A pragmatic upcycling idea which features the transformation of Albini Group production waste and by-products into paper, made with enormous respect for the environment and people. FUTURA is a project born thanks to the collaboration between ALBINI_next and Fedrigoni, a leading European manufacturer of special paper for packaging, graphics and art.
National
Italy
{Empty}
Mainly urban
It refers to other types of transformations (soft investment)
No
No
Yes
2022-11-30
As a representative of an organisation
Name of the organisation(s): Cotonificio Albini S.p.A. Type of organisation: For-profit company First name of representative: Giorgia Last name of representative: Carissimi Gender: Female Nationality: Italy Function: Innovation Manager Address (country of permanent residence for individuals or address of the organisation)<br/>Street and number: Via Dr. Silvio Albini, 1 Town: Albino (BG) Postal code: 24021 Country: Italy Direct Tel:+39 035 777111 E-mail:anext@albinigroup.com Website:https://www.albinigroup.com/en/
ALBINI_next, the Albini Group’s think thank founded in 2019 aimed at blazing a trail to innovative solutions to create the fabrics of the future, and Fedrigoni, global leader in the production of special papers for creative applications and luxury packaging, meet for an Italian collaboration in the name of circularity.
After two years of work between Fedrigoni’s R&D team and Albini_next’s, the collaboration resulted in FUTURA: a new paper 25% of which is made of fibre obtained from the Albini Group’s textile production waste and by-products, thus saving the amount of virgin cellulose normally used in paper production and recovering textile by-products that would be otherwise discarded or downcycled.
The FUTURA production process begins by selecting waste from the weaving and quality control phases and fabrics scraps from clients sampling at Albini. These fabrics are unraveled and converted into fibre, which Fedrigoni then adds to the cellulose mixture needed for the manufacturing of paper. Through this innovative process, almost three tons of paper have been produced to date, upcycling a total of 950 kg of fabric waste.
In a perfectly circular economy logic, Albini Group then chose to use this special paper to make the support cards for presenting its Denim collection and the Service Program of the Albiate 1830 brand, Denim Design.
The collaboration between Albini and Fedrigoni will not stop with this project. In fact, they are planning an entire collection of recycled paper, based on the process already built, to introduce into the market and that will be used also by Albini for internal purposes.
CIRCULAR economy
Special PAPER
TEXTILE WASTE
UPCYCLING
Made in Italy
The project fits perfectly within the corporate sustainability strategy, founded on a number of the SDGs of the 2030 Agenda for Sustainable Development, and complying with the criteria envisaged for innovation, reduction and recycling of waste. More specifically, this activity aims to support Goal 12 “Responsible consumption and production”, which envisages a substantial decrease in the production of waste by means of prevention, reduction, recycling and reuse of waste. Also, it addresses SDG Goal 9 "Build resilient infrastructure, promote inclusive and sustainable industrialization, and foster innovation", and SDG Goal 17 "Partnerships for the goals", which has as objective to strengthen the means of implementation and revitalize the Global Partnership for Sustainable Development.
The production of the paper involves a 25% reduction of virgin cellulose, substituting it with textile waste. This, not only helps to reduce the use of natural resources, but also, gives textile waste a second life, adding more value to the final product. Moreover, the color of the paper was given by the selected blue-dyed textile waste, so further synthetic pigments were not required during the process.
The project was built by two historical Italian companies, each one leader in its own sector. This project provides an example of industrial symbiosis between different businesses giving life to a process of circular economy to produce a high quality product for the market.
FUTURA perfectly fits within the "9 Rs" framework for circular economy. In particular: Rethink, Reuse, Remanufacture, Repurpose, and Recycle.
Other than having a focus on circular economy and upcycle of textile waste, the paper was designed with specific aesthetic requirements, following Albini's mission and vision of "creating the most beautiful products in the world":
1. Futura paper must have a relative heavy weight in order to support textile samples to build the new books of the Denim collection, Albiate 1830. It was designed to weight 300 g/m2, meeting all the quality tests for mechanical resistance.
2. The surface of the paper must have a pleasant touch, trying to reduce the rough aspect of a normal recycled paper and to simulate as much as possible a 100% virgin paper. Moreover, several printing tests were made to make sure we obtained a good quality in terms of printability.
3. The color was an important aspect of the paper because it was intended to be used inside Albini's presentation books which are a marketing asset. The team chose a specific nuance of blue which was achieved by selected textile waste already dyed in such color.
