications and wall applications.

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In addition to the technical and functional aspects, the choice as regards to adhesive for our

product was also dictated by the low environmental impact; this adhesive has been tested

according to the European standard EN 12004, C2 TE.

Several tests were carried out which resulted in demonstrative installations at Majorca S.p.A.

and Mammarosa’s Project S.r.l.

The present action can therefore be considered completed, having achieved all results

expected. No problems have been faced during the implementation of the present action.

For more information on the present action, please refer to “Deliverable B.5 – Demonstrative

installations system” of the final report.

The most suitable adhesives have been selected: highly thixotropic powder adhesives

composed of high-strength cement, quartz of selected size, synthetic resins and special newly

conceived additives. Indoor and outdoor installations have been tested, together with

adhesives. Partners have identified also the best procedures to be implemented to keep clean

coverings for long time making them more lasting.

ACTION B.6 – Definition of end of life procedures and LCA

This study has been commissioned by Majorca SpA to the University of Padova for the

implementation of the Low Resources Low Energy project. The conduction of the analysis

has been carried out according to ISO 14040:2006 and ISO 14044:2006 (ISO 2006a,b).

This study was performed with the aim to quantify the potential environmental impacts

associated with an innovative product manufactured by means of the Life + Project Low

Resource Low Energy and to compare it with the impacts due to a traditional alternative

product. The results can be used to identify the improvement areas of the supply chain of the

product under study.

The study allowed the quantification of the impacts associated with the categories analysed

and the identification of the most impacting factors of the supply chains.

The results calculated by using the ReCipe 2008 method highlight that the Low Resurces Low

Energy product presents less environmental impacts than the traditional one for all of the

categories analysed. On the other hand the most significant contribution to the total impact of

the traditional product is due to the energy consumption during the manufacturing and to the

environmental burdens associated with the utilization of kaolin for the initial mixture.

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Moreover the relative differences between the impacts of the life cycle of the Low Resources

Low Energy product and of the traditional product are greater than 15% for almost all of the

categories analysed, with the exception of natural land transformation.

The study conducted by the University of Padova has clearly shown the positive

environmental benefits that can be achieved applying the innovative technology.

The present action has been implemented without encountering significant problems and it

has been realized within the timeframe foreseen.

For more information and detailed analysis, please refer to “Deliverable B.6 mass, energy and

environmental balances”.

The University of Padova has taken care of the present activity. Data collection took place

directly on the machine directly by University’s staff and Majorca’s workers. With the data

collected the University of Padova has implemented a Mass and Energy balance and

calculated the main environmental indicators. The study has highlighted that Low Resources

Low Energy presents lower environmental impact on every single category analyzed. Such

results have confirmed the great results obtained by the project.

ACTION C.1 – Monitoring of the environmental impact of the project

This study has been conducted by the University of Padova for the implementation of the Low

Resources Low Energy project. The collection of the necessary data for the calculation of the

defined indicators were performed through the production of ad-hoc questionnaires addressed

to Majorca and the suppliers involved during the implementation of the project. The main

information investigated in the questionnaires were:

1 Utilization of non-renewable materials

2 Energy consumption

3 Glass-based waste recycled for the Low Resources Low Energy process

4 Emissions of CO2 associated with the product Low Resources Low Energy

5 Water consumption

6 Transportation

7 Recyclability of the product Low Resources Low Energy after use

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The information collected were finally elaborated and the following table was realized, in

order to show the main environmental characteristics of the process, the improvement reached

in comparison with the conventional process and the expected results.

Environmental Indicators

Indicator Units Conventional

process

Low

Resources

Low

Energy

Improvement

[%]

Expected

result

Utilization of

non-

renewable

materials

kg/m2 tiles 19,68 4,32 -78% -70/82%

Energy

consumption kWh/m

2 tiles 27,84 19,2 -31% -30%

Glass waste

recycled

kg/(day*500

m2 tiles)

- 12-19,2 - -

Reduction of

CO2 emissions

kgCO2/kg

fired tiles - 0,063 - 0,063

Water

consumption m

3/m

2 tiles 0,012-0,025

0,008-

0,018

-33% -

Transportation

consumption km 1200 1000 -17% -

Recyclability

of the product % - Up to 80% - 80%

Questionnaires have been prepared immediately after the beginning of the project and

submitted to Majorca’s suppliers in order to have available the necessary information for the

calculation of the indicators. Indicators have been calculated thanks to the support of external

suppliers, in this way it has been possible to identify the improvement if compared to

traditional plants.

