42190427-b090-430f-90dc-e30d21bfa7df Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE NON-MEMBER CASE STUDY COMPANY: RENEWABLE PARTS LTD. WEBSITE: RENEWABLE-PARTS.COM SECTOR: ENERGY DATE PUBLISHED: 16 JANUARY 2026 TAGS: WINDENERGY, WINDTURBINES, REMANUFACTURING, SUPPLYCHAIN, RENEWABLEENERGY, COMPONENTREUSE, DECOMMISSIONING, CARBONSAVINGS, MATERIALRECOVERY In the second week of September 2025, a delegation of CIRCULÉIRE members and staff was invited to Glasgow, Scotland, by Zero Waste Scotland to meet Circular Economy Industry Pioneers and Stakeholders from the Scottish Ecosystem. On Tuesday, September 9 th , our delegation visited Renewable Parts, a supply chain refurbishment and remanufacture specialist in the wind energy industry. This case study is part of a special series to transfer knowledge and learnings to Circular Economy Pioneers in the Irish Ecosystem. The Challenge The wind energy industry is experiencing rapid growth. In Ireland, wind power’s share of electricity supply has more than doubled in the last decade. It now provides 34% of Ireland’s electricity supply, second only to natural gas at 44% (SEAI, 2024) . Wind has very low emissions; about 13 grams of CO 2 per kilowatt-hour (NREL, 2001) , which mainly comes from the materials, manufacturing, and construction of the wind turbines. Once in operation, a wind turbine produces virtually zero emissions. In comparison, natural gas emits 486 grams per kilowatt-hour (NREL, 2001), making wind 97% cleaner. While this represents a significant leap forward, the industry still faces challenges. How can we make the materials, manufacturing, and construction of wind turbines more sustainable? How do we maintain them and source parts for them decades later? How can the existing turbines be improved upon? What happens to these massive structures when they reach the end of their life? Addressing these questions requires a circular approach. Many wind farms are approaching their end of life, meaning huge quantities of waste materials will need to be disposed of. In Scotland alone, 5,500 onshore turbines will be decommissioned by 2050, creating 1.4 million tonnes of waste material (Jacobs, 2021). If you were to load this onto lorries and line them bumper to bumper, the queue would extend from Cork to Belfast and back (based on a 16.5 metre long articulated truck ( RSA, 2025 ) carrying 27 tonnes ( Espace Global Freight, n.d. )). The industry urgently needs to address this waste. Each turbine has about 8,000 parts ( US DoE, n.d. ), such as gears and motors, many of which will fail or will need to be replaced regularly over its lifespan. These parts currently end up in a landfill or are melted down to be recycled. Producing the materials for replacement parts accounts for 83% of their emissions (Arias Losada, 2021) . The wind industry creates a lot of waste, but the materials used to replace parts are also a major source of emissions. The Circular Solution Renewable Parts is a Scottish company tackling waste in the wind industry. Renewable Parts began exploring the reuse of parts in the Wind Industry in 2012, but it took until 2018 for the idea to gain real traction. This illustrates both the inertia in shifting industry mindsets and the persistence required for circular business models to succeed. Their work points towards a growing recognition that achieving net-zero goals depends on the sustainability of supply chains; and remanufacturing can be central to achieving that. Renewable Parts’ approach is simple: take end-of-life components, remanufacture them to a standard equal to or better than new, and return them to turbine owners. Wind turbines operate for decades in extreme environments, and sooner or later, some of their components are going to break. The failed parts, along with parts from decommissioned turbines, are taken to Renewable Parts’ facility in Lochgilphead. Here they are stripped into components, and everything down to the bolts and washers is cleaned and inspected. The bearings, seals, and grease are always replaced, and individual worn-out components are refurbished or swapped out. Once reassembled, the parts perform like new and even have the same warranty. This reuse of material enables lower cost parts and diverts a huge amount of materials going to waste. Despite common misconceptions that remanufactured parts might be somehow inferior to new parts, industries such as aerospace have long relied on them, proving their safety and reliability. In fact, remanufacturing often outperforms original manufacturing, as data from past failures enables engineers to design out weaknesses and produce improved parts. Far more rigorous than repair, remanufacturing delivers high-integrity products that often surpass the originals, positioning it as a cornerstone of a high-quality and sustainable industrial future. Renewable Parts tracks exactly how components fail: by age, manufacturer, and even the specific conditions of the turbine e.g., wind alignment. By pinpointing the root causes, they can redesign vulnerable parts. The result? Remanufactured components that are stronger and often outlast the originals. In one example, an improved Siemens 1.3 yaw drive showed a 10% reduction in failures compared to the original design (Cross, 2024). The CIRCULÉIRE team visits Renewable Parts in Scotland to see how remanufacturing and circular supply chains are tackling waste in the wind energy sector Renewable Parts demonstrates how remanufacturing with a circular business model can improve quality while reducing time, cost, and carbon. And it's working; turnover is growing by 37% year on year (Zero Waste Scotland, 2024) , with remanufacturing already accounting for 38% of revenue. The company aims to raise this to two-thirds within five years, and in the process create more skilled jobs in rural Scotland. The Differences Between Repair, Refurbishment & Remanufacture Repair is the most basic intervention, focused on fixing a specific fault to get a product back into working order. This process typically involves minimal disassembly and only addresses the failed part without assessing the overall condition of the item. The goal is to restore function, not to improve the product's lifespan or appearance. Refurbishment goes a step further than repair. It involves restoring a used product to a functional, but not necessarily "like-new," condition. The focus is on fixing obvious faults and improving its cosmetic appearance. Parts are repaired or replaced as needed, but the product is not completely disassembled. A refurbished item will often have a limited warranty and may not meet original performance specifications. Remanufacture is the most rigorous and comprehensive process. It involves disassembling the product completely, inspecting all individual components, and replacing or restoring worn-out or obsolete parts with a combination of reused, repaired, and new parts. The goal is to return the product to a like-new or better-than-new condition in terms of performance, appearance, and quality. A remanufactured product typically comes with a new warranty that is equivalent to or better than the original product's warranty. Climate Impact The remanufactured parts offer significant carbon savings. Customers receive carbon certificates, allowing them to measure their reductions and compare the value directly against buying offsets. Between 2018 and 2024, Renewable Parts’ remanufacturing has saved 579 tonnes of CO 2 equivalent (Zero Waste Scotland, 2024) . That’s equivalent to the electricity of roughly 540 homes in Ireland for a year. In that same period, they have diverted 198 tonnes of material from landfill (Zero Waste Scotland, 2024) , or about seven articulated lorries full. The potential impact across the wind industry is vast. Research commissioned by the Coalition for Wind Industry Circularity, of which Renewables Parts is a member, found that if just ten out of the thousands of parts in a turbine used a circular supply chain, it could save 800,000 tonnes of parts from being scrapped in 10 European countries by 2035. This market would be worth 9.6 billion GBP (11.1 billion EUR) and create 20,000 jobs (BVG Associates Limited, 2023) . Circular economy solutions aren’t just good for the environment - they also make clear economic sense. This presents a huge untapped business opportunity; Stephen Fitzpatrick of the National Manufacturing Institute Scotland said, “Renewable Parts Limited are the only company in Scotland, and arguably the UK, that are picking this up. But they can only do so much. We need many, many more of those companies or for Renewable Parts to grow significantly.” Replicability Vestas , one of the world's largest turbine manufacturers, operates a refurbishment facility of 120 people in Lübeck, Germany. Failed generators are refurbished, cutting their CO 2 emissions by more than half compared to producing a new one. This supports their goal of reducing supply chain emissions in their service business by 45% by 2030 (Arias Losada, 2021) . Siemens Gamesa operates 11 repair centres globally, which offer reduced costs and lead-times, with improved reliability and availability of parts (Siemens Gamesa, n.d.) . They have also launched the "RecyclableBlade," the world's first fully recyclable wind turbine blade, which uses a new resin type that allows for the separation of blade materials at the end of life (Siemens Gamesa, n.d.) . BladeBridge , an Irish company and CIRCULÉIRE member, repurposes old wind turbine blades into new products such as bridges and outdoor furniture. The blade is used in place of virgin materials such as steel and concrete, resulting in a 20-50% lower environmental impact. The products also require less maintenance, saving money over their lifespan. Their products have been used on the Achill Sound and Midleton to Youghal greenways, as well as communities across the country. Read our BladeBridge case study here. GE Renewable Energy partnered with Veolia North America (VNA) to process blades from its U.S.-based onshore turbines, shredding them for use as a raw material for cement manufacturing. These examples show how circular solutions are fostering an entire ecosystem of companies, each specialising in different aspects of wind turbines. ALL CASE STUDIES

