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Recycling & Recovery

REMADE Announces $19.6 Million in New Technology Research to Accelerate the U.S.’s Transition to a Circular Economy - Institute Selects 14 Projects in Latest Round of Funding

The REMADE Institute is pleased to announce today that it has awarded $19.6 million in new technology research, selecting 14 new research, development and demonstration projects as part of the Institute’s latest round of funding.

Half of the projects involve research at the demonstration phase, responding directly to the nation’s need to meet multiple U.S. energy, environmental, and economic goals.

"These projects underscore the importance of manufacturing and materials innovations toward advancing a circular economy," said Dr. Christopher Saldaña, Director of DOE’s Advanced Materials and Manufacturing Technologies Office (AMMTO). "The partnership between DOE and the REMADE Institute serves as a conduit for catalyzing transformative practices that not only bolster America's manufacturing expertise but also accentuate our nation's commitment to environmental stewardship."

According to the U.S. Department of Energy, manufacturing accounts for 25% of U.S. energy consumption at a cost of approximately $150 billion. Based on data from the U.S. Environmental Protection Agency, industry is the single largest contributor to greenhouse gas emissions in the nation, at 30%.

REMADE Chief Executive Officer Nabil Nasr said these are just some of the main reasons why a circular approach to manufacturing — “make-use-reuse-remanufacture-recycle” — is so important, and why REMADE is dedicated to the adoption of a Circular Economy.

“A Circular Economy is imperative,” Nasr said. “It’s critical in reducing industry’s energy consumption and emissions in the race to net-zero by 2050. At the same time, a circular approach is vital to increasing U.S. manufacturing’s competitiveness, increasing the resiliency of the nation’s supply chain, and creating new clean economy jobs.”

REMADE Chief Technology Officer Magdi Azer said the Institute’s research seeks to increase circularity for four energy-intensive material classes: metals, plastics/polymers, fibers, and electronic scrap, or e-scrap.

“REMADE’s projects address multiple aspects of the Circular Economy, including systems analysis, circular design, remanufacturing and reuse, recovery and recycling,” Azer said. “These latest R&D projects will, for example, explore better ways to remanufacture cast iron components; remove contaminants from molten aluminum scrap; convert the midsoles of used shoes into a newer, more sustainable foam for footwear; develop machine learning tools to advance the sorting of textiles, design recyclable multilayer flexible packaging; and increase machine learning tools to better determine the state-of-health for used hybrid and electric vehicle batteries.”  

For more detailed information, read the full press release at the button below. A list of all REMADE R&D projects and their descriptions, including the 14 projects announced today, can be found at the “Research” button below.

REMADE Releases New Funding - Up to $20 Million in Funding to Accelerate the Transition to a Circular Economy

The REMADE Institute is proud to announce its sixth Request for Proposals (RFP), representing $20 million in investment to sustain U.S. manufacturing and accelerate the U.S.’s transition to a Circular Economy.

The Institute is seeking technology proposals for research, development and demonstration (RD&D) projects that develop and demonstrate tools and technologies consistent with REMADE’s goals to reduce energy and emissions; achieve better than cost and energy parity; and promote the widespread application of new enabling technologies across multiple industries. RD&D projects must align with one or more of the Institute’s focus areas: systems analysis and integration; design for reuse, remanufacturing, recovery and recycling (design for Re-X); manufacturing materials optimization; remanufacturing; and/or recovery and recycling.

R&D Project Spotlight: Recycling of Plastic for Sustainable Food Packaging

The food industry is a vital part of the U.S. economy, and the food packaging market has experienced double-digit growth in recent years. The COVID-19 pandemic has underscored the critical role that the food and packaging supply chain plays to ensure essential products continue reaching millions of consumers safely.

 At the same time, food packaging containers account for 30% of waste generation in the U.S., and less than 50% of this volume is currently recycled. That recycling rate falls to under 30%[1] for the types of multilayer food packaging targeted in this REMADE R&D project, including the brick-shaped cartons commonly used for a wide range of liquid foods including milk, juices, soups, sauces, and more. This multilayered packaging retains the product in a commercially sterile state for months or even years, but is difficult to recycle.

 The R&D project team is working to develop a process by which these multilayer materials can be replaced by a single mono-material packaging solution produced from up to 100% recycled PET (the same plastic that water bottles are made from), which can be recycled back into the same or comparable products with minimal reprocessing, handling, and transportation. The team is validating the performance of materials and manufacturing process at industrial scale and conducting a recycling pilot with the support of a material recycling facility (MRF) to quantify recycling rates and recycled material quality.

 Following the successful completion of the project, implementation is anticipated through the Ohio Safe Food & Packaging Initiative.

Project Participants:

[1] Source: PET Material Flows in the US (MM lbs) - Postconsumer PET Container Recycling Activity Report by NAPCOR and APR.

R&D Project Spotlight: Transitioning to a Circular Economy for PET and Olefin Polymers

Today, the U.S. only recycles 8.4 percent of the plastic waste that is collected. Although new advanced mechanical and chemical recycling technologies hold the promise of a closed-loop circular economy for plastics in the near-term, the anticipated economic, environmental, and societal benefits of a closed loop system are still not well understood.

With a focus on polyethylene terephthalate (PET) and olefin plastics, which together comprise nearly two thirds of U.S plastic production, the R&D project team successfully built a model that evaluated how the manufacturing and recycling processes in a plastics circular economy can be configured to minimize energy consumption and greenhouse gas emissions. The model predicted that it is possible to reduce greenhouse gas emissions by 24% compared to current recycling approaches.