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ACTION C.2 – Monitoring of social-economic impact of the project

This study has been conducted by the University of Padova for the implementation of the Low

Resources Low Energy project. The collection of the necessary data for the calculation of the

defined indicators were performed through the production of ad-hoc questionnaires addressed

to Majorca and the suppliers involved during the implementation of the project. The main

information investigated in the questionnaires were:

8 Direct economic value

9 Energy costs

10 Raw materials costs

11 Production costs

13 Training courses

The information collected were finally elaborated and the following table was realized, in

order to show the main environmental characteristics of the process, the improvement reached

in comparison with the conventional process and the expected results.

Social-economic Indicators

Indicator Units Results Expected result

Economic value generated

% +(3-5)% +5%

Energy costs reduction % -(25-30)% -30%

Raw materials costs reduction

% -(18-20)% -20%

Reduction of production costs

% -(7-12)% -10%

Training curses hours 150 150

Meetings organized n 1 1

Attendees of the meetings

n 50 150

Partecipated at meetings n 3 3

20

The University of Padova took care of the calculation of the present indicators.

Questionnaires have been prepared immediately after the beginning of the project and

submitted to Majorca’s suppliers in order to have available the necessary information for the

calculation of the indicators. Indicators have been calculated thanks to the support of external

suppliers, in this way it has been possible to identify the improvement if compared to

traditional plants. The results have been positive, this will be used for booster the project

uptake.

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4 Dissemination actions

In order to get always a general updated idea on the situation of the dissemination, to ensure a

comprehensive monitoring, to try to reach all target groups involved equally and for a general

use of the instruments on all the specific dissemination actions, it was decided to put the three

mandatory activities, which have their dedicated deliverable, in a single action that includes

all other dissemination activities proposed.

The dissemination activities involved:

• preparation of 4 LIFE Information Notice Boards, describing the project and the

financing of the Life+ instrument with the Life logo, to be displayed at the entrance of the

company, in the administrative office and in the place where the technical activities have

been implemented (building site) at strategic places accessible to the public.

• Creation of an appropriate bilingual (Italian and English) section of our web site

dedicated to the Life+ project that included a brief description of the company, with

particular emphasis on its environmental sensitivity, a brief description of the project at

issue and its foreseen objectives, as well as updates on the technical development stages

of the project, a detailed description of the actions and of the results achieved upon

completion of the project, a section containing pictures and demonstrative videos, a

section where all can subscribe to the newsletter and download dissemination

documentation that has been realized (previous newsletters, leaflets, brochures) and a

description of the LIFE+ instrument and its objectives. The web site has been available 6

months from the project start and has been regularly updated during the project period in

order to inform all stakeholders about the progress of the activities. This section has been

updated also after the end of the project in the after Life communication plan. The web

site contains a newsletter section dedicated to the stakeholders so that they can

periodically receive information and news about the project. Registered users could also

access data downloaded from the residential complex control system.

• At the end of the project has been produced a bilingual (Italian end English) 10 pages

long Layman’s Report in 200 copies, containing all the information on the project

developed. An electronic version of the layman’s report has been uploaded on the website

for the download and has been sent by e-mail together with newsletters.

• We have participated to sector fairs for the direct dissemination of the project, through

the distribution of expressly produced informative brochures and with a stand area

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dedicated to the project. The company participated to the world most important fair

regarding ceramic materials which is Cersaie which is held every year in Bologna (Italy),

• By the end of the project, has been organized a final event in which have been invited

all those contacts obtained frequenting exhibitions, from website’s newsletter and from

sellers and dealers, aiming to make aware of the issue as many people as possible. Also

local public authorities related to environment, ARPA, universities both students and

researchers, national authorities, municipalities, province and environmental NGOs,

architects, engineers and stakeholders related to construction and building sectors have

been invited.

• We have prepared also an explicative audiovisual contribution that has been shown

during fairs and uploaded on the website and an adhesive labels with the Life+ logo to

attach on corporate letterheads.

• We have also prepared an article for press, acknowledging the LIFE+ support.