9f538ea4-0f34-457d-a6ea-86430a254ba7 Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE MEMBER CASE STUDY COMPANY: MESH BIOPLASTICS WEBSITE: MESHBIOPLASTICS.COM SECTOR : ADVANCED-MATERIALS / SMART MANUFACTURING PUBLISHED: 06TH MAY 2026 TAGS: BIOPLASTICS, BIOPOLYMERS, CIRCULARMATERIALS, AI-MANUFACTURING, SMARTMANUFACTURING, DIGITALTWIN, MEDTECH The Challenge Global plastic consumption is accelerating at a pace the planet cannot absorb. Over 400 million tonnes of plastic are produced annually - half of it single use - equivalent in weight to 800 Burj Khalifa towers ( UN, 2025 ). The plastic lifecycle, from production to disposal, accounts for roughly 4% of global greenhouse gas (GHG) emissions ( UNFCCC, 2024 ). In the EU alone, plastic production generates 13.4 million tonnes of CO₂ yearly, making up 20% of the chemicals sector's total emissions ( EEA, 2024 ). The waste picture is equally stark. Every day, the equivalent of 2,000 garbage trucks' worth of plastic is discarded into oceans, rivers, and lakes ( UNEP, n.d. ). Eighty-five percent of marine litter is plastic, driving toxic leaching and habitat degradation across ecosystems ( EEA, 2023 ). The consequences extend beyond the environment - chemical exposure poses human health risks, disrupted fisheries threaten food security, and coastal communities face growing economic fragility. These pressures are set to intensify. Global annual plastic production is projected to double by 2050 ( EEA, 2024 ), yet global recycling rates remain stuck at just 9%, with incineration accounting for a further 12% ( Houssini et al, 2025 ; EEA, 2024 ). The scale of the problem demands solutions that go beyond recycling alone - rethinking the materials themselves and the processes used to make them. The Circular Solution Mesh Bioplastics , a participant of the 2025 CIRCULÉIRE Venture Accelerator, was founded to address the challenge that the materials used in demanding healthcare and industrial applications needed to meet strict performance requirements while also supporting sustainability and circularity. The company was co-founded by Shane Hannan, who brings over 15 years of experience across plastics manufacturing and regulated life sciences; Tony Hannan, with 30 years in manufacturing and operational scale-up; Dr. Annie Ibrahim, a specialist in artificial intelligence, data science, and scalable SaaS systems and Reinier Kobus, with 25 years in financial strategy and capital structuring for global conglomerates. Between them, the founding team spans the full range of problems Mesh is built to solve - materials science, manufacturing process control, and the digital intelligence to connect them. That combination of expertise is reflected in the company's two connected offerings. On the materials side, Mesh develops bioplastics for healthcare, pharmaceuticals, and manufacturing - sectors where performance cannot be compromised. Bioplastics are materials that are bio-based, biodegradable, or both - made wholly or partly from renewable biological sources such as corn, sugarcane, or cellulose, rather than from fossil fuels ( European Bioplastics, n.d. ). Mesh's biopolymer-based products are designed to match the performance of conventional petroleum-based plastics while significantly reducing environmental harm. On the manufacturing side, Mesh has developed VariControl - a proprietary AI platform that integrates directly with existing factory-floor equipment including injection moulding, extrusion, and thermoforming machines. Using proactive digital twin technology, VariControl builds a live model of each manufacturing process, continuously monitoring for drift and guiding corrective action before issues reach the production line - improving consistency, reducing waste, and supporting faster learning during manufacturing runs. The platform generates structured, audit-friendly process data designed to support validation-ready production in regulated environments such as healthcare. A short explainer on how the VariControl platform works VariControl is material-agnostic, operating equally with virgin polymers, recycled polymers, bioplastics, and recycled bioplastic blends. Its ability to learn and model material behaviour also makes it a powerful tool for bringing novel materials online - including emerging bio-based feedstocks derived from aquatic, agricultural, and waste sources - stabilising molecular drift as new materials are introduced and enabling manufacturers to increase recycled or bio-based content progressively, without sacrificing quality or throughput, and without requiring hardware modifications. Together, these two offerings address the plastic problem from both ends: replacing harmful materials at source and making the production of sustainable alternatives as efficient and commercially viable as possible. Climate Impact Under optimised conditions, bioplastics produced from lignocellulosic waste biomass (plant-based agricultural and forestry residues such as wheat straw, corn husks, and sawdust) can achieve carbon-negative lifecycle emissions, while food waste-derived bioplastics generate just 4.8 kg CO₂ eq. per kilogram produced - far below conventional fossil plastic benchmarks ( de Mello et al., 2025 ). VariControl delivers additional gains at the production stage. The company’s own pilot trials in plastics manufacturing have reported measurable sustainability improvements through real-time optimisation and waste minimisation: 20–25% average reduction in material waste through predictive fault detection and closed-loop process control. Up to 15% decrease in energy consumption production run due to dynamic cycle-time optimisation. Support for up to 50% recycled or bioplastic content without sacrificing quality or throughput, slashing virgin polymer reliance. 25–35% drop in process-related CO₂ emissions versus conventional virgin-material production. Beyond the environmental gains, VariControl reduces raw material costs and waste disposal fees - improving profit margins and making the transition to circular plastics production a commercially attractive proposition for manufacturers, not just a compliance exercise. Replicability The global medical plastics market - the primary target for Mesh's biopolymer-based devices - was valued at USD $61.35 billion in 2025 and is projected to reach USD $99.25 billion by 2033, growing at a CAGR of 6.0% ( Grand View Research, 2025 ). At the same time, the broader bioplastics sector is scaling rapidly. According to the European Bioplastics Association, global biobased plastics production capacity is forecast to double from 2.31 million tonnes in 2025 to approximately 4.69 million tonnes by 2030, driven by regulatory pressure, rising demand across packaging, automotive, and healthcare, and the emergence of more advanced applications ( European Bioplastics, 2025 ). EU regulation is tightening the conditions under which conventional plastics can be produced and placed on the market. The Packaging and Packaging Waste Regulation and the Corporate Sustainability Reporting Directive (CSRD) are together mandating reductions in virgin material use and greater transparency around environmental performance - creating both pressure and opportunity for solutions like those Mesh Bioplastics offers. A number of organisations are developing comparable solutions in the bioplastics and circular plastics space: ReBioCycle is an EU-funded initiative scaling sorting and recycling infrastructure for bio-based plastics, improving recycled content and measuring environmental performance against fossil benchmarks. Sulapac (Finland) develops wood-based biocomposite materials for cosmetics packaging, achieving full biodegradability without compromising on design or performance. Corbion (Netherlands) produces lactic acid-based biopolymers used in medical applications including wound care, surgical sutures, and drug delivery systems, applying fermentation-based production processes and rigorous regulatory compliance to support sustainable healthcare materials. NatureWorks (USA) is one of the world's leading producers of Ingeo biopolymers, derived from renewable resources, with applications spanning packaging, medical devices, and industrial uses - demonstrating the commercial scalability of bio-based alternatives to conventional plastics. ALL CASE STUDIES

