Background The production of glass fibre consumes high levels of energy and material. For each kilogramme of glass melted, 1 kg of carbon dioxide (CO2) is emitted into the atmosphere, in addition to nitrogen oxide and dioxide (NOx), sulphur dioxide (SO2), chloride, fluoride, volatile organic compounds (VOC) and particles. Furthermore 17 GJ of power are consumed for every tonne of melted glass. At end-of-life, some 25% of glass fibre is sent to landfill, amounting to around 250 000 tonnes/year in the EU. This leads to a considerable emission of substances into the environment and the reduction of landfill space. There is a particular need for recycling of the polypropylene and glass fibre compounds from the dismantling of end-of life-vehicles, as established under the ELV Directive (2000/53/EC). Objectives The WGF-PP project aimed to develop a demonstration-scale process for producing polypropylene composites reinforced with glass fibre wastes. Different composites would be specifically formulated for different uses, particularly in making cars and electro-domestic appliances. It hopes thus to show the technical and economic feasibility of the process for large-scale application. The final products should be of good quality, meeting the following standards: Tensile strength: 32 MPa Tensile modulus: 3.125 MPa Flexural strength: 61 MPa Flexural modulus: 3.246 MPa Charpy impact strength (unnotched): 27.125 J/m2The project expected to result in the recycling of 17 000 tonnes/year of glass fibre waste in Spain alone. This equates to energy savings of 2 890 000 GJ/year, which is equivalent to 7 000 tonnes of crude oil and 17 000 tonnes of CO2. If the project is successful, it would enable the recycling of more waste material from the dismantling of end-of-life vehicles. The beneficiary hoped to reduce the amount of glass fibre sent to landfill in the EU by 30%. Results The WGF-PP project demonstrated on a semi-industrial scale an innovative recycling process to recycle glass fibre wastes coming from glass fibre production, using them to reinforce thermoplastics. It first designed and constructed a plant that would allow the technical and economic feasibility process to be evaluated before its application on a larger scale. The plant proved the technical viability and produced several specific final products that were validated by possible future users. The WGF-PP project can be considered as a starting point for reducing the landfilling of fibreglass waste in the EU. Fibreglass waste that is nowadays landfilled accounts for 150 000 tons/year in EU, thus the project has helped to reduce the environmental impact of this waste in landfills. In terms of resource efficiency, it also avoids the production of new fibreglass and thus the consumption of primary raw materials, it produces energy savings and consequently, the reduction of CO2 emitted to the atmosphere. The technology applied is able to introduce fibreglass wastes by using a 90 litre mixer where different types of material can be added, i.e. waste of fibreglass, polypropylene, additives, dyes. The use of non-virgin fibreglass or other material would not be possible in the classic production system as it would be broken when the extrusion or not well mixed, producing a non-acceptable product. The final product, recycled glass fibre reinforced plastics granules, have the necessary properties for specific applications in the automotive and appliance sectors. Rather than sending waste fibreglass to landfills, this project provided a solution to introduce them again in the market, as part of a plastic compound or composite. The process also allows to recycle of reinforced plastics wastes coming from End of Live Vehicles. The project also benefits the environment by reducing the amount of energy-consuming fibreglass consumption/production. Around 17 GJ are needed for the production of one tonne of fibreglass. In Europe, fibreglass producers dump 150 000 tonnes of waste (10% of its production); recycling this waste will produce 500 000 tonnes of reinforced materials and save 2.5 million GJ. Such a result translates to a saving of 1.46 tonnes of CO2 emission for every tonne of recycled fibreglass. Specifically, the plant constructed in this project will reduce the emission of CO2 by 2 920 tonnes a year. Further information on the project can be found in the project's layman report and After-LIFE Communication Plan (see "Read more" section).