• 2000 explicative brochures and leaflets have been produced, at distinct stages of the

project, that has been useful as popular material during exhibitions, in which it was given

explanation of the project’s goals, development, activities, internet references of the

beneficiary and LIFE unit. Using the audiovisual it has been created a DVD to be

distributed during the final event. Each product presents LIFE’s brand and the website’s

references.

The main activities and output, including some not foreseen in the proposal and so not

reported above, are related to:

a) Notice Boards

Throughout the course of the project a number of notice boards were prepared and displayed

in the company, in places of carrying out the project, and presented at the trade fairs attended,

on all the occasions useful e.g. gatherings, visits, workshops and meetings and at the final

event.

An initial version of the boards took inspiration from images taken from the LIFE website

with the insertion of information on the project and were displayed at the company premises.

23

The first versions of notice board:

24

The last version of the notice board:

25

Website section

The website of the company has a section dedicated to the project that has been updated

during the project progress and includes main project information, as the abstract, the

objectives, the activities, the state of advancement, the possibility of download of documents

and newsletter subscription, both in Italian and English languages.

Majorca S.p.A Website:

26

Mammarosa’s Project website:

27

Layman’s Report

The Layman’s Report was drafted and distributed in paper and electronic format. Two

versions of the report have been realized, the last improved the first.

The Layman’s Report describes the project, the objectives attained and the technical and

environmental innovations achieved with also photographs of the pilot plant realized; it is

easy to understand and for this reason it has been distributed in different sectors and to people

from different fields: local authorities, major environmental agencies, university departments

that study the ceramic production process and other interested parties.

28

29

Fairs

Trade fairs are the places in which it is easier to create connections between companies and

with stakeholders and also where it is possible to find new customers. Trade fairs are also the

ideal place to show off a technological innovation, given the conditions of presenting it

simultaneously to all the relevant major players in the industry. In addition, the interaction is

physical between the customer and the company staff and is possible to better interest the

visitor and there is usually more time to address in depth the topics. For these reasons it was

decided to participate in several trade fairs of the sector and on those occasions to present the

project.

The project has been presented in at least 2 fairs per year, among which the most important is

the Cersaie fair which is held every year in Bologna (Italy) at the end of September and is the

most important fair in the world for ceramics and floor/covering goods and tiles. The Cersaie

each year sees about 950 exhibitors of which 35% are non-Italian exhibitors, with 33 nations

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represented. The main object of the fair are the tiles for floor and wall (50%), but also raw

materials and equipment for ceramics, equipment, facilities and services for production and

publishing tied to construction. The entire supply chain is involved and represented at this

fair. Visitors over the 5 days of the exhibition are on average more than 80.000 (of which only

60% are Italians) and, in addition to retailers and wholesalers tend to be professionals such as

architects or interior designers, and salespersons or agents. Even the press is well represented

at the fair, because more than 700 journalists attending the fair each year (of which 40% are

non-Italians). All the most important European producers of floor and coverings visit or

exhibit to this fair and the exchange of information and experiences is at maximum level.

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Many other trade fairs were participated as: Fulda in Germany, Marsiglia in France, Mosbuild

in Russia, Coverings in USA and others in Italy as Fiera di Padova or Fiera di Roma or Fiera

del Mobile of Milano. These are the most important moment of contact with the market but

also with the other producers or market stakeholders in this sector as real point of reference

for the market. The trade fairs selected represent the most important events during the year for

the players in the field of ceramics. Also fairs outside Europe equally important appointment

for world market and to meet all European producers. Thank to the presentation of the project

during these trade fairs, in fact, the project was promoted face to face to the main global

players of the ceramic market.

The main objective of the participation in the trade fairs was to provide information about the

project and the LIFE program and to establish contacts with people interested in the project.

The results of this very important disseminative way were considered very satisfying as all the

promotional material printed was distributed on those occasions and the staff on site were able

to establish numerous contacts with interested people, some of whom requested afterwards

further information about the project and to be kept informed on its development.

Public final event

The final event was organised on 24 May 2014 at the Department of Industrial Engineering of

the University of Padua, where the results obtained were exhibited; it was an important

opportunity to engage in networking activities with other proponents of LIFE projects on

similar topics.

To our great satisfaction the project tutor, Mr. Lorenzo Mengali also took part.