19c8a8d5-aefd-49f6-9c2d-16d77324d22a Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE MEMBER CASE STUDY COMPANY: HaPPE EARTH WEBSITE: HAPPEEARTH.COM SECTOR : MEDTECH PUBLISHED: 06 AUGUST 2025 TAGS: GREENHEALTHCARE, PPEWASTE, INNOVATION, SUSTAINABLEHEALTHCARE, MEDTECH, CIRCULARHEALTHCARE, ESG, COMPOSTABLE, BIOECONOMY, WASTEMANAGEMENT The Challenge Through its vitally important role in the protection of human health, the global healthcare sector generates an enormous and complex waste stream. If the global healthcare sector were a country, it would rank as the fifth-largest contributor to global CO₂ emissions, responsible for over 5% of total emissions, surpassing those from aviation or shipping sectors ( MedTech Europe, 2024 ). One-third of the carbon emissions generated by the healthcare sector, and most of its waste comes from medical devices ( Boston Consulting Group, 2024 ). Ninety percent of medical device waste primarily consists of single-use devices ( Health & EY, 2024 ). During the COVID-19 pandemic, medical waste became particularly visible, especially concerning Personal Protective Equipment (PPE). PPE is classified as any device or appliance designed to be worn or held by an individual for protection against one or more health and safety hazards ( HSA, 2025 ). Globally, an estimated 129 billion face masks and 65 billion gloves were used every month ( Prata et al., 2020 ). Typically, PPE is incinerated, and none is sent to landfill. However, during the pandemic, incinerators were so overrun that many countries were forced to send waste to landfill ( BMJ, 2021 ). By 2021, more than 8,000,000 tonnes of pandemic-associated plastic waste was generated globally, with more than 25,000 tonnes entering our oceans ( PNAS, 2021 ). An estimated 73% came from hospitals ( PNAS, 2021 ). PPE is an unquestionably necessary tool for saving lives. It prevents the spread of pathogens and infections and protects both frontline healthcare workers and patients. However, PPE such as face masks, gloves, and gowns are commonly manufactured from plastics such as polypropylene, polyurethane, polyacrylonitrile, polyethylene, and polyethylene terephthalate which can take as long as 450 years to decompose ( BMJ, 2021 ). Even when incinerated, PPE still releases greenhouse gases and contributes to air pollution ( Kumar et al., 2020 ). The challenge, therefore, is not to eliminate this essential equipment but to fundamentally redesign its lifecycle. The Circular Solution in Practice HaPPE Earth is an Irish company and CIRCULÉIRE member, founded in 2021. They make medically approved compostable PPE aprons from sustainably sourced, proprietary bio-resins. Bioresins are a type of polymer derived from renewable sources such as plants, cellulose, sugars, and other biological materials, instead of traditional petroleum-based sources ( Verde Bioresins, 2025 ). HaPPE Earth’s aprons are used the same as standard petroleum-based PPE aprons, but instead of being thrown away after use, they are sent to HaPPE Earth’s onsite medical biodigester system. The biodigester is offered as a first-of-its-kind Sustainable-Consumables-as-a-Service (SCAAS) business model and requires no capital investment from the healthcare service provider. The PPE aprons are composted alongside the healthcare provider’s food waste, where they break down in days in HaPPE Earth’s industrial composting process, resulting in a valuable, pathogen safe, nutrient-rich fertilizer. In addition, HaPPE Earth offers a real-time data monitoring tool allowing healthcare providers to track their plastic waste and CO 2 reduction and capture food waste data for use in their ESG reporting. The service is provided with a dedicated account management team to help with software integration and training, and technical support throughout the process. HaPPE Earth estimates the compostable apron and digestion system uses 75% less carbon emissions than standard single use aprons ( Health Innovation Hub Ireland, 2023 ). By managing waste on-site, the system saves on carbon emissions from transport while simultaneously preventing waste from entering waterways and avoiding air pollution from incineration. Furthermore, HaPPE Earth estimates their waste re-direction service can save the Irish Health Service approximately EUR €400,000.00, and reduce 8,000 tonnes of carbon emissions each year, all while eliminating PPE plastic waste. HaPPE Earth’s aprons are being trialled in over 20 hospitals in Ireland. However, any sector that uses PPE can use the HaPPE system – including pharmaceuticals, medical device industries and food preparation. Replicability Biodegradable and compostable PPE options are growing across Europe and North America, alongside trials of systems to digest and decompose the products effectively. Some notable examples of companies working to tackle the use of PPE in the healthcare sector include: Revolution-Zero focus on reusable alternatives to medical textiles, including isolation gowns, aprons, transfer sheets, curtains, and warm-up jackets. They offer direct purchase options or Product as a Service models, and offer software for operations, regulatory compliance, asset tracking and environmental reporting. AmorSui – offer a reusable line of PPE made from premium, machine washable materials. Their fabrics are recyclable, and they are currently developing a take-back programme and subscription model to fully align with their circular economy principles. ALL CASE STUDIES

abb2e18b-2e79-4162-97eb-7d22fb6375b8 Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE NON-MEMBER CASE STUDY COMPANY: AHREND WEBSITE: AHREND.COM SECTOR : BUILT ENVIRONMENT PUBLISHED: 27 JUNE 2025 TAGS: BUILT ENVIRONMENT, FURNITURE, CIRCULAR BUSINESS MODELS, CIRCULAR DESIGN, REUSE About Ahrend Furniture Ahrend , established in 1896, is an international leader in office furniture and space solutions, committed to delivering vitalising workspaces. Ahrend furniture is designed to optimise employee’s experiences with the focus on stimulating health, wellbeing, and productivity in workspaces. The Challenge As educational levels improve and the service industry expands, so will the number of individuals with formal office positions, causing a growth in office space and furnishings ( Ellen McArthur Foundation, 2021 ). Although this benefits people’s livelihoods, it has a negative influence on the environment by increasing waste. In Europe, 10.78 million tonnes of furniture waste is discarded yearly ( Forrest et al., 2017 ), which is the approximate weight of 53,900 adult blue whales. Only 10% of that furniture is recycled, while 80% - 90% is incinerated or ends up in landfills ( Forrest et al., 2017 ). Producing the average piece of furniture emits 47 kilogrammes of CO2, which is comparable to burning nearly 20 litres of petrol ( Lai, 2023 ). The Circular Solution In the 1990s, Ahrend was involved in the development of Ecodesign, the European guideline for environmentally-friendly product design. Since then their new products are designed to be modular, sustainable, repairable and parts are designed to be easily separated for reuse or recycling. In 1994, Ahrend designed the A220 office chair which was was one of the first Ecodesign products in the world. In 2011, they became the first and only Cradle to Cradle company in the furniture industry. Cradle to Cradle is a global certification system which scores brands for their commitment to the circular economy, the reduction of waste and hazardous chemicals, more efficient uses of resources and the reuse of materials, energy efficiency, and social responsibility ( Good On You, 2023 ). Ahrend now offers their customers a “Furniture as a Service” (FaaS) option, in which they rent their office furniture for a fee, based on the length of time that they require it. Ahrend provides maintenance, storage, and insurance for all products in use during this time. When a customer no longer requires the furniture, it is returned to Ahrend and refurbished, thereby prolonging its life and decreasing virgin material use. This business model has several advantages. As Ahrend maintains ownership of their product throughout its lifetime they are incentivised to design it for durability and to be easily repairable and remanufactuarable in the future. This in turn reduces waste, CO2 emissions and the need for additional virgin resources. The FaaS business model also ensures the end-of-life of a product is considered right from the early design stages and influences the materials chosen for production, assessing them on their recyclability and lack of toxicity. Climate Impact Ahrend lowers CO2 emissions by up to 40% each year by redeploying materials and products. The FaaS model also cuts costs. Consider a new working environment with a total investment value of €45,000 over a time frame of 60 months. If the FaaS model is opted for versus buying, a €6000 savings could be achieved on the end cost ( Ahrend, 2023 ). FaaS makes more financial sense once you consider the savings from maintaining a work environment such as logistics, interest, storage, and maintenance expenses. Furthermore, Ahrend’s manufacturing process is CO2 neutral, using 100% renewable energy and closed water and energy circuits with heat pumps to reduce its CO2 footprint. Replicability Under the Product as a Service (PaaS) business model companies offer their physical product as a service. This model incentivises companies to consider longevity, maintenance, reuse, re-manufacture, and recycling in their product design. All this is done in close collaboration with customers, who become “users” of a service instead of “consumers” of a product. The PaaS model has already been applied to cars, bikes, smartphones, clothes, printers, solar panels, tires, etc. For example... Amsterdam’s Schipol Airport, pays Philips and Cofely for ‘light as a service ’. They save on maintenance costs and extend the service life of the light fittings by 75%. It further limits raw material consumption, because every component can be recycled or re-used at the end of its service life ( EU, 2023 ). Homie , in the Netherlands, offers a pay-per-use washing machine subscription where customers pay less for wasing at lower temperatures ( CEF, 2023 ). ALL CASE STUDIES

