Collective research projects for SMEs. VOL 3.
Date: 2007-06-07
Institutions: Directorate-General for Research and Innovation
Subjects: EU programme, EU research policy, competitiveness, innovation, research and development, research project, small and medium-sized enterprises

Collective Research projects are one of two distinct types of project supported by the Horizontal research activities involving SMEs 
of  the  EU’s  Sixth  Research  Framework  Programme  (FP6,  2002-2006),  which  together  have  an  overall  budget  of  €473  million. 
They are designed to improve the competitiveness of large communities of SMEs by expanding their knowledge base through 
research and development related to widely-shared technological, environmental, safety or standards issues. This folder contains 
profiles of 35 FP6 Collective Research projects,  prepared in the months immediately following their official launch. Similar folders, 
presenting a selection of projects from the FP6’s Co-operative Research and Economic and Technological Intelligence (ETI) calls, 
are also available. 

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Introduction

Collective Research
Volume 3

Collective Research projects are one of two distinct types of project supported by the ‘Horizontal 
research activities involving SMEs’ of the EU’s Sixth Research Framework Programme (FP6, 2002-
2006), which together have an overall budget of €473 million.

Collective Research projects are designed to improve the competitiveness of large communities 
of SMEs by expanding their knowledge base through research and development related to widely 
shared technological, environmental, safety or standards issues.

Lasting up to three years, and with budgets of between €2 million and €5 million, these projects 
are led by transnational industrial associations or groupings (IAGs). The IAGs are responsible for 
outsourcing the required work to ‘research performers’ – normally, universities or research centres 
– and become the exclusive owners of the resulting intellectual property rights. ‘Core groups’ of 
individual SMEs test the relevance and quality of the results, and may benefit directly from early 
access and preferential use of them. The IAGs ensure the widespread take-up and exploitation of 
these results by their member SMEs.

Similar folders, presenting a selection of projects from the FP6’s first Co-operative Research and 
Economic and Technological Intelligence (ETI) calls, are also available. 

The  Collective  Research  scheme  is  managed  by  the  SME  unit  of  the  European  Commission’s 
Directorate-General for Research.

Further information
•  SME  TechWeb,  a  dedicated  web  service  for  SME  participants  in  the  EU  Research  Framework 
Programmes, is at http://sme.cordis.europa.eu/home/

• Specific enquiries may be submitted at http://ec.europa.eu/research/enquiries/

• SME National Contact Points (SME-NCPs) in each EU Member State and Associated State offer a 
tailored support service for SMEs. Contact details for each SME-NCP can be found at http://cordis.
europa.eu/fp6/ncp.htm.

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Collective Research
Volume 3

TABLE OF CONTENTS

Contract

number	

Acronym	

30338   ADOPTIC 

Additive Optimisation For Improved Ceramics

Project

030348  AGROBIOGAS 

An Integrated Approach For Biogas Production With Agricultural Waste 

30269  Barley Bread 

European Guideline For Healthy High Fibre/Low Salt Baking Process Based On The Use Of European Barley

30340  BEET-PULP 

Use Of Micronised And Bleached Beet Pulp As Additive In White Board And Papers

30300  COMFOR  Collective Work Science Approach To Solving The Common Problems Of Occupational Health And Performance In 
European Forest Operation SMEs

30421  CrustaSea 

Development Of Best Practice, Grading And Transportation Technology In The Crustacean Fishery Sector

30298-2 DIOFUR 

Dioxins In Cupolas, Rotary And Electric Arc Furnaces — Emissions Free Melting Practices In Foundries

30490  ECWINS 

A European CE-based Assessment Tool For Flexible And Innovative Window Systems

30339  EMOLD 

Total Life Cycle Approach For Efficient And Networking Plastic Injection Moulding Processes

30386  eSUPPORT 

A Knowledge Transfer And On-site Information Agent Driven Access System For Sme Field Service Engineers

30364 

FILTER 

A Total Metalworking Fluid Disposal Technology

30273 

FLEXFORM 

                  Development Of A New Flexible Manufacturing Process For Low Series Production Of Metal Parts For 
Custom And Special Vehicles