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33

34

Explicative audiovisual

Once the process was complete, during the first final tests, an audio-video was created for

presentation at the trade fairs and at meetings such as workshops and meetings both within the

company and at the showrooms of customers and also for download from the internet site. An

audio video explains in a short and pleasant manner what you need to know about the project,

showing the process and at the same time indicating the results achieved. This important tool,

which always receives positive feedback on its ability to get the message across in a simple

manner, will also be used in the future.

Partecipation to an event for the LIFE 20th

Anniversary

Even if the project had not yet begun, Majorca participated as a guest and speaker to one of

the events organized for the twentieth anniversary of the LIFE program and in particular in

the event organized by the University of Padua, a partner in the project and already engaged

in other LIFE projects in progress, held on 4 June 2012 at the Palazzo del Bo, hall of the

ancient archive, in Padua, which was attended by the project manager and a number of

persons who are currently involved in the project. The project and its objectives were

presented together with other LIFE projects experiences that are being started or already in

progress in a beautiful public setting.

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“ITALIAOGGI” newspaper article

The project was also presented in an article that appeared in an edition of the newspaper

Italiaoggi of 4 August 2012 detailing two cases of green economy and technology in the

ceramic district entitled "Here's how LIFE+ funding creates a green company", emphasising

the projects as well as the EC's commitment to the environment.

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Leaflets

2000 bilingual leaflets and flyers were produced and then distributed at trade fairs and events

either organised or attended. A pdf version of the leaflets is available for download on the

website.

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5 Project Results

The major results are mainly of environmental nature, but they also include some technical

benefits deriving from the newly proposed building solutions:

- Reduction of non renewable raw materials resources up to 82%

- Setup of a demonstrative line for conversion of glass-based waste, exhausted lime and

natural stone cuttings into low-temperature fired coverings, able to process 500 square

metres per day.

- Substitution of currently used natural or synthetic raw materials

- Reduction of energy consumption during firing of the coverings: this amounts to a

reduction of more than 30% of the energy consumption;

- Reduction of emission CO2

- Complete recyclability of the product at its end of life

- Reduction of energy consumption also in milling operations

- Lower manufacturing cost of the coverings

All the tools and the activities realized gave good feedback and permitted to spread the project

knowledge to different stakeholders, also thank to the ceramic industrial district and the

events participated. Among the best tools which revealed to be very useful, in addition to the

website, fundamental and point of reference, there are, in fact, the meetings and the fairs.

Talking face to face about new matters and new materials, such as those proposed, is the best

solution to make the people aware of the project and its future reach. The rest is quite outline

and serves to reinforce the message or leave a remembrance to those who have met the project

for the first time. The after-LIFE Communication Plan is focused, in fact, mainly on meetings,

workshops, exhibitions and other opportunities to meet the stakeholders both in the ceramic

field and in the environmental field. A good way to spread information as daily, quickly and

easily read by market actors, stakeholders and customers are the web portals, which will be

pushed for the future and have been fostered as well during the project. Some of them send

information about new articles or general news to subscribers and registered, so they can be

considered as “external newsletter”, and the whole sector is registered to major portals about

building and construction industry.

The dissemination activity gave also a lot of new contacts to be exploited for the project

objectives and other marketing activities of the company.

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Indicators of progress

- Leaflets: realization, print and distribution of 2000 pieces in occasion of fairs,

exhibition and at customers and representation agencies;

- Company website: realization of the part dedicated to the project (month 6), quarter

update with new results and objective achieved of the project, running newsletter and

download;

- Project notice board: realization of 4 fixed board placed in strategic places of the firm

(month 4);

- Newspaper article: bought of 10 pages of specialized press (near end of the project);

- Layman’s report: 200 pieces realized and printed;

- Events: realization of the final event, program and chart of organization realized, at

least 200 letters of invitation printed;

- fairs: participation at least to 1 fair exhibition per year, exposition place chosen and

bought, stand drawing and realization, project information designed (brochure,

audiovisual;

All indicators have been achieved within the timeframe foreseen, obtaining the expected

results. Leaflets and brochures have been designed and printed in 2000 copies and distributed

during fairs and exhibitions to which Majorca has participated. The company website has

been updated with a section related to the LIFE project immediately. 4 noticeboards have

been designed and printed and installed in the company’s premises and at the University. One

article has been published however it doesn’t develop on 10 pages, such decision was linked

to the audience of people reading the newspaper. Since the main public is a general public,

partners have preferred to invest on other activity more focused on an audience that could

generate networking or links. Layman’s report has been designed, printed and distributed

during events and to main stakeholders. One final event has been organized to which almost

50 people were present. Majorca has also participated to 6 fairs during the project some of

them also out of the EU.