19feae94-bf87-492b-9672-8eea545fb81b Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE NON-MEMBER CASE STUDY COMPANY: RUBI LABORATORIES WEBSITE: RUBI.EARTH SECTOR: TEXTILES & APPAREL MANUFACTURING / INDUSTRIAL BIOTECHNOLOGY PUBLISHED: 11 th SEPTEMBER 2026 TAGS: CIRCULAR MANUFACTURING, BIO-BASED MATERIALS, CELLULOSIC FIBRES, ENZYMATIC BIOCATALYSIS, RAW MATERIAL SUBSTITUTION, DECARBONISATION, TEXTILE INNOVATION, RESOURCE EFFICIENCY, SUPPLY CHAIN RESILIENCE The Challenge The textile industry is one of the most resource-intensive sectors globally, contributing to environmental degradation and labour rights violations across its supply chain ( Brown and Börkey, 2024 ; Keßler, Matlin and Kümmerer, 2021 ). Within the EU, textile consumption ranks as the fifth largest contributor to greenhouse gas emissions and the fourth largest in raw materials use from a global life-cycle perspective ( European Commission, 2020 ), placing it among the highest-impact product categories assessed ( Long, Lee-Simion and Connock, 2022 ). This impact is a function of scale. Global fibre production reached a record 124 million tonnes in 2023, more than double the volume produced in 2000, and is projected to reach 160 million tonnes by 2030 on current trends ( Textile Exchange, 2024 ). Synthetic fibres, now the dominant feedstock, carry a disproportionate emissions burden due to their fossil origin and energy-intensive production ( Duhoux et al., 2025 ). Natural fibres present a related constraint: cotton alone is cultivated on 2.5% of the world's arable land ( FAO, 2023 ), and producing a single cotton t-shirt requires 2,700 litres of fresh water ( EU Parliament, 2025 ). Regardless of feedstock, the raw materials stage carries the heaviest footprint: land conversion, deforestation, chemical use and irrigation energy make fibre production one of the most environmentally significant points in the value chain ( OECD, 2022 ), and manufacturing alone involves more than 15,000 different chemicals ( Niinimäki et al., 2020 ). Processing compounds this further, with dyeing accounting for roughly 20% of global industrial water pollution ( EU Parliament, 2025 ). Global manmade cellulosic fibre (MMCF) production rose from 7.4 million tonnes in 2022 to 7.9 million tonnes in 2023 ( Textile Exchange, 2024 ). These pressures culminate at the point of consumption, EU textile use generated 355 kg of CO 2 per capita in 2022 ( EU Parliament, 2025 ), underscoring that any credible circular solution must intervene furthest upstream, at fibre production itself. A Circular Solution Founded in 2021, Rubi Laboratories addresses the raw-materials bottleneck identified above by removing agricultural cultivation from fibre production altogether. Rather than growing and pulping trees or plants for cellulose, Rubi's process begins with flue gas, the CO 2 -laden waste stream from manufacturing facilities. This gas is diverted into a bioreactor system before it can reach the atmosphere, where cell-free enzymes convert the captured CO 2 directly into pure cellulose pulp, driving the same chemical transformation plants use to build cellulose, only without cultivating a single plant. Rubi calls this "symbiotic manufacturing", a cyclical rather than linear process, built on capturing existing waste streams rather than extracting new resources ( Rubi Laboratories, n.d.a. ). Crucially, the resulting cellulose is chemically the same material used in viscose and lyocell, so it doesn't require textile manufacturers to change their equipment, it can be dissolved, extruded into fibre, spun into yarn, and woven or knitted through the industry's existing production lines ( Rubi Laboratories, n.d.a. ). This directly answers the land- and water-intensity problem raised, with the company reporting virtually zero water and zero land use compared with cultivated fibres ( Rubi Laboratories, n.d.b. ). At end of life, the pure cellulosic textile is fully biodegradable, returning captured carbon to the natural cycle rather than persisting as waste. Rubi also describes its production units as modular and deployable at or near existing manufacturing sites rather than requiring large, centralised, land-intensive facilities ( World Economic Forum, n.d. ). Environmental, Social and Economic Impact Each garment made with Rubi's cellulose is estimated by the company to avoid and capture the equivalent of around 20 bathtubs of CO 2 per pair of jeans, roughly 18 avoided and 2 directly captured from industrial flue gas, alongside virtually zero water and zero land use compared with cultivated fibres, and full biodegradability at end of life ( Rubi Laboratories, n.d.b. ). The technology offers a renewable, forest-free alternative to wood pulp. According to Rubi's NSF Phase II award abstract, at pilot scale and measured against wood-pulp cellulose, their technology delivers around 50% lower CO₂e emissions, 60% less water use and 98% less land use ( America’s Seed Fund by NSF, n.d. ). Conventional cellulose and cotton processing exposes workers to heavy agrochemical and industrial chemical use, links to respiratory illness and other health effects ( Niinimäki et al., 2020 ); replacing field cultivation and chemical pulping with enzymatic conversion would, by removing those inputs, plausibly reduce this category of occupational exposure. Beyond the factory floor, the platform is expected to generate new employment and strengthen domestic manufacturing capacity, tapping into a serviceable obtainable market estimated at $2 billion in the United States ( America’s Seed Fund by NSF, n.d. ). [PW1] Economically, the technology has drawn both public and private validation. Rubi was awarded a $969,961 Small Business Innovation Research Phase II grant from the U.S. National Science Foundation to scale its carbon-to-cellulose platform, following a completed Phase I award ( America’s Seed Fund by NSF, n.d. ). It was also named to Forbes' Under 30 list for Manufacturing & Industry, with reporting noting $4.5 million raised and pilot agreements underway with clothing brands ( Feldman, Ohnsman and Brier, 2022 ). Commercially, cell-free enzymatic conversion is reported to cut energy and capital costs by up to a factor of ten, moving cellulose toward cost parity with conventional fibres and drawing engagement from Walmart, H&M, Patagonia and Stella McCartney ( World Economic Forum, n.d. ). Replicability Rubi is not alone in treating carbon emissions as a feedstock rather than a waste. A handful of companies are converting captured or waste carbon into usable materials, by different routes: Fairbrics (France) - has built a chemical process, pairing catalysis with electrochemistry, that captures CO 2 from industrial sources and turns it into the organic building blocks used in plastics manufacturing. Its first commercial application replaces fossil-derived inputs in polyester production with this captured carbon, and the company is working toward a version of the material that is fully carbon-negative. LanzaTech (USA) - captures waste industrial gases and converts them into usable raw materials through a recycling process. One commercial result of this is CO2Renu , a fleece line developed with outdoor brand Craghoppers that is built from carbon LanzaTech has diverted from industrial emissions rather than drawn from virgin fossil sources. Newlight (USA) - operates Eagle 3, the world's first fully integrated commercial-scale production system converting air and greenhouse gas into a biomaterial called AirCarbon. Using naturally occurring microorganisms discovered in California that convert air and dissolved greenhouse gas into PHB, the technology produces decarbonised, compostable materials now used in foodware and packaging. ALL CASE STUDIES

2c9a9b59-6fa0-4656-b9d2-b832a7784dcc Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE MEMBER CASE STUDY COMPANY: ST. LOARN GROUP WEBSITE: STLOARNGROUP.IE SECTOR: BUILT ENVIRONMENT PUBLISHED: 14 th AUGUST 2026 TAGS: CIRCULAR MANUFACTURING, GEOPOLYMER CEMENT, VALORISATION, BAUXITE RESIDUE, INDUSTRIAL SYMBIOSIS, LOW CARBON CONSTRUCTION, WASTE VALORISATION, ALUMINIUM INDUSTRY, DECARBONISATION, MATERIAL SUBSTITUTION The Challenge Cement is a major contributor to global carbon emissions. It accounts for roughly 7.1% of global CO₂ emissions and around 4% of the EU's ( Marmier, 2023 ). Most of this comes from producing clinker, cement's key ingredient, which requires heating limestone to extreme temperatures. About 65% of the resulting emissions come directly from that chemical reaction, calcination; the rest from the fossil fuels burned to drive it ( Nikolakopoulos et al., 2024 ). Cement production has also been linked to elevated health risks in nearby communities, including respiratory and cardiovascular conditions, associated with the release of particulate matter and heavy metals ( Bărbulescu & Hosen, 2025 ). Aluminium production presents a related but distinct waste challenge. Extracting alumin a from bauxite ore through the Bayer process produces a hazardous industrial by-product known as bauxite residue, red mud, or processed bauxite ( da Silva et al., 2025 ). The EU generates an estimated 7 million tonnes of this residue annually, of which less than 100,000 tonnes are recycled. The remainder is stored indefinitely, as large-scale reuse options remain limited ( European Commission, 2020 ). Due to