30313 

Flexoline@home 

Development Of A Cost Efficient, Innovative, Reusable, Integrated Power Supply System, Enabling 
Interference Free High Speed Power Line Based Communication Architecture For The Affordable Smart House

030307  IBIOLAB 

Improvement Of Bio-lubricant Manufacturing And Development Thanks To The Obtaining Of Eco-labels In A Wide 
Range Of Industrial Sectors 

30485  

InCaS 

Intellectual Capital Statement – Made In Europe

30312 

INNOTEX 

A Tool Box To Catalyse Continuous Process INNOvation Within The TEXtile Manufacturing Lines In Europe

30238   KnowEDM 

Automated Knowledge Based EDM Technology For Integrated Toolmaking And High Precision Components

30379 

LOWJUICE 

Novel Processes For Reducing Sugar And Adding Fibre To Natural Apple Juices For Increased Public Health And 
Increased Competitiveness Of The European Fruit Juice Industry

30208  MagForge 

Magnesium Forged Components For Structural Lightweight Transport Applications

30434  MICRO-MELT  Development Of Advanced Retro-fit Processing Technologies For Rotational Moulding To Reduce Product Cost 
And Processing Time And Increase Surface Performance

030299  MODELPACK 

Advanced Quality Prediction Tool For Knowledge-driven Packaging Design And Manufacturing In European SMEs

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Collective Research
Volume 3

30377  OVULTEST  Improving Profitability Of Dairy SMEs Through Developing, Validating And Promoting The Use Of A Biosensor For 
Ovulation Detection 

30392 

PATHOMILK                                                             Providing Milk Supply Chain With A Rapid, Portable And Cost Effective Biosensor 
For Multipathogen Detection In Milk

30191 

PEPT-Flow  Innovative Polymer Flow Visualisation For Optimised Machine Design, Improved Mixing And Material Properties, 
Process Efficiency And Energy Reductions

30205  Pro4Plast 

New Product Development Guidance System (PDGS) For Complex Injection Moulded Plastic Parts By Enhanced 
Injection Moulding Simulation And Material Data Measurement Applicable By SMEs 

30278  RISKSCRA 

Dairy Products In Mediterranean Sheep Populations: Quantification Of Scrapie Risk

30285  SAFECHEESE 

A Barrier For Preventing Pathogenic Bacterial Growth In Cheese From Non-pasteurised Milk

30305  SAFEWORKER 

Reduction Of Occupational Asthma And Dermatitis In The Vehicle Repair Industry

30195  SAFFIC 

Methodologies For Implementing International Standards For Saffron Purity And Quality

30287  SlipSTD 

Development Of Slip Resistance Standard Surfaces

30270  SPIES-DETOX  Active Biological Monitoring And Removal Of Toxins In Aquaculture Ecosystems And Shellfish — Including The 
Development Of A Solid-phase In-situ Ecosystem Sampler And Detoxification Of Shellfish

30384  SustainAqua 

Integrated Approach For A Sustainable And Healthy Freshwater Aquaculture

29743 

TECH-SPRING 

Improving Technical Performance Of Springs Through Scientific Understanding Of Dynamic Stress Profiles 
Utilising Advances In Software Design And Measurement Technologies

30234 

TESS 

30433  X-Gear 

Development Of Gear Drive-trains Based On New Materials And Novel Gear Systems

Toolbox To Evaluate Sustainable Systems

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THE PERFORMANCE ENHANCING 
ADDITIVE
“Gone are the days when ceramics were only 
used for making table and sanitary ‘ware’.”

ADOPTIC

What  do  a  digital  watch  and  a  soup 
bowl have in common? Well, nothing, at least at 
first glance. But with a more thorough look, we can find 
that common point: ceramic. Ceramic is quite visibly the main 
material used to make soup bowls, but it is more difficult to see that 
the tiny quartz crystal measuring time in watches is also made of ceramic. 
This  example  of  two  completely  different  objects  shows  how  widely  ceramics 
are used. To produce the various types of ceramic needed for the manufacturing of 
different products, additives are used. The general aim of the Adoptic project is to capture 

and increase knowledge on how additives improve ceramics manufacturing. 

