Hera Group unveils FIB3R, a pioneering plant that regenerates carbon fibre
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Hera Group unveils FIB3R, a pioneering plant that regenerates carbon fibre
Innovation and performance define the first plant of this kind in Europe to operate on an industrial scale, built in Imola to recycle carbon fibre composites while reducing environmental impact. Here, end-of-life waste goes in and regenerated carbon fibre comes out, as light and strong as virgin fibre, ready to be reused in a potentially infinite cycle in various strategic Made in Italy sectors. At present, the Group’s plant is expected to produce 160 tonnes of recycled carbon fibre each year, with a 75% energy saving compared to virgin fibre
The Hera Group is moving swiftly towards the circular economy of the future and has inaugurated, in Imola (Bologna), at the heart of the country’s Motor Valley, the first plant of its kind in Europe, capable of regenerating carbon fibre on an industrial scale. It is called FIB3R, a name that reflects the 3 R's that stand at the basis of the project: recover, reduce, reuse. Carbon fibre is thus recovered and reused, reducing the use of virgin fibre and therefore the environmental impact that would be required to produce it.
There is one important competitive advantage: the fibre regenerated from FIB3R retains the virgin fibre’s characteristic lightness and high strength, guaranteeing - through a state-of-the-art pyrogasification process - that the regenerated product is ready to be reused, rewoven and/or impregnated, for the high-performance purposes for which this type of material is intended. The number of industrial sectors interested in these outstanding features is increasing, ranging from automotive to aerospace, nautical, furniture, textiles and fashion in the broadest sense, only to give a few examples.
The Hera Group’s commitment to advancing the ecological transition, as well as the expected increase in demand for carbon fibre over the next few years, have led it to anticipate this megatrend, accepting the challenge of applying it to this material as well, on an industrial scale. This will reinforce the virtuous path towards the circular economy that has been the basis of its strategy for years, combining economic growth with environmental sustainability. A path that places itself at the heart of the Italian Circular Valley, as this very territory has been developing material recovery initiatives with circular solutions for over forty years.
This path is the right one, as confirmed by the interest of the European Union, which has allocated FIB3R financing coming to more than 2.2 million euro as part of NextGenerationEU for its innovative technology and the strategic importance of the materials processed. The total investment planned by the Hera Group to build the Imola plant amounts to 8 million euro.
At present, the plant is expected to produce 160 tonnes of recycled carbon fibre each year, with energy savings coming to 75% compared to virgin fibre.
“FIB3R is the first plant of its kind in Europe able to recycle carbon fibre. It is aimed at promoting short and circular supply chains, in line with the strategy of making our served areas more competitive and resilient,” states Orazio Iacono, CEO of the Hera Group. “FIB3R is also a concrete example of how the Hera Group is able to combine technological innovation and sustainability, by exploiting the cross fertilisation between the advanced skills of the Group’s various sectors. Recovering carbon fibre not only reduces the environmental impact of this waste, but also creates new market opportunities in strategic industrial sectors. Investing in this kind of circular infrastructure increases the resilience of production chains, reduces dependence on imports of critical raw materials and, at the same time, creates value through sustainable business models. With over 100 advanced plants and 5 new facilities under construction, we have consolidated our country’s largest and most modern set of plants for material treatment and recovery, strengthening our role as a reference operator in the sector and a driving force for the circular economy in Italy. Our Business Plan confirms this strategy, with 2 billion euro in investments for 2024-2028 destined for regenerating resources, a commitment intended to generate value for all our stakeholders.”
This morning's inauguration of the FIB3R plant within the Group’s main facility in Imola, near Bologna, offered a chance to engage in a debate on the future of carbon fibre, combining innovation and sustainability. After the institutional welcome given by Marco Panieri, Mayor of Imola, and Irene Priolo, Councillor for the Environment, Local Planning, Mobility and Transport and Infrastructures of the Emilia-Romagna Region, Herambiente CEO Andrea Ramonda opened the event. This event saw the participation of important representatives of the industrial and academic communities: Davide Abate, Ferrari’s Chief Technologies and Infrastructures Officer; Roberto Frassine, Chairman of Assocompositi; Loris Giorgini, Director of the Department of Industrial Chemistry at the University of Bologna; Raffaella Luglini, Chief Sustainability Officer Leonardo; Horacio Pagani, Founder of Pagani Automobili; Andrea Rangone, Full Professor of Entrepreneurship and Digital Business Innovation at the Milan Politecnico; Ferruccio Resta, Chairman of the Fondazione Bruno Kessler FBK. The meeting came to a conclusion with a contribution by Orazio Iacono, CEO of the Hera Group.
Before FIB3R
The Imola plant was developed by Group subsidiary Herambiente, Italy’s leading waste recovery and treatment operator, which had been experimenting with the carbon fibre recovery process for some time. This involved a collaboration with the Department of Industrial Chemistry of the University of Bologna and its technological partner Curti Costruzioni Meccaniche, a Ravenna-based company and leader in the production of automatic machines for industrial applications, which offered its knowledge and pilot plant to model the formula being studied. After three years of tests, the Hera Group, based on its expertise in engineering and waste treatment, industrially developed the project and built the FIB3R plant, to recycle composite materials and help bridge the gap between supply and demand of virgin fibre, reducing its environmental impact.