In the next phase of the R&D project, the team is expanding the model to include material flow analyses, material transportation and logistics analyses, recycling process modeling, energy and environmental life cycle assessments, techno-economic analyses, and regional / national economic studies.

The model will be validated with a case study in the state of Michigan in close collaboration with the Michigan Department of Environment, Great Lakes, and Energy (EGLE). The modeling simulation will be developed using CHEMCAD and UniSim, allowing results to be disseminated broadly to accelerate the U.S. transition a circular economy for PET and Olefin polymers. Doing so would save material, energy, and emissions associated with plastic recycling and close the annual gap of more than 1 billion pounds between the current U.S. supply and projected 2025 demand for recycled PET (rPET) for use in bottles.


Project Participants:

R&D Project Spotlight: Vehicle Design for High-Value Recycling of Aluminum

The embodied energy of vehicles is increasing as energy‐intensive materials such as aluminum auto body sheet (ABS) are used to deliver improved performance. Unfortunately, the current system cannot effectively recycle automotive aluminum at end-of life (EOL) because the shredded aluminum is frequently contaminated with steel rivets, steel alloys, and copper wiring. As a result, 90% of auto shred aluminum is exported and downcycled.

In addition, the shift to electric vehicles (EVs) will increase the demand for high‐quality aluminum ABS and advanced high strength steels (AHSS) for light weighting, double the amount of copper wire (thereby increasing end-of-life contamination), and potentially reduce demand for vehicle castings that could utilize the lower quality scrap.

To address these end-of-life issues upfront, the R&D project team is developing a new design for recycling tool that considers how vehicle design, recycling system infrastructure, and sheet manufacturing process decisions impact factors such as EOL recycled content, closed and open‐loop recycling rates, greenhouse gas (GHG) emissions, and primary feedstock consumption and energy demand under different scenarios from 2020‐2050 (e.g. rapid deployment of EVs).

The tool will be integrated into the Argonne National Laboratory (ANL) GREET model, which is already widely used by the car industry to quantify environmental impacts. Once developed and implemented, this tool has the potential to reduce the consumption of primary steel and aluminum by 2.35 million metric tons (MMT) and 0.19 MMT, respectively.

Project Lead

Project Participants

REMADE R&D Project Featured in The Verge story, “Scientists are building an AI-powered robot to take apart your old phone”

A new REMADE research and development project, announced as part of RFP5 awards on Dec. 1, 2021, was featured in a story in The Verge titled, “Scientists are building an AI-powered robot to take apart your old phone.” The R&D project, “Improving Recycling Efficiency of Portable Electronics by Automating Battery Disassembly,” is led by Idaho National Laboratory and is comprised of project team members University at Buffalo, Iowa State University, and e-waste recycler Sunnking. According to the story, “if such technology can be commercialized, researchers are hopeful it could vastly improve the recycling of smartphones and other small, portable electronics.”

Scrap News: REMADE Extends Deadline for EWD Proposals

REMADE’s Letter of Intent deadline for our latest RFP is fast approaching. Learn more about our RFP to grow U.S. manufacturing and accelerate the U.S.’s transition to the Circular Economy in the June 23 Scrap News story below. The article, written by Dan Hockensmith, includes a statement from REMADE CEO Nabil Nasr, information on the education and workforce development topic areas of the RFP, and ISRI's involvement with REMADE, including their project selected from the fourth round of funding. Read more:

REMADE Increases Latest Round of Funding to $50M+

REMADE issued its fifth RFP last month, initially representing $45 million in available funding. Today, we are pleased to announce that that amount has now been increased to more than $50 million. Companies, universities and organizations that have research or workforce development projects that might align with REMADE’s RFP are strongly encouraged to submit an LOI next week.

Scrap News: REMADE RFP to Promote American Manufacturing, Circular Economy

REMADE’s Letter of Intent deadline for our latest RFP is fast approaching. Learn more about our RFP to grow U.S. manufacturing and accelerate the U.S.’s transition to the Circular Economy in the May 14 Scrap News story below. The article, written by Hannah Zuckerman, includes an interview with REMADE CEO Nabil Nasr, information on the transformational and traditional research and development topic areas of the RFP, details on the education and workforce development component of the RFP, and insights into how REMADE’s work will enable the U.S. to meet the nation’s aggressive climate goals. Read more:

Dr. Nabil Nasr Named Fellow by the Institute of Industrial and Systems Engineers

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The REMADE Institute is proud to announce that our Chief Executive Officer, Dr. Nabil Nasr, has been named a Fellow by the Institute of Industrial and Systems Engineers (iise.org), the organization’s highest honor. The designation recognizes outstanding leaders who have made significant, nationally recognized contributions to industrial and systems engineering. Nasr will be recognized by IISE during its virtual conference on May 24.

Nasr is a renowned international leader in sustainable manufacturing, remanufacturing, and the Circular Economy. He has served as an expert delegate for the federal government in several international forums and is a member of the United Nations Environment Programme’s International Resource Panel. He is also a trustee of the Ellen MacArthur Foundation in North America.

“I am honored and humbled to be recognized by IISE, a professional society I joined as a student a long time ago,” said Nasr. “From teaching to management and technology development, I have continually focused on applying the system thinking and approaches that IISE promotes.”

IISE is the world's largest professional society dedicated solely to the industrial engineering profession and individuals involved with improving quality and productivity. Founded in 1948, IISE is an international, nonprofit association that provides leadership for the application, education, training, research, and development of industrial engineering.