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6 Long-term benefits

The environmental benefits regards the reduction of the consumption of non renewable

resources, raw materials of natural origin in primis, used to manufacture ceramic coverings,

like wall and floor tiles. Considering that the high quality tiles (porcelainized stoneware) have

a surface density of 27 kg/square metres, and that the EU production exceeds the 700 millions

of square metres, it is evident that such kind of manufacturing activity absorbs huge quantities

of valuable materials like sands, feldspars, alumina, zirconia, mullite, clays, not to speak of

the water used during processing.Regarding raw materials, a further aspect must be taken into

account, i.e. that the manufacturing of high qualitytiles requires special raw materials, whose

provenience can be from extremely distant sources. For instance, kaolin is preferably

purchased from Turkey or Ukraine, zirconia comes almost entirely from Australia, feldspars

are extracted in eastern Europe. Thus, transportation adds to the already pressing

environmental problems related to the use of such non renewable resources .Also water plays

an important role, and its consumption in ceramic tiles manufacturing occurs basically in two

operations: milling of raw materials and finishing of fired tiles (cutting, polishing), the latter

not directly addressed by the present project. To give a rough indication of water consumption

in tiles manufacturing, it can be considered that: water requirement is of 8-18 m3 to mill raw

materials required to produce 1000 m2 of tiles; 7-15m3 to prepare the enamels to glaze such

surface, and 800 m3 for cutting, grinding and polishing [G. Busani et al.,“Piastrelle

Ceramiche e Ambiente”, Assopiastrelle, EdiCer]. This becomes a particularly high

consumption considering that ceramic tiles manufacturing tends to occur in well defined

regions. For instance, in Italy, 90% of the production occurs between the town of Modena and

Reggio Emilia, which are 30 km distant; in Spain, most of the production occurs near the city

of Castellon. Thus, such enormous amount of water is consumed in very small areas,

worsening the problem of water consumption.

The environmental problem is the current enormous consumption of non renewable resources,

raw materials of natural origin in primis, used to manufacture ceramic coverings, like wall

and floor tiles. Considering that the high quality tiles (porcelainized stoneware) have a surface

density of 27 kg/square metres, and that the EU production exceeds the 700 millions of square

metres, it is evident that such kind of manufacturing activity absorbs huge quantities of

valuable materials like sands, feldspars, alumina, zirconia, mullite, clays, not to speak of the

water used during processing.

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The process ‘LOW RESOURCES LOW ENERGY’ allows:

• Drastic reduction of non renewable raw materials resources up to 82% weight

compared to conventional ceramic tiles;

• Substitution of currently used natural or synthetic raw materials, having a high

embodied energy and CO2 footprint, like silica, alumina, mullite, kaolin, with waste

glass and sandstone or marble cuttings;

• Reduction of energy consumption during firing of the coverings: currently 1.16 kWh

are required to fire 1 kg of porcelanized stoneware at 1250°C, while the new process

requires less than 0.8 kWh/kg, due to the lower firing temperature (900/920°) and

consequently lower heat losses. This amounts to a reduction of more than 30% of the

energy consumption: as a result CO2 emissions have been lowered;

• Complete recyclability of the product at its end of life.

The long-term economic benefits are related, given also the crisis that has been stifling the

construction sector for some years, to the research into new products, less expensive, with

large environmental benefits and therefore marketable as true innovation is becoming

increasingly frequent. The tile sector, has several products that are wholly similar in shape

and aesthetics and made with the same features and systems. International competition is very

wide and fierce especially from those countries that cannot contain the cost of the labour

market and thus apply prices that are not sustainable by European producers for products with

low added value and therefore not very differentiated. A truly innovative product could ensure

sustainability and economic benefits for European producers for the future because it could

differentiate the product, as was the case for the introduction of porcelain stoneware and in a

short time it will gain advantages over the competitors and replace all the similar products

ensuring ample revenue for European companies for years. The proposed approach is thus

more economical than the current one. The regional development of such a technology is very

high given the industrial district linked to ceramic tile manufacturing. It is not only Italy that

has an industrial ceramic district. There is also one in Spain with others emerging in Poland,

France, Germany although on a smaller scale. Concentrating such a waste of resources within

the radius of a few square kilometres leads to logistical problems and as well as the

transposition of necessary resources. This in addition to exploiting enormously the resources

of limited spaces. Drastically reducing the use of the resources themselves can only bring

41

economic and logistical advantages to a major European industry. The manufacturing cost

reduction is 40% less respect to the conventional ceramic tile’s process

The social benefits that can be achieved by this project consist of the improvement of the

working environment and condition thank to the reduction of CO2 emissions.

