Periodic Reporting for period 3 - SURPASS (Safe-, sUstainable- and Recyclable-by design Polymeric systems - A guidance towardS next generation of plasticS)
Période du rapport: 2024-12-01 au 2025-11-30
Plastic waste persists for centuries, causing endocrine disruption, pollution of land, air and water, and greenhouse gas emissions. Despite these impacts, 70% of plastic waste collected in Europe is still landfilled or incinerated.
The SURPASS project aims to accelerate the transition towards Safe, Sustainable and Recyclable by Design (SSRbD) polymeric materials. The consortium of 13 partners develops SSRbD alternatives without potentially hazardous additives through industrially relevant case studies.
Beyond material innovation, SURPASS optimizes reprocessing technologies adapted to these systems and develops a scoring-based assessment framework covering the full life cycle (hazard, health, environmental and economic aspects).
Key results include:
Building sector: bio-based recyclable polyurethane (PU) with vitrimer properties to replace PVC in window frames
Transport sector: lightweight epoxy-vitrimers as alternatives to metals in train structures
Packaging sector: MultiNanoLayer (MNL) films with reduced compatibilizers and improved recyclability, combined with a decontamination process
Digital infrastructure: an open platform (surpass.geonardo.com) providing data, methodologies and tools for SSRbD implementation, particularly targeting SMEs
The SURPASS project aims to accelerate the transition towards Safe, Sustainable and Recyclable by Design (SSRbD) polymeric materials. The consortium of 13 partners develops SSRbD alternatives without potentially hazardous additives through industrially relevant case studies.
Beyond material innovation, SURPASS optimizes reprocessing technologies adapted to these systems and develops a scoring-based assessment framework covering the full life cycle (hazard, health, environmental and economic aspects).
Key results include:
Building sector: bio-based recyclable polyurethane (PU) with vitrimer properties to replace PVC in window frames
Transport sector: lightweight epoxy-vitrimers as alternatives to metals in train structures
Packaging sector: MultiNanoLayer (MNL) films with reduced compatibilizers and improved recyclability, combined with a decontamination process
Digital infrastructure: an open platform (surpass.geonardo.com) providing data, methodologies and tools for SSRbD implementation, particularly targeting SMEs
Over 42 months, SURPASS delivered major advances in polymer design, reprocessing, and SSRbD assessment. The project analyzed regulatory frameworks, operationalized the SSbD concept for polymers, compiled additive toxicity data, and contributed to standardization (CWA 18305).
Main achievements:
1) Digital infrastructure: Open platform integrating criteria, metrics, scoring strategies and decision-support tools for SSRbD polymers
2) SSRbD assessment framework: Covering performance, hazard, environmental and economic dimensions
3) Guidance tools: Supporting the design of high-performance, recyclable and safer polymers with reduced environmental impact and acceptable costs
4) Three innovative recyclable-by-design polymers:
- Case Study 1 (Building): Bio-based PU with vitrimer properties
40–45% lower thermal transmittance than PVC
No harmful additives
20–37% weight reduction vs reinforced PVC
Recyclable through multiple cycles with minimal loss
Two patents filed (one granted)
- Case Study 2 (Transport): Epoxy-vitrimers for railway structures
Fire-resistant and compliant with EN45545-2
>30% lighter than metal
75% material recovery via mechanical recycling
Chemical recycling enables fiber/resin separation
Debondable flame retardants developed
Life Cycle Costing shows major operational energy savings
- Case Study 3 (Packaging): MNL films
High barrier performance (<10 ml/m²/day OTR)
Up to 99% contaminant removal
>90% sorting efficiency (RecyClass)
Reduced compatibilizers while maintaining performance
5)Standardization contribution: Development of a decontamination process published as CWA 18305 (“challenge test” for contaminants).
Main achievements:
1) Digital infrastructure: Open platform integrating criteria, metrics, scoring strategies and decision-support tools for SSRbD polymers
2) SSRbD assessment framework: Covering performance, hazard, environmental and economic dimensions
3) Guidance tools: Supporting the design of high-performance, recyclable and safer polymers with reduced environmental impact and acceptable costs
4) Three innovative recyclable-by-design polymers:
- Case Study 1 (Building): Bio-based PU with vitrimer properties
40–45% lower thermal transmittance than PVC
No harmful additives
20–37% weight reduction vs reinforced PVC
Recyclable through multiple cycles with minimal loss
Two patents filed (one granted)
- Case Study 2 (Transport): Epoxy-vitrimers for railway structures
Fire-resistant and compliant with EN45545-2
>30% lighter than metal
75% material recovery via mechanical recycling
Chemical recycling enables fiber/resin separation
Debondable flame retardants developed
Life Cycle Costing shows major operational energy savings
- Case Study 3 (Packaging): MNL films
High barrier performance (<10 ml/m²/day OTR)
Up to 99% contaminant removal
>90% sorting efficiency (RecyClass)
Reduced compatibilizers while maintaining performance
5)Standardization contribution: Development of a decontamination process published as CWA 18305 (“challenge test” for contaminants).
SURPASS advances both material development and recycling processes across sectors.
Case Study 1: Introduced vitrimer chemistry and disulphide bonds into bio-based PU to enable reprocessability, demonstrating strong potential despite the need for further optimization.
Case Study 2: Developed recyclable epoxy vitrimer composites with non-halogenated flame retardants meeting railway requirements. Mechanical and chemical recycling approaches successfully recovered key components.
Case Study 3: Addressed contamination challenges in MNL films through washing, extractive extrusion decontamination and reprocessing. The process reduced volatile organic compound emissions and ensured recyclability according to RecyClass.
In parallel, WP4–WP5 enabled the operationalization of the SSbD framework (criteria, methods, scoring), supported by extensive data generation on hazard, exposure and sustainability impacts. This knowledge was structured into the SURPASS digital infrastructure, implemented, tested and publicly released.
The integrated approach supports early-stage eco-design, recyclability and sustainable innovation across sectors.
Standardization activities (WP6), supported by UNE, ensured alignment with European and international frameworks, leading to the publication of CWA 18305.
Case Study 1: Introduced vitrimer chemistry and disulphide bonds into bio-based PU to enable reprocessability, demonstrating strong potential despite the need for further optimization.
Case Study 2: Developed recyclable epoxy vitrimer composites with non-halogenated flame retardants meeting railway requirements. Mechanical and chemical recycling approaches successfully recovered key components.
Case Study 3: Addressed contamination challenges in MNL films through washing, extractive extrusion decontamination and reprocessing. The process reduced volatile organic compound emissions and ensured recyclability according to RecyClass.
In parallel, WP4–WP5 enabled the operationalization of the SSbD framework (criteria, methods, scoring), supported by extensive data generation on hazard, exposure and sustainability impacts. This knowledge was structured into the SURPASS digital infrastructure, implemented, tested and publicly released.
The integrated approach supports early-stage eco-design, recyclability and sustainable innovation across sectors.
Standardization activities (WP6), supported by UNE, ensured alignment with European and international frameworks, leading to the publication of CWA 18305.