The Seville-based engineering firm IDENER has participated in the technical conclusion of the European VITAL project in Finland, consolidating its leadership in process digitalisation and optimisation for high-efficiency bio-based foamed thermoplastics.

The VITAL project consortium recently gathered in Turku to hold its Final Review Meeting. After more than three years of intensive research, this milestone marks a significant step in Europe’s ambition to replace fossil-based thermoplastics with bio-based alternatives, aiming to reduce the industrial carbon footprint by approximately 75,000 tonnes of CO₂ equivalent per year. As a key technological partner, IDENER has provided its expertise in process engineering and digitalisation, critical elements in addressing the processability and cost challenges that have traditionally limited the widespread adoption of bio-based materials.

The VITAL project has developed innovative foaming processes and smart digital control systems that enable bio-based thermoplastics to be processed using both conventional machinery, such as foam injection moulding, and advanced techniques such as 3D foam printing. During the final review in Turku, IDENER’s contributions were highlighted across several strategic areas. The company focused on the implementation of smart digital control systems using advanced algorithms to ensure material stability and quality during processing. In addition, IDENER worked on value chain optimisation to improve material efficiency and make bio-based alternatives economically competitive with synthetic plastics. The company also provided essential support for the circular economy by integrating “circularity by design” approaches and mechanical recycling strategies for the newly developed thermoplastics.

The project’s results, validated through six specific use cases, will directly impact key industries such as automotive, electronics, and the marine sector. IDENER’s participation reaffirms the role of Spanish engineering as a key driver of the twin transition—digital and green—in Europe.

One of the most significant outcomes of the project is the creation of a Learning Factory, which will allow industrial companies to access pilot-scale production lines. IDENER will continue collaborating in transferring this knowledge to reduce risks for European industry in adopting these sustainable technologies.