Spreading the news
To  fully  disseminate  the  results  of  the  project,  a  spin-off 
entity  has  been  created,  called  IPECC  srl.  This  institution  is 
specifically aimed at transferring knowledge concerning ceramic 
piezoelectric devices to industrial actors. 

Adoptic will have a direct positive impact on the whole European 
ceramics manufacturing sector. Indeed, the project is upgrading 
and introducing new rheological quality control tests, in order 
to assist in the development of future production standards. 

However,  the  most  important  tool  being  developed  by  the 
research  team  is  a  web-based  knowledge  system,  to  support 
industrials  in  identifying  and  selecting  the  more  appropriate 
additives  for  their  field  of  activity.  This  system,  or  software, 
incorporates the existing additives and a database of industry 
specifications  and  manufacturing  methods.  When  queried  by 
the user, the software will identify the best additive for the best 
possible performance for a given product.

The Adoptic project intends to improve the competitiveness of 
the  whole  ceramics  manufacturing  sector  by  encouraging  the 
use  of  additives  to  produce  better  products  with  contained 
costs. The web-based knowledge system will benefit all ceramic 
producers, from table and sanitary ware to high-tech ceramics.

The future of European SMEs involved in ceramics depends on 
their ability to choose the best additives to optimise production 
efficiency and create more varied and better quality products. 
The range of additives available is very large and companies are 
not  always  aware  of  what  products  can  best  suit  their  needs. 
New research is needed to raise awareness on how to make the 
most of existing additives. 

The  Adoptic  consortium  gathers  25  partners  from  four  EU 
Member States and comprises IAGs, SMEs and RTD performers. 
The project supports the ceramic manufacturing industry, which 
needs  to  improve  the  yields  and  properties  of  end-products, 
because it faces strong competition from emerging countries. 
New and improved additives could bring SMEs the competitive 
edge needed to fend off the competition.

From pottery to high technology
Gone  are  the  days  when  ceramics  were  only  used  for  the 
production  of  table  and  sanitary  ware,  such  as  plates  and 
chamber pots. Nowadays, high tech electronics and mechanical 
devices rely on ceramic elements for top level performance. 

Ceramic  is  a  hard,  porous  and  brittle  material,  but  different 
chemistries  can  introduce  a  variety  of  important  properties 
(e.g.  good  conductive  and  piezoelectric  characteristics  — 
piezoelectricity  being  the  ability  to  use  electricity  to  produce 
a movement, or the opposite). These attributes are the reason 
why ceramic is often used for high-tech applications, such as 
digital  watches  or  in  surge-protection  devices.  It  can  also  be 
used  in  actuators,  sensors  and  transformers  in  the  fields  of 
mechatronics, robotics, domotics and biomedicine. 

The  Adoptic  project  proposes  to  study  existing  additives 
to  improve  the  performance  of  ceramics  in  all  the  possible 
application fields. The research focuses on developing a better 
understanding of the link between additives and the properties 
of  ceramic  products,  and  to  investigate  the  performance  of 
various  types  of  additives.  By  taking  a  broad  approach  to 
include  the  most  common  ceramic  production  methods  — 
pressing, plastic forming and suspension technologies, as well 
as emerging nano-ceramics — the project will offer answers to 
the specific additive related issues raised by the industry.

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Collective Research Volume 3

“The Adoptic project proposes to study existing 
additives to improve the performance of 
ceramics in all the possible application 
fields.”

