A new thermolysis technology developed by Composite Recycling (Ecublens, Switzerland; www.composite-recycling.ch) breaks down fiber-reinforced polymers (FRPs) into their fundamental constituents, enabling reuse as valuable feedstock for the creation of new composite materials. “Past efforts to recycle composites have allowed waste producers to avoid landfilling or incineration, but only by downcycling the material into lower-value fuels or fillers. What sets our process apart is that it leaves the fibers largely undisturbed, in particular carbon fibers, retaining their original mechanical properties. This results in fibers that can be directly reused in the production of new composite materials,” says Pascal Gallo, co-founder of Composite Recycling.
The company’s static thermolysis technology breaks down fiber-reinforced polymers into their core components through a controlled heating process in an oxygen-free environment. “This method enables the recovery of high-quality fibers and thermolysis oil, both of which have significant potential for reuse. The thermolysis oil is rich in compounds such as benzene, styrene and phenols, which can be applied in various chemical processes,” explains Gallo. The absence of oxygen during the process is critical because with oxygen present, the polymers would simply burn instead of turning into oil, he adds.
Another key differentiator is operation at moderate temperatures, which helps to preserve both fiber integrity and the chemical compounds in the thermolysis oil, and a focus on minimizing solid residues (other than useful fibers) within the process. The fibers’ presence in process actually helps to reduce the amount of char in the unit, which is well below 5% of the initial mass of composite. The units are also modular and containerized (photo) for easy deployment at waste-generation sites.
The company recently delivered its first industrial-scale recycling unit to a site in Western France operated by Veolia (Paris; www.veolia.com). “The unit is capable of processing up to two ton/d of composite waste, recovering fibers and thermolysis oil that can be reused in new composite manufacturing or other industrial applications. Initial results are in line with our calculations in terms of cycle duration and energy consumption,” says Gallo. The company notes that its best results obtained so far were with the Elium resin developed by strategic partner Arkema S.A. (Colombes, France; www.arkema.com), with a recovery rate surpassing 70%. The next step for the technology will be to add advanced filtration systems to the process, which will enable the treatment of halogen-containing polymers.
At the JEC World 2025 conference in Paris, Composite Recycling is launching a major collaboration program focused on circularity of boat materials, securing a circular supply of recycled composites for the construction of new boats. Composite Recycling’s partners on the initiative include Arkema and Veolia, as well as Groupe Beneteau, Owens Corning and Chomarat.
According to Guillaume Perben, co-founder of Composite Recycling, this initiative “this isn’t just about sustainable boat building — it is a proof of concept for every industry that uses composites.”
“We have entered a new era where products are made recyclable by design, and this powerful collaboration is a prime example. Working alongside such large and visionary partners is a huge opportunity for us,” adds Pascal Gallo.