Towards Circular Enterprise 4.0

An industrial research and experimental development project to transform the Italian ceramics and mining industry into a Circular Economy 4.0 model.

FUNDING

Ministry of Enterprise and Made in Italy – Agreements for Innovation (Ministerial Decree of March 5, 2018)

PROJECT CODE

F/160016/01-05/X41

DURATION

October 2020 – December 2023

THE CONTEXT

A challenge of sustainability and circularity

When the project was launched, the Italian ceramic industry was a global benchmark for quality, innovation, and design. With exports accounting for almost 80% of production and an average price more than three times that of its main competitors, the sector had built up a competitive advantage based on manufacturing excellence and the ability to meet the most sophisticated needs of contemporary architecture.

However, this leadership was confronted with structural challenges that called into question its long-term sustainability. The ceramic supply chain was largely dependent on mineral raw materials whose supply was subject to geopolitical constraints, market fluctuations, and growing environmental pressures. Extraction and production processes generated waste and by-products that represented an economic cost and an often underestimated ecological impact. The fragmentation of information along the supply chain made it difficult to accurately assess the environmental and social footprint of finished products.

These critical issues were compounded by a significant technological gap: while the ceramics industry had achieved advanced levels of digitization, the mining sector upstream of the supply chain was still operating with poorly integrated monitoring and management systems. This asymmetry hindered the creation of a transparent supply chain and the full adoption of circular economy principles.

In this scenario, the transition to more sustainable production models was not only an ethical imperative, but also a necessary condition for preserving the sector's competitiveness and responding to growing market, regulatory, and social expectations. A new approach was needed, one capable of integrating technological innovation, resource circularity, and collaboration between businesses and research.

Fragmentation of data along the value chain

Dependence on virgin raw materials

Waste of mining waste and by-products

Asymmetry in digital maturity between mine and factory

THE PROJECT

Three integrated dimensions

REDiRECT was created to address these challenges with a systemic and multidisciplinary approach. The goal was to design, implement, and validate a Circular Enterprise 4.0 model applied to the entire ceramic supply chain, from the mine to the finished product, integrating the principles of the circular economy with Industry 4.0 technologies.

The project combined three fundamental dimensions.

01

Sustainability

Each stage of the production cycle has been analyzed and optimized according to environmental, economic, and social criteria, using internationally recognized methodologies such as Life Cycle Assessment and developing new assessment tools specific to the sector.

02

Circularity

Mining waste and by-products have been studied, characterized, and reintroduced into the production process as secondary raw materials, reducing dependence on virgin resources and transforming waste into value.

03

Digitization

The implementation of IoT technologies, Business Intelligence systems, and integrated management platforms has enabled the creation of a connected, traceable supply chain capable of supporting informed decisions in real time.

The approach adopted was holistic: rather than focusing on isolated individual aspects, REDiRECT built an integrated model in which technological improvements, process innovations, and new business strategies reinforce each other, generating an impact greater than the sum of its parts.

THE PROCESS

Three years of research and experimentation

The project was developed over a three-year period divided into complementary phases, each building on the results of the previous ones and aimed at generating knowledge, tools, and concrete solutions.

PHASE 1
Analysis

Building the knowledge base

The work began with an in-depth analysis of existing mining and ceramics processes, mapping material, energy, and information flows throughout the entire supply chain. Characterization campaigns were conducted at extraction sites in Tuscany, Sardinia, and Calabria to assess the availability and properties of potential secondary raw materials.

At the same time, new life cycle inventory models specific to the mining sector were developed, filling a significant gap in the scientific literature and available databases.

PHASE 2
Methodologies

Development of innovative tools

Based on the knowledge acquired, innovative tools for integrated sustainability assessment were created. A new concept of technological sustainability was defined, complementary to the traditional environmental, economic, and social dimensions. A multidimensional composite index was constructed to summarize the circularity performance of the entire supply chain. Predictive statistical models were developed to support the planning and monitoring of mining activities.

At the same time, new formulations of ceramic mixtures and glazes were studied and optimized, integrating secondary raw materials while maintaining high quality standards.

PHASE 3
Digitalization

Industrial implementation

The third phase saw the translation of the knowledge and tools developed into operational solutions. Advanced sensor systems were installed at mining sites for real-time monitoring of production parameters. An integrated software architecture was created that connects field data to company management systems. In the ceramic factories, production lines were adapted for the processing of secondary raw materials and a management platform based on in-memory databases was implemented for the efficient processing of large volumes of data.

PHASE 4
Validation

Industrial prototyping

The final phase demonstrated the industrial feasibility of the model through the production of pilot batches of circular minerals and the prototyping of a new collection of ceramic tiles. Tests confirmed that the required quality standards had been met and that the solutions developed were compatible with existing production processes.

THE RESULTS

Concrete and measurable innovation

REDiRECT has generated a coherent set of results which, when integrated, form the operational basis for the transition to Circular Enterprise 4.0.

7

secondary raw materials validated

4

digital platforms developed

1

MSCI Index for the supply chain

100%

supply chain traceability

Models, metrics, and tools for sustainability and circularity

REDiRECT has developed an advanced, integrated system for assessing sustainability throughout the entire supply chain, from the mine to the finished product. The framework combines Life Cycle Assessment (LCA), Life Cycle Costing (LCC), and Social LCA (S-LCA) tools, extending the analysis to the raw material procurement phase, which is traditionally under-researched.