Contact Person
Dr Phil Jackson
Ceram Research Ltd
Queens Road Penkhull
ST4 7LQ
Stoke-on-Trent
United Kingdom
Tel. (+44) 1782 764 253
Email: phil.jackson@ceram.com 

Participants
1. Ceram Research Ltd (UK)
2. Federceramica (IT)
3. Ceramicolor (IT)
4. Associação Portuguesa da Indústria Cerâmica (PT)
5. Associação Industrial do Distrito de Aveiro (PT)
6. British Ceramic Confederation (UK)
7. GRAF (IT)
8. Industria Colori Srl (IT)
9. NEOMI Ceramiche Srl (IT)
10. Eurocoating Spa (IT)
11. Cer.Invest Srl (IT)
12. Fabryka Naczyn Kamionkowych (PL)
13. Zaklad Ceramaiki Sanitarnej Stanislaw Hybner (PL)
14. Star Dust Sp. Z.o.o (PL)
15. Pastas Cermaicas S.A. (PT)
16. AGORAMAT — Produção de Materiais Cerâmicos (PT)
17. Domínio Indústrias Cerâmicas S.A. (PT)
18. Vulcan Refractories (UK)
19. Parkinson Spencer Refractories (UK)
20. TENMAT (UK)
21. Commercial Clay (UK)
22. Consiglio Nazionale delle Ricerche — Istituto di Scienza e 
Tecnologia dei Materiali Ceramici (ISTEC) (IT)
23. Universitá di Modena e Reggio Emilia (IT)
24. AGH, University of Science and Technology (PL)
25. University of Aveiro (PT)

Project title
Additive Optimisation for Improved Ceramics (ADOPTIC)

Contract number
30338

Duration
36 months

Global project costs
€1 863 899

EC contribution
€1 316 782

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OPTIMISING AGRICULTURAL 
RESOURCES FOR THE PRODUCTION 
OF GREEN ENERGY

“Biogas is the main product of AD, 
along with a rich liquid and a solid 
residue, potentially used as 
fertilisers.”

Over  the  past  decade,  the  economic 
situation of European farmers has deteriorated 
constantly,  and  some  farmers  have  been  forced  out 
of  business  by  their  severe  economic  predicament.  In  the 
meantime, a potential treasure has literally been wasted: agricultural 
waste. Each year, around 700 million tons of residue, such as straw and 
manure, are produced and inadequately disposed of. Agrobiogas is a research 
project aimed at encouraging anaerobic digestion (AD) as a waste treatment process, 
which  can  not  only  prevent  pollution,  but  also  enable  energy  production  and  generate 

AGROBIOGAS

additional income for farmers.

Decomposition by AD is a natural process for organic material 
such  as  grass  clippings,  sewage  or  animal  waste.  AD  plants, 
or  installations,  are  already  being  used  to  produce  biogas 
and fertilisers in some European countries, like Germany. The 
purpose of Agrobiogas is to offer farmers the ideal conditions 
that  would  encourage  them  to  treat  their  own  residue,  and 
to  provide  them  with  the  opportunity  to  generate  profit  as  a 
result.

However,  before  European  farmers  can  have  AD  plants  that 
will produce biogas and their own heat or electric energy, and 
boost  their  income,  further  research  is  needed.  Agrobiogas 
participants  are  in  need  of  further  research  concerning  the 
financial, legal and technical requirements for the development 
of  AD  treatments,  that  will  be  suitable  for  diverse  European 
locations and conditions.

A landmark for biogas production
Biogas  is  a  green  energy,  with  high  availability  of  source 
materials. In the process of AD, organic material is decomposed 
under  the  action  of  microbes.  In  plants,  digesters  are  filled 
with animal waste and energy crops; when decomposed, these 
produce higher quantities of biogas. Biogas is the main product 
of  AD,  along  with  a  rich  liquid  and  a  solid  residue,  with  the 
potential to be used as fertiliser.

The main objective of Agrobiogas is to increase the efficiency 
of  agricultural  waste’s  AD  in  co-digestion  with  other  organic 
materials.  To  achieve  this,  the  project  team  is  conducting 
laboratory experiments on co-fermentation of agricultural waste 
and  preparing  a  database  of  substrates.  A  simulation  toolkit 
for the evaluation of the best substrate mixtures is also being 
planned. Furthermore, in the course of the project, participants 
will be gathering the scattered information about local biogas 
projects  throughout  Europe.  The  knowledge  pool  will  serve 
as a source of information for farmers and their associations, 
enabling the improvement of existing and future AD plants. 