its alkalinity and heavy metal content, bauxite residue is costly and hazardous to store, handle, and transport ( Evans, 2016 ). These risks materialised in October 2010, when a storage reservoir failure at an alumina refinery in Ajka, Hungary, flooded nearby villages and caused fatalities and chemical burns ( European Parliament, 2010 ). The scale of the challenge continues to grow. Global bauxite residue inventories are projected to reach 10 billion tonnes by 2050 ( International Aluminium, 2022 ), underscoring the urgent need for viable, large-scale approaches to reuse rather than storage, a need that spans both the cement and aluminium sectors. The Circular Solution St Loarn Group , a CIRCULÉIRE member, has developed a geopolymer cement (GPC), currently patent pending, that replaces Ordinary Portland Cement (OPC) entirely, using bauxite residue, a major by-product of aluminium production, as its primary raw material, although composition varies by application. Bauxite residue contains high concentrations of silica and alumina. When activated with an alkaline solution, these dissolve and reconnect into a gel that hardens and binds the material together ( da Silva et al., 2025 ). St Loarn Groups technology differs from this conventional route, in its specific blend of constituents requires only water to initiate the geopolymer reaction and produce a strong binder. More broadly, geopolymer materials of this type have been shown to perform effectively in structural applications, with strength comparable to standard cement concrete ( Saeed et al., 2022 ). St Loarn Group reports that the bauxite residue it uses is sourced with a lower pH than material straight from processing and is classified as inert by the EPA and equivalent EU bodies. By using a material that would otherwise require costly and environmentally damaging disposal, St Loarn Group addresses two problems with a single product: valorising potentially hazardous industrial waste from the aluminium industry and eliminating the need for carbon-intensive Portland cement. The product has achieved certification to ASTM C1157, a US international performance specification for hydraulic cement ( St Loarn Group, 2025 ). Structural testing confirmed that St Loarn Group's geopolymer beam exceeded the structural performance of standard Portland cement. It reaches full compressive strength within 28 days and has minimal shrinkage ( St Loarn Group, 2025 ). The company has also completed demonstrator pours, including concrete beams and cattle slats, in partnership with Harrington Concrete and Quarries. St Loarn Group is also working with the International Aluminium Institute, the global body representing the aluminium industry, and the Jamaican Bauxite Institute. Environmental, Social and Economic Impact Geopolymer cements deliver substantial climate and environmental advantages compared to Portland cement. The production of OPC is energy-intensive and generates significant carbon dioxide emissions ( Zaland et al., 2026 ). GPC can cut carbon dioxide emissions by up to 80% relative to OPC, while also being more cost-effective and making use of industrial waste streams ( Singh et al., 2020 ). St Loarn Group reports that their geopolymer cement's carbon footprint reduction could be as high as 93%. The company is targeting the global cement industry, valued at $394.82 billion in 2026 and projected to reach $500.3 billion by 2034 ( Fortune Business Insights, 2026 ), underlining the scale of the market this technology could reach. Cement is among the EU's largest-emitting energy-intensive industries, while aluminium, highly electro-intensive and recognised as a strategic raw material, has demand projected to rise 33% by 2050. Across these industries, decarbonisation has lagged EU climate targets ( European Commission, 2026 ). The Industrial Accelerator Act, proposed by the European Commission in March 2026, aims to build EU demand for low-carbon industrial products through faster permitting and Single Market measures, naming both cement and aluminium specifically among its target sectors, the same market St Loarn Group's technology is positioned to serve. St Loarn Group's geopolymer cement not only mitigates harmful pollutants by utilising industry waste streams, but also significantly lowers the waste treatment burden for producers. Replicability St Loarn Group's approach reflects a wider shift toward low-carbon construction materials in Ireland and internationally, with organisations pursuing this goal through different routes. Ecocem (Ireland) - produces GGBS (Ground Granulated Blastfurnace Slag), a by-product of iron manufacturing, as a low-carbon substitute for a portion of Portland cement in concrete. Replacement rates of up to 70% are permitted under EU concrete standards, giving GGBS concrete a lower carbon footprint alongside improved chemical resistance and finish. Techrete (Ireland) - developed a new range of lower-carbon concrete products, targeting a 50% reduction in embodied carbon by 2025. The R&D programme, supported by Enterprise Ireland, incorporates lower-carbon materials such as GGBS, fly ash, and limestone filler. Trinity College Dublin & FLI Precast Solutions (Ireland) - developed methods for incorporating biomass ash, a by-product of Bord na Móna's Edenderry Power Station, into low-carbon concrete. Edenderry, Ireland's largest dispatchable renewable energy facility, moved to 100% biomass generation in late 2024, giving this waste stream a productive use rather than disposal. Kilsaran (Ireland) - adopted CarbonCure technology, which injects captured CO₂ into concrete during mixing. The CO₂ mineralises permanently within the concrete, reducing both the cement required and the product's overall carbon footprint. Holcim ’s (Switzerland) - Recygénie project demonstrated that social housing can be built using 100% recycled demolition concrete, diverting over 6,000 tonnes of construction waste from landfill while reducing reliance on virgin cement. Read the CIRCULÉIRE case study on Holcim here . ALL CASE STUDIES

35571c7f-11f5-4ff4-b582-1dbcc4883a23 Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE NON-MEMBER CASE STUDY COMPANY: IPERIONX WEBSITE: IPERIONX.COM SECTOR : ADVANCED MATERIALS PUBLISHED: 13 NOVEMBER 2025 TAGS: CRITICALRAWMATERIALS, TITANIUM, RECYCLING, SUPPLYCHAIN, RESOURCERECOVERY, AEROSPACE, ADVANCED-MATERIALS The Challenge Titanium is a critical mineral valued for its exceptional strength, light weight, and resistance to corrosion ( Schulz et al., 2017 ). It is an essential metal for industries such as aviation, shipbuilding, power generation, and medical implants, where durability and lightweight materials are crucial ( Schulz et al., 2017 ). Titanium dioxide (TiO2), an oxide form of titanium, is widely used in pigments and renewable energy applications due to its photocatalytic properties - its ability to use light to trigger chemical reactions that can, for example, enhance the efficiency of sunlight conversion into electricity in solar panels ( TDMA, 2023 ). Recognized as both a critical and strategic raw material under the European Union's Critical Raw Materials Act , titanium is vital for key sectors including civil aviation, defence, space, advanced manufacturing, and the green and digital transitions ( Joint Research Centre, 2025 ). Despite its importance, the EU relies heavily on imports of titanium minerals and metal, primarily from countries like China, Russia, and Ukraine, which exposes the supply chain to geopolitical risks, market concentration, and long lead times. These vulnerabilities have led the EU to prioritize circular economy strategies such as increased recycling, diversification of supply sources, and development of secondary raw materials to reduce import dependency and increase supply resilience ( Joint Research Centre, 2025 ). The extraction and processing of titanium has additional environmental and human health costs. Titanium mining can result in deforestation, habitat loss, and contamination of air and water - especially when waste is improperly managed ( Farjana et al., 2018 ). The overall process is energy- and water-intensive, contributing to greenhouse gas emissions and exacerbating water scarcity in mining regions. A Circular Solution IperionX, a U.S.