These tools are complemented by a new technological sustainability framework, designed to assess the real industrial applicability of the solutions adopted.

On this basis, the Multidimensional Sustainable Circularity Index (MSCI) was developed, a synthetic index that integrates environmental, economic, social, and technological dimensions. The index can be calculated using a dedicated algorithm and is designed for integration into management control systems to support continuous monitoring, scenario building, and strategic planning.

Secondary raw materials and process innovation

The project validated the use of secondary raw materials for the ceramic industry through a systematic study of mining by-products from different geographical areas. In particular, de-ironized Sardinian granite, obtained from the recovery of waste from the stone industry, proved to be suitable for completely replacing traditional feldspars in specific mixture formulations, without any negative impact on product performance.

At the same time, innovative glaze formulations were developed that eliminate the sintering process, significantly reducing energy consumption and the associated environmental impact.

Digitization of mines and factories: towards circular Industry 4.0

REDiRECT has enabled the transformation of mining sites into Mine 4.0, introducing real-time monitoring and data collection systems. Automatic scales, energy consumption meters, and digital platforms now allow for the traceability of material flows and operational performance. The software architecture developed integrates field data with management systems, enabling the production of minerals with measurable and certifiable circularity indicators.

An advanced digital infrastructure has been implemented in ceramic factories: in-memory data warehouses, IoT-based warehouse management systems, and interactive dashboards for real-time monitoring of production, quality, and sustainability. These tools support rapid, informed, and resource-efficient decisions.

Product and industrial demonstration

The project led to the industrial prototyping of a circular ceramic collection, made with mixtures containing secondary raw materials.

The results confirm full compliance with the quality standards required by the market, demonstrating that sustainability can be integrated without compromising the technical and aesthetic performance of the product.

Territorial knowledge, supply chain, and industrial symbiosis

REDiRECT has generated a wealth of territorial knowledge to support the development of circular supply chains.

In Sardinia, the extraction sites in the Buddusò–Alà dei Sardi area have been mapped and characterized, identifying opportunities for waste recovery and defining guidelines for the environmental restoration of quarries. In Calabria, the first systematic analysis of regional georesources for ceramic use was conducted, opening up concrete prospects for new production supply chains.

Epidemiological and environmental studies have also confirmed the absence of significant negative impacts of mining activities on ecosystems and local communities, reinforcing the overall sustainability of the model.

Environmental, economic, and competitive impacts

The introduction of secondary raw materials reduces pressure on natural resources and landfill disposal, while the elimination of frying for certain enamel formulations generates significant energy savings. The digitization of processes contributes to a more efficient use of resources and a reduction in waste, making the environmental footprint of products measurable and communicable.

From an economic point of view, the Circular Enterprise 4.0 model improves competitiveness by reducing procurement costs, optimizing processes, and differentiating the offer towards markets that are sensitive to sustainability. Traceability and certification of environmental performance become distinctive elements throughout the supply chain.

The model validated by REDiRECT is designed to be replicable and scalable. The assessment tools and circularity indices can be adopted by other companies in the ceramic supply chain and adapted to other manufacturing sectors. The digital platforms are designed for integration with external systems and functional evolution.

Finally, the knowledge generated contributes to the scientific and regulatory debate on the transition to a circular economy, in line with European and national strategies for industrial sustainability.

THE PARTNERSHIP

Integrated skills for innovation

REDiRECT has brought together an ecosystem of complementary skills, integrating industrial capabilities and academic know-how in an impact-oriented collaboration model.

Industrial companies have contributed manufacturing experience, process knowledge, and the ability to transform research results into operational solutions.

Gruppo Ceramiche Gresmalt

One of Italy's leading manufacturers of porcelain stoneware, it has made its factories, production lines, and technological expertise available for the industrial validation of the innovations developed.

Eurit

A mining company specializing in the production of raw materials for the ceramics industry, it has contributed its mining expertise and implemented Mine 4.0 technologies at its sites.

The partner universities contributed methodological rigor, analytical skills, and multidisciplinary expertise.

University of Modena and Reggio Emilia

Coordinated sustainability assessment activities, the development of assessment tools, and research on ceramic materials, drawing on expertise in engineering, economics, life sciences, and telecommunications.

University of Calabria

Conducted research on the enhancement of georesources and the development of statistical models and environmental monitoring systems.

University of Sassari

Led studies on the Sardinian territory, from the characterization of mining sites to construction solutions for circular architecture.

THE IMPACT

Rethinking ceramics between circularity and innovation

REDiRECT has demonstrated that the transition to a more sustainable and circular ceramics industry is not only possible, but economically advantageous and technically feasible with the skills and technologies available today.

The Circular Enterprise 4.0 model developed offers a concrete response to the challenges facing the sector: it reduces dependence on virgin raw materials, enhances the value of resources that until recently were considered waste, improves process efficiency, generates information for more informed decisions, and lays the foundations for transparent communication of the environmental and social value of products.

The results of the project are not confined to the partners involved. The methodological tools, technological platforms, and knowledge generated are designed to be shared and adapted, contributing to the transformation of the entire Italian ceramic supply chain and offering a replicable model for other manufacturing sectors.

In a context where sustainability is increasingly a market requirement and a regulatory imperative, REDiRECT charts a viable path for combining manufacturing excellence, environmental responsibility, and economic competitiveness. It is a concrete contribution to building an industry capable of generating lasting value for businesses, communities, and the environment.

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