From waste to riches
Agrobiogas  will  support  efforts  to  convert  what  is  currently 
a  disposal  problem,  into  a  source  of  income  for  farmers.  AD 
allows for the production of biogas from waste which, to date, 
has been mainly disposed of in landfills (a method soon to be 
prohibited throughout the EU). Farmers will be able to produce 
and sell biogas and even energy surpluses to energy production 
companies, and AD residues will have the capacity to be sold 
as fertilisers. For example, a small AD plant for the production 
of  biogas  from  cow  manure,  from  a  herd  of  150  heads,  could 
generate an additional income of EUR 2 500 a year. 

These revenues can be complemented by support systems such 
as  EU  subsidies,  established  under  the  Common  Agricultural 
Policy (CAP). Since the latest CAP reform in 2003, subsidies are 
partly allocated on the basis of compliance and contribution to 
environmental standards. Farmers producing energy crops, and 
using  them  in  AD  plants  during  co-fermentation  of  waste,  are 
entitled to such aid. 

Farmers  are  not  the  only  group  that  could  benefit  from  the 
development  of  AD.  There  are  currently  3  000  biogas  plants 
run by SMEs, of which 800 are agricultural plants. Agrobiogas 
results  can  potentially  increase  the  demand  for  more  plants, 
increasing new expansion prospects for plant manufacturers. 

barriers, 

establishment 

The  Agrobiogas  project  aims  to  eliminate  the  performance 
and 
information 
which  have  hampered 
the 
of  AD  plants  as  a 
widespread means 
producing 
of 
biogas. 
Once 
farmers are able 
to  convert  farm 
waste  into  gas, 
they  will  not 
only  put  an  end 
to  the  disposal 
problem,  but  also 
enjoy 
revenues.

additional 

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Collective Research Volume 3

“Agrobiogas will support efforts to convert a 
disposal problem into a source of income for 
farmers.”

Contact Person
Dr Joergen Hinge
Danish Agricultural Advisory Service
Udkærsvej 15
8200 Århus N
Denmark
Tel. (+45) 87405574
Fax: (+45) 87405010
Email: joh@landscentret.dk

Project website
www.agrobiogas.eu

Participants
1. Dansk Landbrugsrådgivning Landscentret (DK)
2. European Biomass Industry Association (BE)
3. Fachverband Biogas e. V – German Biogas Association (DE)
4. Asociación Agraria Jóvenes Agricultores (ES)
5. Slovenska Asociacia pre biomasu (SK)
6. Deutsche Gesellschaft für Sonnenenergie e.V. (DE)
7. Coordinadora de Organizaciones de agricultures y ganaderos (ES)
8. Panhellenic Confederation of Unions of Agricultural 
Cooperatives (EL)
9. Anneberg Gård (SE)
10. Hagaviks Gård AB (SE)
11. Azienda Agricola Testa Lara (IT)
12. Polnohospodarske druzstvo Agricultural Cooperative (SK)
13. Biomasse Energie GmbH (DE)
14. Elbe Bioenergie GbR (DE)
15. Reliable Environmental Solutions (IT)
16. Santiago Apóstol SCA (ES)
17. Bioazul S.L. (ES)
18. EARL des Brimbelles (FR)
19. Verein zur Förderung des Technologietransfers an der 
Hochschule Bremerhaven e.V. Umweltinstitut (DE)
20. Syddansk Universitet (DK)
21. Lunds Universitet (SE)
22. Universität für Bodenkultur Wien (AT)
23. Centre Wallon de Recherches Agronomiques (BE)
24. Universitat de Barcelona (ES)

Project title
An integrated approach for biogas production with agricultural 
waste (AGROBIOGAS)

Contract number
030348

Duration
36 months

Global project costs
€2 891 939

EC contribution
€2 103 464

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ADAPTING AN ANCESTRAL TRADITION

Barley Bread

“There are no functional healthy bread alternatives 
on the European market today that can 
contribute with healthy ß-glucan, high 
fibre and prebiotics, be low on salt, 
and still satisfy the consumer 
preferences.”