-based producer of critical minerals and materials, has partnered with European metals recycler Aperam Recycling through its American entity ELG. ELG has longstanding expertise in sourcing and processing titanium, stainless steel, and superalloys, handling over one million metric tonnes of metal annually ( Aperam, 2024 ). Using University of Utah-developed technology, IperionX can produce competitively priced titanium metal from both mined mineral and scrap. Unlike the industry-standard Kroll process, their method enables 100% scrap usage, making a fully closed-loop circular system possible ( IperionX, 2025 ). IperionX utilises Hydrogen Assisted Metallothermic Reduction (HAMR), an energy efficient thermochemical process that can produce either Commercially Pure (CP) or alloyed titanium powders at low cost and with low carbon emissions in a sustainable closed loop ( IperionX, 2025 ). The IperionX Titanium Demonstration Facility has the capacity to produce 125 tonnes of titanium powder per year ( Stockhead, 2023 ) and the company has scale-up plans to achieve a capacity of 1,400 metric tonnes of titanium per year by mid-2027 ( Metal AM, 2023 ). Climate Impact Recycling titanium scrap into powder produces over 90% fewer greenhouse gas emissions than conventional plasma atomisation methods, resulting in a carbon footprint as low as 7.8 kg CO2e per kilogram ( IperionX, 2023 ). By relying on recycled feedstock, IperionX reduces the need for new mining, conserves natural resources, and minimises waste. Additionally, by producing titanium powder domestically, the U.S. can lower transport-related emissions and costs - addressing a major supply chain gap as the nation currently imports all high-quality titanium ( Stockhead, 2023 ). Replicability The titanium market, valued at $2.44 billion in 2023, is set to grow at over 6% annually through 2030, largely due to increased demand from aviation and industrial sectors ( Grand View Research ). The uptake of circular recycling approaches, like those of IperionX, is likely to accelerate as industries seek lower-carbon and resource-efficient solutions. European initiatives focusing on titanium recycling and sustainable production include: EcoTitanium (France), is a leading European plant specializing in recycling aerospace-grade titanium alloys using advanced furnace technology. The EcoTitanium recycling plant is supported by significant EU investment, and produces thousands of tons of titanium alloy annually while helping to reduce emissions compared to traditional ore-based production. EcoTitanium is currently the main large-scale titanium recycling facility in Europe and aims to strengthen European supply chains and reduce import dependency ( EIB, 2018 ). The EURO-Titan Project is a multi-partner EU-funded project working to establish low-carbon titanium metal production from industrial residues and scraps within Europe. It aims to create traceable, continuous titanium metal production aligned with decarbonization and supply chain resilience goals. ALL CASE STUDIES

c11d36ad-d879-4496-8638-4af7801836e0 Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE MEMBER CASE STUDY COMPANY: WELL SPENT GRAIN WEBSITE: WELL-SPENT-GRAIN.COM SECTOR : FOOD PUBLISHED: 24 APRIL 2024 TAGS: FOOD WASTE, CIRCULAR BUSINESS MODEL The Challenge One of the earliest steps in the beer brewing process is when grain is steeped in hot water to stimulate the release of fermentable sugars for brewing. Once those sugars are released, the liquid is drained away and used in the next stage of the process. The grain that is left behind is no longer of any use to the brewer and is called Brewer’s Spent Grain (BSG). This spent grain accounts for approximately 85% of the waste created through the entire brewing process (Terefe, 2022). The brewing industry produces an estimated 39 million tonnes of spent grain per year (Bachmann, Calvete and Féris, 2022), that’s equivalent to the weight of 7.8 million African elephants. 70% of spent grain is commonly used as low-value cow feed or fertiliser, 20% is usually either disposed of in a landfill and the remaining 10% is converted into biogas (Terefe, 2022). That means approximately 7.8 million tonnes of BSG ends up in a landfill every year. Every tonne of BSG disposed of in landfill emits 513 kilogrammes of CO2 equivalent (LIFE-Brewery). BSG disposed of in landfill emits about 4 billion kilogrammes of CO2 each year. This is comparable to the same annual amount of CO2 emitted by burning 22,053 railcars worth of coal (EPA.gov). The Circular Opportunity BSG for human consumption has gained popularity in recent years, owing mostly to its health-related bioactive components. BSG is thought to be the most abundant source of phenolic chemicals, particularly hydroxycinnamic acids (HCAs) (Ikram et al., 2017). These phenolic chemicals are natural antioxidants that have been linked to the prevention of age-related chronic diseases such as cardiovascular disease, neurodegenerative diseases, type I and type II diabetes, and some cancers (Ikram et al., 2017). BSG is also regarded as a source of dietary fibre for humans, mainly viscous fibres, which aid in raising cholesterol and fat excretion and improving the digestive process (Ikram et al., 2017). The Circular Solution In Practice Well Spent Grain, a CIRCULÉIRE New Venture, is a Dublin-based Irish start-up founded by Sunkyung Choi and Patrick Nagle in March 2022. Well Spent Grain collect BSG from brewers like Rascals Brewing Company and transport it immediately to their kitchen for processing or storage. They upcycle it by creating tasty value-added snack bites. Well Spent Grain collaborated with the Prepared Consumer Foods Team in Teagasc Food Research Centre in Ashtown to develop the snacks and validate the production process. They work with ENSO to create and implement their sustainability strategy, track, and verify their performance. Their first product, Born-Again Peanut and Dark Chocolate soft snack bites, are made from upcycled BSG plus 5 additional ingredients (dates, 100% peanut peanut butter, toasted hazelnut, 70% dark chocolate and maple syrup). They provide good nutrition and a boost to adults’ energy levels. Each pack of Born-Again Bites has a natural malty, nutty, fruity flavour, with hints of dark chocolate and maple syrup. They provide 4.6g of protein per pouch and are high in fibre. They are accidentally vegan, have 100% recyclable packaging, and are hand-crafted locally. Well Spent Grain offer the consumer the opportunity to take part in the circular food economy in the easiest way possible. By picking up a pouch of Born Again Peanut and Dark Chocolate Soft Snack Bites, you are already taking part, and you get a delicious treat for your trouble. Replicability The global upcycled food market size was valued at USD 53.7 billion in 2021, and is projected to reach USD 97 billion by 2031 (J & D, 2023). Well Spent Grain has a great opportunity to cement and scale its business model alongside the thriving market while promoting the circular economy. Nutrient recovery from food waste and residues has been utilised in a variety of cases, including Niskus Biotec, a CIRCULÉIRE member, who upcycles and adds value to brewery and whiskey distillery by-products by using them to grow gourmet mushrooms (e.g., oyster, lion’s mane, and shiitake) and create myco-fermented food ingredients. ALL CASE STUDIES

cb7c465f-6983-49e7-acbe-5a9b7ab331ef Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE MEMBER CASE STUDY COMPANY: CIRCULAR FOOD CO. WEBSITE: CIRCULARFOOD.CO SECTOR : FOOD & BEVERAGE PUBLISHED: 8 TH APRIL 2026 TAGS: FOOD WASTE VALORISATION, UPCYCLED INGREDIENTS, WASTE TO VALUE, BIO-BASED SOLUTIONS, RESOURCE EFFICIENCY, INDUSTRIAL SYMBIOSIS, MATERIAL EFFICIENCY, CIRCULAR FOOD SYSTEMS, EMISSIONS REDUCTION, SUSTAINABLE NUTRITION The Challenge Food loss and food waste create profound environmental and social burdens worldwide. Despite food production claiming nearly a third of global agricultural land, approximately 1.05 billion tonnes of food were wasted in 2022 – while 783 million people faced hunger and a third of the global population grappled with food insecurity ( UNCC, 2024 ). This inefficiency generates 8-10% of global annual greenhouse gas (GHG) emissions, roughly five times the emissions of the aviation sector ( UNCC, 2024 ). In the European Union (EU), annual food waste exceeds 58 million tonnes ( Eurostat, 2025 ), producing emissions equivalent to 252 million tonnes of carbon dioxide ( European Commission, 2023 ). If food waste were an EU Member State, it would rank as the bloc's fifth-largest GHG emitter ( European Commission, 2023 ). Notably, food and beverage manufacturing accounts for 19% of this waste ( Eurostat, 2025 ). In 2023, Ireland generated 835,000 tonnes of food waste ( EPA Ireland, 2025 ). The brewing sector alone produces over 170,000 tonnes of spent grain yearly ( DAFM, 2025 ), much of which ends up as low-value animal feed or waste, intensifying resource inefficiency ( Teagasc, 2022 ). When such organic waste decomposes in landfills, it releases methane, a GHG with 84 times the warming potential of carbon dioxide over a 20-year period, exacerbating climate change ( EEA, 2025 ). Circular Solution Circular Food Co , a participant of the 2025 CIRCULÉIRE Venture Accelerator, transforms food industry by-products and surplus like spent grain into high-value, plant-based ingredients for the bakery, meat, snacking, and nutrition sectors. The company collects surplus from Irish producers, uses thermal dehydration to retain flavour and nutrition, and analyses functionality to create fibre-, protein-, and antioxidant-rich products. Their process diverts waste from disposal, enabling brands to meet ESG targets with upcycled ingredients that enhance taste and nutrition without new cultivation. Climate Impact Circular Food Co delivers substantial environmental benefits through upcycling, preventing landfill methane emissions and avoiding emissions tied to virgin resource production. Their ingredients offer near-total reductions: 100% in water use and 99% in land use, alongside 25% lower carbon footprints compared to conventional alternatives ( Circular Food Co, n.d. ). Upcycling closes nutrient loops, curbing demand for new production and mitigating climate impacts. To date, the company reports diverting over 200 tonnes of food waste, averting roughly 320 tonnes of CO₂e emissions while achieving over 70% resource efficiency with minimal extra water or energy. Replicability Food loss and waste exact a heavy economic toll, costing the global economy roughly USD 1 trillion annually ( UNCC, 2024 ). The EU Waste Framework Directive mandates Member States to cut food waste by 10% in processing and manufacturing by 2030 ( European Commission, 2025 ). Upcycling unlocks value from this waste stream, tapping into a €132 billion opportunity across the chain ( European Commission, n.d. ). Companies like Circular Food Co exemplify how to valorise waste and meet ambitious 2030 targets. Similar initiatives include: UpGrain , a Swiss company, which upcycles brewers' spent grain into protein- and fibre-rich ingredients for snacks and baked goods, saving CO 2 and disposal costs. Agrain , a Danish company, which converts spent grain into nutritious flour using proprietary technology, saving 24-44 kg CO 2 per 100 kg and 2 m² land per kg compared to traditional flour. Well Spent Grain upcycle brewer's spent grain into sustainable and delicious snacks. Read the CIRCULÉIRE case study on Well Spent Grain here A Note on By-Products & End of Waste A by-product is a residue left over from the production of another product. In Ireland, Regulation 27 of the Waste Directive sets out the circumstances in which a material can be considered a by-product and not a waste. It is essential you notify the EPA to determine if your material satisfies the criteria of a by-product. The EPA will confirm if it can be categorised as a by-product or if it must be categorised as a waste. If the substance is classified as a waste then it may need to achieve End-of-Waste status via Article 28 of the Waste Directive to be kept in use as a resource. ALL CASE STUDIES

