Background Bonding processes are important for the production of many consumer products, including absorbent hygiene products (AHP). Bonding processes normally involve glue. The production of nappies in the European Union uses more than 30 000 tonnes/yr of glue. This is estimated to be responsible for an environmental footprint of more than 200 000 tonnes of CO2 equivalent. Furthermore, some 1 269 Twh/yr of energy is consumed by nappy manufacturing, and gluing is one of the most energy-intensive sub-processes. Finally, disposal of post-consumer AHP generates, in Europe alone, more than six million tonnes/yr of AHP waste that is currently landfilled or incinerated. Worldwide, disposable absorbent products and nappies represent about 4% of solid waste and about 2% of all waste sent to landfill. Landfilling and incineration cause air, water and soil pollution. The environmental impact of AHP production should therefore be tackled by reducing use of petrochemical-based materials, by reducing the energy intensity of AHP manufacturing, and by cutting pollution from AHP waste. Objectives The LIFE GLUELESS project will demonstrate that a significant reduction in the environmental impact of AHP can be achieved through a drastic reduction in the use of glue in the production process. Gluing can be replaced by novel combinations of thermo welding and ultrasonic bonding, which promise reductions of 65% or more in the use of primary non-renewable materials (petrochemical-based glue), and significant energy and cost reductions. The project's main objectives are: To convince AHP producers to adopt a cost-effective (and environmentally friendly) alternative bonding solution by demonstrating that it meets performance criteria; and To underpin via an industrial demonstration project (including dissemination to multiple industry sectors) public environmental policy objectives of decoupling environmental impact from economic growth, and implementing the number one priority in the waste hierarchy: waste avoidance. Expected results: The project expects to achieve the following technical, environmental and economic outputs: Demonstration of new combinations of thermal welding and ultrasonic technologies to replace current gluing processes in five sub-processes; Production of a demonstration nappy using the novel bonding technologies; the demonstration product will have equivalent performance to current products, but will use 65% less glue; A 10% energy saving from the reduction in the use of glue and the implementation of less energy-intensive processes; and An assessment of the financial savings secured by reducing the use of glue. Assuming the cost of 1 kg of glue is €3.50, for an average manufacturing facility, savings could reach €500 000/yr.