Barley  production  has  become  a 
European  specialty  owing  to  the  favourable 
climate,  excellent  growth  conditions,  and  a  heritage 
spanning over 8000 years. To date, barley crop has been an 
extremely important source for animal feed. However, it is increasingly 
being replaced by soybeans, which have proved to be even better suited to 
animals. Given Europe’s leadership in barley production, a substantial part of its 
agrofood sector is now at stake. The BARLEY BREAD initiative has been launched so as 

to provide this European specialty with a new future.

farming  sector,  22%  of  those 

Within  the  European 
in 
employment  are  currently  associated  with  the  production  of 
barley,  which  represents  EUR  5.9  billion,  or  approximately  1% 
of the total European food and beverage production. However, 
due to the emergence of soya feed, the demand for barley has 
been diminishing continually over the past years. Owing to the 
properties of the competing crop, it is unlikely that alternative 
or novel markets will be established for barley. Consequently, 
3  European  organisations  representing  the  agro-food  sectors 
in Norway, Spain and Denmark, (accounting for some 345 000 
farmers, 2 000 millers and 27 000 bakeries), have joined forces 
in an attempt to address this issue.

From feed to food
The  BARLEY  BREAD  project  aims  to  forge  a  closer  connection 
between barley farmers and the supply chain within the milling 
and bakery sector. Its purpose is to provide new technological 
input and knowledge, so as to significantly increase barley use 
in the production of bread and other baked products. Indeed, 
less than 1% of the total amount of produced barley is currently 
used  as  food;  the  existing  varieties  are  more  suited  to  feed. 
Nevertheless,  European  barley’s  potential  for  success  in  the 
bread  markets  should  not  be  underestimated.  Barley  bread 
is  an  excellent  source  of  several  valuable  health-promoting 
compounds. White bread – the best-selling type of bread type 
on the market – may taste better, but it is also less healthy. 

Due  to  the  huge  commodity  trade  of  bulk  wheat  and  wheat 
flour,  ‘white’  cereals  are  dominating  the  European  and  Global 
Market. But such products are commonly low in fibre and high 
in  salt.    Furthermore,  there  are  currently  no  viable  healthy 
bread  alternatives  containing  healthy  ß-glucan,  high  fibre 
and  prebiotics,  and  low  salt,  which  can  still  satisfy  consumer 
preferences. Barley bread has the potential to become such an 
alternative.

Healthy and tasty
The BARLEY BREAD consortium has embarked on an exploration 
of  the  crop’s  hitherto  uncharted  potential.  Firstly,  a  novel 
process  that  measures  barley  grain  size  prior  to  milling,  will 
allow  for  retention of at  least  75%  of  its  healthy components. 
Secondly,  recent  improvements  in  wheat-based  ingredient 
technologies  have  been  adapted  and  further  developed; 
this will result in the production of a mixed bread (wheat and 
barley) with a salt content below 0,4% that is just as tasty as 
conventionally  produced  wheat-based  bread.  Finally,  a  new 
formulation and baking process is being developed for use with 
specific combinations of barley and wheat flour. This will help 
to reduce the enzymatic degradation of the starch in the barley-
based dough. The bitter taste normally associated with barley-
based products will be reduced with the addition of antioxidants 
and minute amounts of spices. The salt content will be further 
reduced by applying alternative salt types and specific flavour 
enhancers. Throughout the process, primary consideration will 
be  given  to  the  end  consumer,  with  recognition  of  local  and 
regional preferences. 

Altogether, the impact of the BARLEY BREAD project will be felt in a 
higher added-value market for barley farmers, inclusive of a presence 
on  the  health  food  market.  Furthermore,  the  understanding  and 
exploration  of  milling  and  baking  technology  knowledge  will  be 
expanded. But barley bread’s success will not be vital for the European 
milling  and  baking  industry  alone.  As  an 
affordable,  tasty  and  healthier 
to 
alternative 
based  bread, 
also 
improve  consumer 
health, especially 
the 
through 
of 
reduction 
the 
of 
risk 
cardio-vascular 
disease.

considerably 

it  will 

wheat 

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Collective Research Volume 3

“As the name suggests, the outcome of the Barley 
Bread project will be bread. But not just any 
bread.”