All the previous aesthetic properties infused the product with a particular appeal transmitting high quality and ensuring a long life. Furthermore, the product can be used in multiples ways depending on the client’s needs.
The product was driven by eco-design principles by acknowledging the source and quantities of the raw materials; trying to reduce as much as possible the added chemical products, for example, by eliminating the need of colored pigments; and by making the resulting product recyclable again.
Albini and Fedrigoni gave life to a product and business model that can be replicated by other companies and industries. FUTURA is an example of industrial symbiosis within the region that creates a virtuous circular economy and can foster the regional development.
With the proper studies and tests, it can also be adapted to the user’s needs in terms of color, paper weight and surface touch, reducing its limitations and increasing the accessibility to all kind of users. Moreover, the product was marketed with a competitive price, making it available to any customer interested in having a high-quality paper made differently.
In terms of the production process, the project respects the regulations and safety procedures of the machinery, tools, and materials used throughout every step of the production. Thus, making it possible to extend the participation of people with disabilities, already present and employed in several other processes of the companies involved, also in this project.
The project involved the collaboration between two different companies and other suppliers and stakeholders. This generated several job opportunities, from the selection of the waste and raw materials, to their modification, the production of the paper, and its final commercialization and use. All the people that participated in each step of the process were key players to conclude it successfully, establishing a virtuous production chain and creating finally a beautiful and high quality product.
From an environmental point of view, the project helps reducing the need of natural resources, like virgin cellulose, protecting forests, their ecosystems and surrounding communities. Moreover, the paper is produced between companies located in the same Italian region, avoiding complex transportation routes of materials and thus, reducing the process’ carbon footprint.
FUTURA, thanks to the collaboration between Albini Group and Fedrigoni aimed at developing a sustainable product, can help to increase the awareness and sensitivity of the local citizens about the importance of the sustainability topic. This can in turn foster the community to behave in a more responsible way in terms of consumption choices. Another way to educate and inform citizens on all these topics could be to organize local fair trades of the Futura paper to promote the purchase of recycled products.
The process was divided into three main development phases: research and testing, prototyping, and production and final use.
In the first phase, both Albini’s and Fedrigoni’s innovation labs were involved in the selection of the raw materials and the development of the right recipe. Fedrigoni’s team was then dedicated to the improving of mechanical and aesthetical properties. In this phase, the correct management of waste was critical since it is regulated by strict local standards. Therefore, the participation of regional and local authorities was key for the correct development of the entire project.
In the second phase, Fedrigoni’s research and development team continued with the first prototypes of the paper. During this time, the marketing teams of both companies and Albini’s product development team were involved in the selection of the colour shade and texture desired for the paper.
The final phase was developed at Fedrigoni’s production site, having the participation of technicians and experts of the paper industry. Afterwards, the product was sent to the printing supplier, to start with the Albini’s sampling book production. The final product was then delivered to Albini who then made it available to its customers.
During the whole process, several professionals from both companies were involved:
1. Chemists: dedicated to the development of the paper recipe. Their role was key during the first research and testing phase.
2. Textile technicians: they did the selection of textile waste (fibers and colors), following specific requirements and standards given by the local waste management regulations.
3. Environmental manager: this person had to ascertain the correct implementation of environmental laws and procedures related to waste disposal and circular economy.
4. Project managers: dedicated to the organization and process monitoring. They had constant communication with all the participants of the project, making sure all the steps were concluded successfully and in the established times.
5. Technicians of the paper industry: experts in the paper production and quality control. They were essential to obtain the desired product with all its properties.
6. Marketers: key players during the decision making of the product’s characteristics. The marketing teams were also responsible for the communication and promotion of the project.
7. Textile product developers: people in charge of accepting the final product in terms of aesthetics and using it inside Albini’s sampling books.
8. Printing technicians: people that tested and printed on the produced paper
9. Legal team: it was essential for the control of copy rights and legal issues involved in terms of the circular economy framework.
10. Commercial experts: they studied and defined the product’s price, together with the marketing teams.
The main knowledge fields involved in the development of this project were:
a) Management: operation, project, and human resources related.
b) Sustainability of production
c) Product quality control
d) Open innovation, by means of the collaboration between companies belonging to different industrial sectors.
e) Business Economics and Marketing
The main outcome of the project was creating a circular model and giving more value to textile waste. Up to date, more than 3 tons of textile waste have been upcycled and 12 tons of special paper were produced, substituting 25% of virgin cellulose with textile waste. A new industrial symbiosis between two historical companies, Albini and Fedrigoni which have an important position in their own markets.