Data sheet
How carbon fibre is reborn
In the Imola plant, the rebirth of carbon fibre happens inside a 60-metre tunnel where an innovative and advanced pyrogasification process takes place. In the first phase, pyrolysis, the carbon fibre, which is more resistant to heat, is released from the resin, and in the second phase, gasification guarantees a regenerated fibre of the highest quality, pure, shiny and entirely sustainable as regards the environment. The resin decomposed in a gaseous form is reused to generate part of the energy required for the process, maximising energy recovery. The dust remaining in the fibres is vacuumed and sent to the abatement system. The result, after treatment, is the finest high-purity carbon fibre, with all its mechanical properties intact and ready to be rewoven and impregnated for all the typical uses of virgin fibre.
Energy savings and closing the circle
The recycling is potentially infinite and energy savings are very high compared to the production of virgin fibre, which is extremely energy intensive due to the high temperatures used. Furthermore, producing virgin carbon fibre requires the use of fossil raw materials and an increased reliance on landfills, since waste from fibre processing is almost exclusively destined for disposal. Life cycle analysis shows that energy demand for producing recycled fibre is 75% lower and avoids 74% of greenhouse gas emissions, significantly reducing disposals in landfills. And that’s not all: the unique nature of FIB3R also depends on the total traceability of the processed material. The used carbon fibre, in fact, enters the plant inside containers equipped with a QR code, which contains their identity card: technical characteristics, weight and origin. Once the process is complete, the same traced material returns to its owner in the form of regenerated carbon fibre, closing the circle and ensuring maximum sustainability, transparency and quality.
FIB3R’s travelling companions
To be effective, the closed cycle that distinguishes the innovative Imola plant needs partnerships between Hera Group and companies in the complex carbon chain, given that this material is increasingly present in hi-tech production sectors and, consequently, in waste management cycles. The Leonardo Group has already taken up the challenge of applying the circular economy to its production processes and, in this specific case, through its Aerostructures Division, it has launched an industrial synergy with the Hera Group by supporting a project within the Imola plant to recover carbon fibres used to reinforce the polymer matrix composites used to construct aircraft parts. Therefore, thanks to Herambiente’s assets and the know-how developed in the Leonardo Group’s laboratories, this precious material will be recycled with positive consequences in terms of sustainability and circularity. More specifically, Leonardo’s Aerostructures Division will confer to Herambiente part of the waste fibres deriving from the construction of the components of some of the best-known civil aircraft in the commercial aviation sector, such as the stabiliser of the ATR turboprop, the fuselage and horizontal stabiliser of the Boeing 787, and the tail pieces of the Airbus A220.
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The facility can process up to 30,000 tonnes of polymers per year and produce flakes of a quality comparable to that of virgin raw material. €48.8 million has been invested, including €7.7 million from Italy’s NRRP funds, to develop a state-of-the-art facility designed to anticipate the growing demand for secondary raw materials driven by recent EU regulations.
Aliplast, a Hera Group subsidiary and one of Italy’s leading companies in plastics collection, recycling and regeneration, inaugurated its rigid plastics recycling plant in Modena this morning. The official opening of R3GID (Recover Recycle Regenerate Plastic), attended by Gilberto Pichetto Fratin, Italy’s Minister of the Environment and Energy Security, makes Hera one of the first multiutilities in Europe to operate a facility equipped to meet the growing demand for recycled plastics expected in the short to medium term under new EU regulations, including the Packaging and Packaging Waste Regulation (PPWR) and the End-of-Life Vehicles (ELV) Regulation.
Construction of Aliplast’s recycling plant began in 2024. Already operational for several months, the facility will employ 80 people at full capacity. It is among the most innovative plants in its sector in Europe and can process up to 30,000 tonnes of high-quality recycled polymers annually, with properties comparable to virgin materials derived from fossil feedstocks and a certified purity level of over 99%.
With an investment totalling €48.8 million, including €7.7 million in direct funding from Italy’s National Recovery and Resilience Plan (NRRP), Hera Group is providing Italian industry with a facility capable of recycling rigid plastic waste from both municipal and industrial sources. This includes sectors such as automotive, cosmetics, home and personal care, consumer electronics and furniture, which generate materials that are generally not recyclable and would therefore be sent for energy recovery or to landfill. At the Modena plant, Aliplast instead regenerates this waste into high-quality, traceable and certified polymers produced in Italy. These can be reused by the same industries to manufacture a wide range of products, including plastic components for televisions, computers and household appliances, make-up containers, tanks and bumpers, and garden furniture.
“R3GID is a clear example of how Italy can anticipate the challenges posed by new European regulations, from the PPWR to the ELV Regulation, and turn them into opportunities for industrial growth,” said Gilberto Pichetto Fratin, Minister of the Environment and Energy Security. “This plant combines Italian technology, an entirely Italian supply chain and a certified, traceable product with quality comparable to virgin raw materials. Producing secondary raw materials locally means strengthening the country’s competitiveness, reducing dependence on foreign markets and making our supply chains more secure, even in the face of geopolitical tensions and price volatility. Facilities such as this benefit the country as a whole.”