Project title
European Guideline for healthy high fibre/ low salt baking 
process based on the use of European Barley (Barley Bread)

Contract number
30269

Duration
36 months

Global project costs
€1 847 547

EC contribution
€1 104 392 

Contact Person
Berit Bull-Gjertsen
The Norwegian Federation of Food and Drink Industries
Essendropsgate 6, Majorstuen
N-0305 Oslo
Email: Berit.bullgjertsen@nbl.no

Participants
1. Norwegian Federation of Food and Drink Industry (NO)
2. Spanish Federation of Food and Drink Industry (ES)
3. Danish Fruit, Vegetable and Potato Board (DK)
4. Kevili Põllumajandusühistu (Trade Organisation of Grain 
Producers) (EE)
5. Can Halefuglo (TR)
6. Targi Tarimsal Girisim Sanayii ve Ticaret A.S. (TR)
7. Troyka Makine Gida Sanayii Danismanlik ve Pazarlama Ltd 
Sirketi (TR)
8. Silvery Tweed Cereals (UK)
9. Tor Sevaldens Konditori AS (NO)
10. AS Hallik (EE)
11. MacPhie (UK)
12. Matforsk (NO)
13. PERA (UK)
14. Scottish Crop Research Institute (UK)

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4/16/07   12:26:23 PM

 
 
 
 
 
 
 
 
 
 
 
WRITING THE NEW LIFE OF BEET PULP 
RESIDUES
“Finding a new valorisation system for beet pulp 
would positively impact on the economic 
revenues of beet producers and paper 
manufacturers.”

Combining  environmental  concerns 
with economic interests is not an easy task for 
European businesses. This struggle hampers a variety 
of industries, one of which is that of paper production. Paper 
producers are required to deliver high quality paper materials, while 
at the same time reducing the industry’s environmental burden. The BEET-
PULP  project  aims  to  replace  at  least  partly  the  mineral  fillers  currently  used 
in  the  making  of  paper,  with  vegetable  micro-fillers  from  beet  pulp.  This  improved 
application for the residue of beet sugar production will represent a new source of income 

BEET-PULP

become a reality, it is necessary to micronise (i.e. to reduce to 
particles the size of a thousandth of a millimetre) and to bleach 
beet  pulp  components.  The  project  team  intends  to  research 
the  best  methods  of  bleaching  to  match  paper  and  board 
specifications, such as brightness characteristics, for instance. 
The bleaching will be performed using environmentally friendly 
chemicals, such as oxygen, hydrogen peroxide, and ozone.

Fodder or paper: that is the question
The results obtained by the BEET-PULP project are expected to 
add value to the residue of sugar beet production by transforming 
it into paper filler material, allowing it to be exploited beyond its 
use as cattle feed. To facilitate the process for sugar and beet 
producers, the project will explore the possibility of integrating 
the production process of the beet filler into sugar factories.

For the paper industry, this project provides new opportunities 
to improve product quality. It also supports efforts to respond 
to  environmental  protection  requirements,  by  reducing  the 
prevalence  of  mineral  fillers  in  the  manufacture  of  paper  and 
board. As a result, paper producers can expect to enhance their 
competitive edge by producing a new type of ‘greener’ paper.

Accordingly,  the  valorisation  of  beet  pulp  as  a  paper  additive 
may serve as a source for higher incomes for beet producers, 
whilst  offering  paper  manufacturers 
a  means  of  producing  more 
environmentally-friendly 
products.

for nearly 400 000 beet-growing SMEs.

The  116  million  beet  plants  produced  annually  in  Europe  are 
used principally for sugar production. The final residue of this 
production is a dry matter, called beet pulp, and it amounts to 
roughly  7  million  tons  a  year.  Under  the  Common  Agricultural 
Policy, it is the beet producers who own and are responsible for 
the beet pulp. 