Speaking of the external environment, the project had an important impact on the national press, raising awareness amongst the general public on topics like circular economy, sustainability and upcycling. FUTURA has indeed demonstrated that sustainable innovation can also be implemented on rather traditional products and processes.
This project represents a model that not only entails environmental sustainability, but is can also have an impact in terms of social sustainability. As a matter of fact, FUTURA’s objective of reducing the carbon footprint of the two companies by reusing and remanufacture textile waste for creating a completely new product, can support the fight against wild consumism and make the community be more sensitive about the sustainability topic, fostering more responsible behaviors regarding consumption and waste production, thus creating an ecosystem that embraces the values of sharing and green economy.
Another outcome of the project was the implementation of the new special paper as a marketing asset for Albini, the Albiate’s new Denim sample book.
From an internal standpoint, Albini has the chance, thank to this project, to develop a new methodology for the classification and separation of their industrial waste, implementing it through its entire production site. This system can smooth and fasten the waste classification process, thus making different types of waste immediately available for reuse or remanufacture in other types of projects.
The innovative character of FUTURA relies on the use of textile waste to substitute an important percentage of virgin cellulose in high-quality paper. Since the output, i.e., textile waste, coming from a specific type of industry becomes the input for the produciton process of a company belonging to another type of industry, i.e., paper, this product represents a perfect example of innovation developed in an industrial symbiosis context, which is one of the best approaches to foster eco-innovation development and to create a culture based on sustainable innovation values. Moreover, the innovative feature of this project is that not only develops a more sustainable solution in a collaborative environment, but it also give, as main outcome, an upcycled product, thus generating a paper with reliable characteristics only by implying production waste.
Also, one fo the most relevant features of the product is that, by selecting like-coloured textile waste, not only the cellulose is upcycled, but also the colour, thus avoiding the use of synthetic pigments to colour the final product.
Therefore, the project proposes a new way to upcycle textile waste and the possibility to replicate the process can in turn generate a know-how that can be implemented and transferred to other industrial realities.
The methodology used follows ALBINI_next intent towards innovation. That means, an open innovation approach which champions cross-discipline collaboration and sharing of knowledge.
This way, ALBINI_next chooses to collaborate with different partners in pilot projects which are structured in three different phases: research, industrialization and commercialization.
The first phase includes the selection of the partner, the signature of the different contracts like NDA or MTA agreements and the preliminary testing phase in the laboratory to validate the technology at small-scale.
Once the technology has been approved at laboratory scale, the second phase starts testing the technology at industrial scale, starting with the minimum industrial capacity and following with more significant industrial tests. Along this process, several quality controls are made to approve or discard certain parameters or processes and finally, the limitations of the technology are defined.
Once all the different quality controls have been approved, the project arrives to its last phase of commercialization. During this phase, the commercial team works really closely with the design team, COMM’s and the ALBINI_next to build the story around the project in order to better communicate it to all stakeholders.
The whole production process of FUTURA can be replicated and adapted to other industrial realities. Moreover, it can also be modified to produce different varieties of paper following client’s needs.
The entire circular model, from the selection of textile waste to the production of the paper, quality controls and commercialization, can be transferred to other industrial realities equipped with the right technology. The outcome of the technology transfer will depend on the requirements of the different stakeholders, the experience of the producers and the limitations of the infrastructure. However, the know-how can be fully transferred to third parties in several different geographic location providing a virtuous example for future generations.
Therefore, this project entails the opportunity to be replicated and transferred even when considering different aspects and contexts. As for technology, products and processes, companies similar to Albini Group and Fedrigoni and belonging to the same industrial sectors, would take advantage of the same know-how, tools and approaches to easily and successfully implement these type of projects.
Nevertheless, the methodological approach and the learning transfer process that took place in FUTURA can serve as a starting point for developing best practices and standards that, appropriately adapted, can be applied to other industrial contexts.
This project perfectly addresses the 2030 UN SDGs, thus placing itself in line with the response against the challenges that the entire world is required to face from now on. Indeed, by reusing industrial wastes and reducing the use of natural resources, FUTURA aims at the reduction of the carbon footprint of the companies involved. In addition, this parameter is also reduced by eliminating the transportation of materials across countries, since the stakeholders involved are both located in the same geographical region. Furthermore, the upcycled material come from the fashion industry, which is known to be one of the most polluting industries of the world that primarily needs a deep transformation.
Thus, the project contributes on the global battle against global warming by answering to the main challenge of Net Zero and Scope 3 Emissions, also by building on circular economy principles.