“Europe faces a structural gap in recycling: capacity is stagnant or declining, while new regulations will increase demand for recycled plastics with quality equivalent to virgin polymers,” said Orazio Iacono, Chief Executive Officer of Hera Group. “The figures speak for themselves. Europe currently has plastics recycling capacity of 13.5 million tonnes, but only 3.5 million tonnes for rigid plastics, including approximately 440,000 tonnes. By 2040, an additional 5.7 million tonnes2 of recycled rigid plastics will be needed: a substantial gap. R3GID is our response as a first mover. It provides Italian manufacturers with high-quality, locally produced materials, reducing import costs and ensuring security of supply. There is also a benefit for the country: Italy pays the European Union around €800 million each year in Plastic Tax on non-recycled plastic packaging, while the Modena plant alone could generate savings of approximately €24 million if its entire output were used for packaging.”
Hera Group developed the plant using best available technologies. NEXTCHEM, a MAIRE Group company, participated in the project as a technology partner, providing its proprietary NX Replast™ technology, an advanced solution for plastics upcycling. More broadly, the plant’s equipment and technologies enable the production of high-purity recycled polymers and compounds designed to replace virgin fossil-based materials in high-value-added applications. They also enable the development of tailor-made materials to meet specific functional, mechanical, aesthetic and regulatory requirements, expanding the potential uses of recycled plastics even in the most demanding market segments.
The circular economy on a single site
R3GID is located at Hera Group’s industrial hub on Via Cavazza in Modena, which already houses a waste-to-energy plant and a wastewater treatment plant. These existing facilities have enabled the creation of a circular system with Aliplast’s new plant: treated water supplies the rigid plastics recycling process before returning to the wastewater treatment plant, while electricity generated by the waste-to-energy plant powers the new business activities.
This reduces energy costs, which, even before the energy crisis, accounted for around 30% of production costs in Italy’s recycling sector, excluding raw materials. The plant also avoids approximately 30,000 tonnes of CO₂ equivalent emissions compared with production from virgin plastics, on a like-for-like production cycle basis.
Aliplast doubles its capacity
The Modena plant, the expansion of the facility in Borgolavezzaro (Novara) dedicated to low-density polyethylene (LDPE) recycling, and the acquisition of a 70% stake in Kronos Polymer Polska, also an LDPE specialist and expected to complete by the end of 2026, will enable Aliplast to double its recycling capacity and increase its operational flexibility. Annual capacity for high-quality secondary plastic raw materials will exceed 210,000 tonnes, with total production capacity reaching 255,000 tonnes per year.
The Modena investment forms part of the €2 billion allocated to the circular economy under the Group’s 2025–2029 Business Plan, out of total planned investment of €5.5 billion.
Innovation combining sustainability and competitiveness
This morning’s inauguration of Aliplast’s Modena plant provided an opportunity to discuss the future of plastics recycling, focusing on innovation and sustainability. Following institutional addresses by Massimo Mezzetti, Mayor of Modena, Michele de Pascale, President of the Emilia-Romagna Region, and Minister Gilberto Pichetto Fratin, Hera Group CEO Orazio Iacono outlined the plant’s role within the Group’s strategy. Andrea Ramonda, CEO of Herambiente, presented R3GID’s key features, while Michele Petrone, CEO of Aliplast, opened the morning’s proceedings.
The event continued with a roundtable moderated by Francesca Gambarini, a journalist at L’Economia, Corriere della Sera, bringing together representatives from industry and research: Paolo Accastello, Stellantis Manufacturing – Vehicle Area Manager Italy & Poland; Luigi De Nardo, Head of the “Giulio Natta” Department of Chemistry, Materials and Chemical Engineering at Politecnico di Milano; Fabrizio Di Amato, Chairman and Founder of MAIRE Group; Antonino Furfari, Managing Director of Plastics Recyclers Europe (PRE); Paolo Goi, Global Innovation, Research & Quality Director at Davines; Maurizio Mezzelani, Head of R&D at Fratelli Guzzini; and Simone Targetti Ferri, Sustainability Officer at L’Oréal Italia. Following the ribbon-cutting ceremony, the morning concluded with a guided tour of the plant.
The European plastics recycling landscape and regulatory developments
The Packaging and Packaging Waste Regulation (PPWR), adopted by European countries in 2025, will require an additional 5.7 million tonnes of recycling capacity for rigid HDPE and PP plastics across Europe by 2040 compared with current levels. Of this, 2 million tonnes will need to be available by 2030 to meet increasing regulatory requirements for recycled content in packaging. The End-of-Life Vehicles (ELV) Regulation, approved in June 2026, will also contribute to demand. It introduces minimum recycled plastic content requirements for new vehicles of 15% from 2032 and 25% from 2036, with at least 20% of that recycled content required to come from end-of-life vehicles. As the ELV Regulation applies only to new models placed on the market, its full impact on the entire vehicle fleet is not expected before 2042. By that date, 1.2 million tonnes of post-consumer recycled plastics will be required.