5d2f185c-5482-4e4a-846f-d64c4ffe141b Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE MEMBER CASE STUDY COMPANY: FINLINE FURNITURE WEBSITE: FINLINEFURNITURE.IE SECTOR : BUILT ENVIRONMENT PUBLISHED: 30 JULY 2025 TAGS: BUILT ENVIRONMENT, FURNITURE, CIRCULAR BUSINESS MODELS, REFURBISH, REUSE, RECYCLING About Finline Furniture Established in 1979, Finline Furniture is one of Ireland's leading manufacturers of high-end furniture. Every piece of Finline furniture is handcrafted in their headquarters in Emo, County Laois, and since their inception Finline have garnered an excellent reputation for designing and making high-quality, long-lasting sofas, chairs, and footstools both for residential customers and commercial projects. The company exports worldwide and has developed its network to include showrooms in Dublin, Cork, and Galway. The Challenge Ireland generates a substantial amount of municipal waste each year. Municipal waste is waste from households and other locations such as schools, shops, small businesses and commercial premises ( EPA, 2024 ). In 2022, Ireland generated 3.19 million tonnes of municipal waste ( CSO, 2024 ). That’s equivalent to the weight of more than 40 million adults, which is nearly eight times the entire population of Ireland, and only 41% of it was recycled ( EPA, 2024 ). Although exact figures are not isolated for furniture waste alone, it is part of the broader category of bulky waste, including but not limited to furniture, and mattresses. More than 1.2 million potentially reusable bulky items are going to landfill or incineration in Ireland every year ( EPA, 2020 ). The EUs Circular Material Use Rate (CMUR) measures how much of the consumed material (in tonnes) in a given country, is reused. Ireland recorded a CMUR rate of 2.8% in 2023 ( Eurostat, 2024 ). The average CMUR in Europe is 11.8% ( EEA, 2025 ). A key objective in Ireland’s Whole of Government Circular Economy Strategy 2022 – 2023 is to raise Ireland’s CMUR so that the national rate is above the EU average by the end of this decade ( DCEE, 2021 ) that will require consumers and businesses alike to get much more comfortable with the concept of reuse. The Circular Opportunity Finline Furniture estimates that there are more than 500,000 pieces of their furniture in circulation and they don’t want to see them end up in landfill. To encourage customers not to throw away any worn-out sofas, Finline have partnered with the ‘Loved Back to Life’ team in Aiseiri to launch their REVIVE product line. Aiseiri provide community and residential services to help young people, adults and families overcome addiction and lead meaningful lives in recovery. Finline customers are incentivized with €100 vouchers to return their old sofas which are subsequently stripped back to their core frame by members of the ‘Loved Back to Life’ program. The quality sofa frames are then reupholstered by the Finline team and sold at more affordable prices - typically 20 per cent lower than the lowest price point in store. These re-manufactured pieces then come with a 20-year guarantee demonstrating to customers the confidence Finline have in their frames and workmanship. Finline and Aiseiri not only prevent sofas from ending up in landfill, thereby reducing waste and keeping valuable materials in circulation, but they also train people in recovery adding a valuable social element to the initiative. Climate Impact Finline Furniture aim to reduce waste and save resources by refurbishing 20 suites in the first year, with a target of 80 by year three. This will prevent the furniture from reaching landfills and save the need for new raw materials by using end-of-line and recycled fabrics. In contrast to manufacturing new furniture, refurbishment requires less processing and therefore generates lower greenhouse gas emissions. Additionally, Finline uses FSC-certified timber and 100% recyclable packaging, further supporting sustainability ( Finline Furniture, 2023 ). These efforts put together enhance resource efficiency, extend the life cycle of materials, and show a strong commitment to environmental responsibility. Replicability REVIVE by Finline Furniture is a replicable model which other companies could adopt to promote sustainability, support local economies, and generate social value. The initiative's concentration on quality assurance, resource efficiency, and scalable processes promotes long-term success and market acceptance. This approach enables a company to realize several benefits that extend beyond environmental concerns: improved brand reputation and customer loyalty. Other examples of the circular economy in the furniture industry include: Ahrend who manufactures office furniture products with modularity, disassembly, and life extension as core design principles. They offer Furniture-As-A-Service (FAAS) models where customers pay a monthly fee and return the furniture when they no longer need it. Goldfinger is another example of a social enterprise using reclaimed materials to craft sustainable high-quality furniture for residential and business clients. They reinvest their profits into their Goldfinger Academy which teaches skills to marginalised young people and isolated community members plus their People’s Kitchen, where they make community meals from surplus food. ALL CASE STUDIES

2dc12c74-05af-4598-8972-bdd48e032415 Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE NON-MEMBER CASE STUDY COMPANY : MONAGHAN MUSHROOMS WEBSITE: MONAGHAN.EU SECTOR : FOOD PUBLISHED : 21 OCTOBER 2025 TAGS: FOODWASTE, SUSTAINABLEAGRICULTURE, MUSHROOMS, PEATFREE, CIRCULARAGRI, INDUSTRIALSYMBIOSIS, AGRIFOOD, RESOURCEEFFICIENCY, SUSTAINABILITY, ZEROWASTE The Challenge The United Nations Food and Agriculture Organisation estimates that around one-third of all food produced globally is lost or wasted each year ( FAO, 2013 ). About 13% of food is lost in the supply chain from harvest to retail, with a further 19% wasted at the consumer, retail, and food service stages ( FAO 2022 ). In Ireland, approximately 835,000 tonnes of food waste were generated in 2023 ( EPA, 2023 ) Reducing food waste is critical, especially given that between 638 and 720 million people faced hunger in 2024. ( FAO, 2025) . Food waste not only represents wasted food but it also contributes significantly to resource depletion and greenhouse gas (GHG) emissions, generating 8–10% of GHGs globally ( UNEP 2024 ). If food waste were counted as a country, it would be the third-largest emitter in the world ( EDGAR 2024 ). A Circular Solution Monaghan Mushrooms, a family-owned Irish business with over 40 years’ experience, is one of the largest mushroom producers worldwide. The company operates farms, packhouses, substrate production sites, and offices across Ireland, the UK, the Netherlands, Germany and Canada. Monaghan addresses food waste and resource efficiency through a comprehensive circular economy approach. They produce their own mushroom substrate (the growth medium in which mushrooms grow) from materials like straw, horse manure, poultry manure, and gypsum. These are by-products from other agri-industries such as cereal crop production, poultry production and the horse stable industry ( Monaghan, 2024 ). After harvest, the spent substrate is reused as a soil conditioner, closing the loop sustainably. Notably, Monaghan is the first UK and Ireland producer to cultivate peat-free mushrooms, eliminating virgin peat from their substrate mix, switching instead to fully recycled natural materials. Peat extraction for mushroom substrate damages peatlands, which are crucial natural carbon sinks and reservoirs of biodiversity. This innovative change reduces carbon footprint and improves product quality with firmer, longer-lasting mushrooms ( Monaghan, 2024 ). The company employs state-of-the-art environmental control systems to optimize growing conditions while maximizing energy and water efficiency. Their Irish sites purchase green electricity, with the Tyholland farm installing solar panels to further reduce reliance on the national grid ( Monaghan, 2024 ). Rainwater capture systems help alleviate pressure on water resources, and biodiversity is promoted with initiatives like insect hotels and