The reduction of the process costs, moreover, represent also a social benefit together with the

possibility of extending the European market uptake possibilities thank to the new production

characteristics and the environmental message behind.

Furthermore, the ability to offer to the international market products obtained through new

environmental friendly technologies, that get better quality of life, is a good way for the

European companies to offer an added value to the new product on the market and to develop

new marketing strategies in order to maintain market share threatened by the global economic

crisis and the ever more pressing and not always right business competition by extra-UE

companies. Better economic condition means also better social conditions.

7 Relevance for environmentally significant issues or policy areas

The project and the product realized are in the framework of the EU policy towards the

reduction of waste, pollution prevention, recycling and sustainable usage of resources and is

relevant and can contribute to update or integrate, among the others, the following important

themes and following directives:

1. Waste management

The Waste Framework Directive (2006/12/EC of the European Parliament and of the Council

of 5 April 2006) on waste establishes the legislative framework for the handling of waste in

the Community. It defines key concepts such as waste, recovery and disposal and puts in

place the essential requirements for the management of waste, notably an obligation for an

establishment or undertaking carrying out waste management operations to have a permit or

to be registered and an obligation for the Member States to draw up waste management plans.

It also establishes major principles such as an obligation to handle waste in a way that does

not have a negative impact on the environment or human health, and an encouragement to

apply the waste hierarchy. The present project, aiming at recycling a large amount of a special

waste is in agreement with such directive and can update the BAT and the policy linked to

building sector.

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2. Pollution prevention and control

The objective of the Integrated Pollution Prevention and Control (IPPC) Directive is to

prevent and control emissions to air, water and soil from industrial installations across the

European Union by promoting the use of Best Available Techniques. The present project

addresses this issue with the implemented new process able to create new products with a

reduction of CO2 emission up to 6 times (80% less) lower than state of the art. Also the 7th

Environment Action Programme (EAP), guiding European environment policy until 2020, is

related to this important result, considering the objective of turn the Union into a resource-

efficient, green, and competitive low-carbon economy or safeguard the Union's citizens

from environment-related pressures and risks to health and wellbeing

3. Kyoto protocol

The EU commitment to reduce CO2 emissions is addressed by the present project, since the

use of this new products, low CO2 footprint materials and techniques as the lower energy

consumption will allow to reduce significantly the energy requirement related to floor and

covering goods in a life cycle assessment. Therefore the project can update the EU policy

about pollution and emissions.

4. Energy use efficiency

The Directive 2006/32/CE and decision 406/2009/CE on energy efficiency aims to enhance

the cost-effective improvement of energy use efficiency in the Member States. Member States

shall adopt and aim to achieve an overall national indicative energy savings target of 9 % for

the ninth year of application of the Directive, to be reached by way of energy services and

other energy efficiency improvement measures. Member States shall take cost-effective,

practicable and reasonable measures designed to contribute towards achieving this target. The

objectives of this project, of 60% reduction of energy consumption, can indicate very good

ways to these purposes in a sector with traditionally extremely high consume of energy. Only

the elimination of the firing in the manufacturing of floor tiles or bricks may seem a dream in

this sector and can contribute to policy amendments or updates. Also the 7th Environment

Action Programme (EAP), guiding European environment policy until 2020, is related to this

important result, considering the objective of turn the Union into a resource-efficient, green,

and competitive low-carbon economy or safeguard the Union's citizens from environment-

related pressures and risks to health and wellbeing

5. Natural resources

The use of natural resources is influenced by numerous environmental policies, including

strategies on the marine environment, soil protection, biodiversity, urban environment, as well

43

as climate change policy, the water framework directive and many others. In addition, many

non-environmental policies strongly influence resource use as fiscal, transport, agricultural

and energy policies. The Thematic Strategy on the Sustainable Use of Natural Resources