wildflower areas integrated into farm lands ( Monaghan, 2024 ). Packaging innovations include a transition to recycled PET plastics, sustainable cardboard trays, removal of colourants to aid recyclability, and phasing out PVC films in favour of polyethylene alternatives ( Monaghan, 2024 ). Climate Impact Monaghan has achieved a 17% reduction in energy use per tonne of mushroom produced, aiming for further cuts in the upcoming years ( BIOrescue Consortium, 2019) . Over the past year, the company exceeded its energy-reduction target by 13% across its Irish sites by installing LED lighting and innovating cooling technologies that use fresh air rather than mechanical cooling ( Monaghan Mushrooms, 2024 ). These improvements contributed to an 8% decrease in direct carbon emissions. Through solar PV adoption and green power purchasing, Monaghan decreases its demand on carbon-intensive energy grids further supporting decarbonisation ( Monaghan Mushrooms, 2024 ). Alongside environmental gains, Monaghan’s partnership with UK food redistribution charity FareShare has provided over 1.3 million meals to people in need since 2017, preventing food waste and associated emissions, while reinforcing social impact ( Monaghan, 2024 ). Replicability The global mushroom market was valued at USD 54.9 billion in 2022 and is expected to surpass USD 115.8 billion by 2030 ( Kerry Group, 2023 ). Mushrooms require minimal space, energy, and water, making them well-suited to sustainable intensification in food production. Rich in vitamins, proteins, and antioxidants, mushrooms now serve growing consumer demand in health, wellness, pharmaceutical, and personal care sectors ( Kerry Group, 2023 ). Monaghan’s circular model—combining sustainable substrate production, resource-efficient farming, innovative packaging, and community engagement—offers a replicable blueprint for agricultural industries seeking to transition to circularity. Its reliance on agro-industrial by-products and smart energy systems demonstrates industrial symbiosis in practice. Additionally, Monaghan’s innovation division, mBio , exemplifies circular innovation by leveraging mushroom mycelium to develop bio-based materials and nutraceuticals, expanding mushroom-derived products beyond food into construction, packaging, and health supplements ( mBio, 2024 ) This diversification highlights the potential for circular research and development to create new economic and environmental value streams within agri-food ecosystems. Other companies tackling food waste include: Meade Farm (Ireland) valorises surplus and “non-table grade" potatoes by converting them into premium food-grade starch, significantly reducing food waste and creating a new revenue stream. Well Spent Grain (Ireland) divert brewers spent grain from landfill and turn it into ‘Honest, Delicious, Sustainable Snacks.’ Toast Ale (UK) produces beer brewed with leftover bread from bakeries to reduce food waste while fostering social enterprises. Winnow Solutions (Global) offers smart kitchen technology to monitor and reduce food waste in commercial kitchens by providing real-time data analytics. Renewal Mill (USA) recovers nutrient-rich by-products from food manufacturing, like okara from tofu production, and repurposes them into flour and baking ingredients. Full Harvest (USA) operates a platform to sell surplus and imperfect fruits and vegetables to food and beverage companies, reducing farm-level food waste. These companies demonstrate diverse approaches—waste valorization, ingredient upcycling, technological innovation, and marketplace solutions—showing the breadth of circular economy practice in food. They offer useful analogies and potential partners for Irish food and agri-business stakeholders aiming to scale circular solutions. A Note on By-Products & End of Waste A by-product is a residue left over from the production of another product. In Ireland, Regulation 27 of the Waste Directive sets out the circumstances in which a material can be considered a by-product and not a waste. It is essential you notify the EPA to determine if your material satisfies the criteria of a by-product. The EPA will confirm if it can be catogorised as a by-product or if it must be categorised as a waste. If the substance is classified as a waste then it may need to achieve End-of-Waste status via Article 28 of the Waste Directive to be kept in use as a resource. ALL CASE STUDIES

121bac0e-7611-436c-9e08-8ecda0e35c88 Facebook X (Twitter) LinkedIn Copy link CIRCULÉIRE NON-MEMBER CASE STUDY COMPANY: ETH ZURICH WEBSITE: ETHZ.CH SECTOR : BUILT ENVIRONMENT PUBLISHED: 18 SEPTEMBER 2025 TAGS: SUSTAINABLECONSTRUCTION, GREENCONCRETE, CIVILENGINEERING, MATERIALINNOVATION, CEMENT, CONSTRUCTIONTECH, RECYCLEDAGGREGATES The Challenge Concrete manufacturing is a major contributor to global greenhouse gas emissions, accounting for approximately 6–8% of worldwide CO2 emissions. This stems largely from the energy-intensive process of heating limestone at very high temperatures during cement production, a key ingredient in concrete ( IEA, 2023 ). With ongoing urbanisation and industrial growth, demand for concrete is expected to rise, intensifying its environmental impact. Energy consumed during the day-to-day functioning and maintenance of buildings represents about 30% of global energy consumption. This increases to 34% when including the energy used to produce of cement, steel and aluminium in their construction ( IEA, 2023 ). The construction sector also requires huge amounts of resources and accounts for about 50% of all extracted material ( European Commission, 2018 ). These figures underscore the critical need for circular approaches that reduce resource use and emissions in construction. The Circular Opportunity Zurich’s Ultra Green Concrete (UGC) project, led by ETH Zurich, offers an innovative model for sustainable concrete production. Cement production typically involves using around 95% clinker mixed with a small proportion of gypsum. The clinker is created by heating limestone and clay in kilns at roughly 1,450 °C, a process that inherently generates carbon dioxide through the breakdown of limestone ( Ethz.ch , 2023 ). The UGC project reduces reliance on clinker - the most carbon-intensive components in cement - by substituting it with alternative minerals such as calcined clay and limestone. This lowers the overall cement content and cuts CO 2 emissions in the concrete manufacturing process ( Ethz.ch , 2023 ). In parallel, the ETH Zurich ‘Airlements’ project utilises recyclable mineral foam to create 3D-printed formwork components, which further reduces the volume of concrete needed on site. The foam is made from recycled industrial waste formed together with foam and finished with a cement-free protective plaster which can be assembled into a two-meter-tall system for non-structural walls ( Designboom, 2023 ). This combination of material innovation and smart construction techniques improves both resource efficiency and sustainability in building processes. ETH Zurich’s approach also focuses on recycling demolition waste as input for fresh concrete production. By reusing up to 98% of recycled concrete in new builds, exemplified by and extension to Zurich’s main art gallery Kunsthaus Zurich, this approach avoids landfill disposal and conserves virgin raw materials ( Bloomberg, 2021 ). Climate and Resource Impact These circular methods have yielded measurable emissions reductions. The UGC project has achieved nearly a 40% reduction in CO 2 emissions compared to traditional concrete mixes. Depending on the application, the project’s concrete can emit as little as 80–100 kg of CO 2 per cubic metre, compared with approximately 300 kg/m³ for conventional mixtures ( ETH Zurich, 2023 ). Additionally, by employing recyclable mineral foam formwork, UGC reduces concrete usage by up to 70%, further amplifying the environmental benefits ( 3D Printing Industry, 2025 ). The project has also saved an estimated 17,000 m³ of virgin materials and significantly reduced landfill requirements, aligning with circular economy principles of waste minimisation and resource conservation. Replicability and Industry Innovation Zurich’s success has inspired a growing movement among companies and cities worldwide to adopt circular concrete technologies. The UGC project aims to make high-performance, low-carbon concrete more accessible to the broader construction sector ( ETH Zurich, 2023 ). The UGC project serves as a practical model for sustainable manufacturing of construction materials. Ireland’s own manufacturing and construction industries can draw valuable lessons to support circularity, reduce emissions, and meet net-zero commitments through innovation in recycled concrete technologies and material efficiency. Examples of emerging sustainable concrete innovations include: CarbonCure Technologies injects recycled CO 2 into fresh concrete, permanently mineralising the gas and lowering the carbon footprint while maintaining performance. Biomason uses microorganisms to ‘grow’ biocement, dramatically cutting emissions from cement production and producing certified biocement products in commercial-scale factories. Neustark captures carbon dioxide from industrial biogas plants, storing it safely within recycled concrete aggregates to create a long-lasting carbon sink and producing certified carbon credits. These innovations demonstrate significant progress in transforming concrete from a major CO 2 emitter into a material aligned with circular economy and climate goals. ALL CASE STUDIES