(COM(2003) 572) aims to raise awareness of potential tradeoffs assessing how far policy-

choices in these different areas are compatible with the overall aim of decoupling economic

growth from the impacts of resource use and suggest alternatives wherever possible. The

reduction of consumption of raw materials for the ceramic tile base, as clays, minerals, sands,

quartz, pigments, etc. using only kaolinite and feldspars, which are common at the two

processes, the project can go in the direction of this Strategy in a sector highly negative from

the point of view of the natural resources consumption (the tendency in this last 2 years is to

realize tiles with oversized thickness, i.e. 12 mm or 15 mm or 20 mm). Moreover, On 21st

December 2005 the European Commission proposed a Strategy on the Sustainable Use of

Natural Resources used in Europe. The objective of the strategy is to reduce the

environmental impacts associated with resource use and to do so in a growing economy.

Focusing on the environmental impacts of resource use is a decisive factor in helping the EU

achieve sustainable development and the project can update some directives in this way.

6. Ceramic sector

The continuous effort of Confindustria Ceramica in Italy regarding the improvement of

environmental indicators of ceramic tiles manufacturing is in agreement with the project

objectives. The Italian ceramic tile industry was one of the first to develop a strong

environmental awareness and to seek to combine environment protection, health and safety

with sustained market competitiveness. Over the past decade the industry has shown a shift

towards sustainable development projects through integrated and comprehensive standards

and regulations (ISO 14001 and EMAS Regulation) that take account of the causes of

environmental impact and the tools to be used for preventing or at least minimising it. Recent

introduction of LEEDS is expected to further improve this tendency, especially in the

recycling activities, and the present project lies exactly in this EU policy and can contribute to

update it.

8. Hazardous waste and substances

The materials used and especially the waste produced by the ceramic industry which mainly

include porcelain stoneware waste are composed by hazardous substances and the waste is

special waste often disposed to landfill due to its particular chemical composition. So, the

project, thank to its great possibility of waste recycling, can implement novelties as regards

the following directives and regulations or communications: DIRECTIVE 2002/95/EC RoSH

44

(Restriction of Hazardous Substances), REGULATION (EC) 1907/2006 of the European

Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation,

Authorisation and Restriction of Chemicals (REACH), DIRECTIVE 91/689/CEE on

hazardous waste, DIRECTIVE 75/442/CEE of the Council on waste, COM(2003) 301 -

Towards a thematic strategy on the prevention and recycling of waste, COM(2005) 666 final -

Taking sustainable use of resources forward: A Thematic Strategy on the prevention and

recycling of waste

9. Climate and Energy package

On 03 of March 2010 was delivered by the European Commission a Communication

(COM(2010)2020 - Europe 2020: “A strategy for smart, sustainable and inclusive growth“)

with some great goals for Europe to be reached by the year 2020 including low carbon

emissions. The aim is to decouple economic growth from resource and energy, reduce CO2

emissions, enhance competitiveness and promote greater energy security. This has been

confirmed on march 2010 after that on 2008 the European Council and member states

concluded the agreement 20-20-20 about the climate and energy package. Under this

agreement, a 20% reduction of greenhouse gas emissions, an increasing in energy efficiency

by 20% and a 20% share of renewable alternative energy, must be reached by 2020. Italy is in

charge of cut 13% of CO2 emissions by 2020 and this more in energy-intensive sectors. So

this project is involved in this important european goal.

Moreover, the project objectives lie in the framework of the Horizon 2020 objectives, since it

has the potential to contribute to lower carbon emissions, lower energy consumption, create a

new way of recycling and also a more efficient use of resources, therefore the project well fit

under "Climate action, resource efficiency and raw materials" priority. It also provide tools of

competitiveness for small and medium enterprises, as required in "Competitive Industries" not

only for tiles or bricks producers, which can have a real new product for the future, but also

for sellers, representatives, accessory treatment industries, producers of equipments, etc.

The achievable results are thus in agreement with all the objectives and pillars of Horizon

2020 about: "scientific excellence" making a significant contribution to an innovative way to

realize floor and coverings goods in a very new manner, "industrial leadership", thanks to the

development of new environmentally friendly process, having a low energy consumption,

reduced carbon footprint and high quality of the final products, "societal challenges" and in

particular the efficiency in terms of resources and raw materials and especially in recycling of

particular waste.