To date, beet pulp has been used as cattle feed. However, the 
income generated from its sale is extremely low (approximately 
€1,00). Finding a new valorisation system for beet pulp would 
positively impact on the economic revenues of beet producers 
and paper manufacturers. To achieve its goals, the BEET-PULP 
consortium  relies  on  the  expertise  of  its  14  members  in  the 
fields of beet and paper processing. 

Greener paper production
Paper  was  originally  prepared  from  100%  vegetal  fibres.  As  a 
result of the evolution of manufacturing processes, paper now 
constitutes  a  combination  of  natural  wood  fibres  (from  60  to 
100%) with recycled paper, mineral components (from 0 to 40%) 
and different chemical additives (up to 2% of the composition 
of a paper). 

In  the  process  of  paper  making,  wood  fibres  are  mixed  with 
mineral fillers to improve the opacity of different paper grades. 
Despite  this  being  common  practice,  the  addition  of  such 
materials  poses  an  environmental  problem,  and  negatively 
affects the mechanical properties of the paper. Indeed during 
the recycling of the paper, part of these mineral fillers ends up 
in the deinking sludge, which needs to be disposed of or burnt. 
In this latter case, the presence of mineral fillers will result in 
the production of ash residues.

To  reduce  the  negative  impact  of  paper  making  on  the 
environment,  the  BEET-PULP  project  proposes  that  these 
mineral fillers be replaced with organic material. Some types of 
papers already exist that are using no mineral fillers (sanitary 
and tissue paper, and paper used for packaging based on virgin 
fibers), but all the writing and printing papers contain mineral 
fillers. This project thus intends to apply beet pulp additives to 
the production of more mainstream paper types.

BEET-PULP is a cellulosic matter which could partly or completely 
replace  the  mineral  fillers  used  today.  For  this  possibility  to 

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Collective Research Volume 3

“Beet pulp is a dry matter which could replace, 
partly or as a whole, the mineral fillers used 
nowadays.”

Project title
Use of micronised and bleached beet pulp as additive in white 
board and papers (BEET-PULP)

Contract number
30340

Duration
36 months

Global project costs
€1 496 881

EC contribution
€956 950

Contact Person
Dr Christine Chirat
Institut National Polytechnique de Grenoble (INPG) — École 
Française de Papeterie et des Industries Graphiques (EFPG)
461 rue de la Papeterie
BP 65
38402 Saint-Martin d’Hères
France
Tel. (+33) 476826907
Fax: (+33) 476826933
Email: Christine.Chirat@efpg.inpg.fr 

Participants
1. Institut National Polytechnique de Grenoble — École 
Française de Papeterie et des Industries Graphiques (FR)
2. Confédération Internationale des Betteraviers Européens (FR)
3. Krajowy Zwiazek Plantatorow Buraka Cukrowego (PL)
4. Association de Recherche Technique Betteravière (FR)
5. Union des Sica de Transformation de Pulpes de Betteraves (FR)
6. Fabrication et Ateliers L. Choquenet (FR)
7. W. Kunz Drytec AG (CH)
8. Sécopulpe de Bourgogne (FR)
9. Juan Romaní Esteve, S.A. (ES)
10. Papeterie des Deux Guiers (FR)
11. Åbo Akademi University (FI)
12. Micronis (FR)
13. Daniel Gomez (FR)

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4/16/07   12:26:30 PM

 
 
 
 
 
 
 
 
 
 
 
HEALTHY BUSINESS IS GOOD 
BUSINESS
“The pan-European problem of poor occupational 
health and economic performance calls for a 
collective solution.”

Throughout  Europe,  SMEs 
in  the 
forestry  sector  are  affected  by  new  realities 
such  as  the  outsourcing  of  forest  operations  and 
mechanised harvesting. These structural changes are causing 
an  increasing  number  of  occupational  health  problems  in  forestry 
work as well as economic pressure on SMEs involved in this field. Current 
ergonomic research provides solutions for healthier working practices and also 
improves performance. However, putting science into practice is difficult for businesses 
that face practical and financial barriers. The COMFOR project has been launched to change 

COMFOR

Pan-European approach
The  COMFOR  methodology  draws  on  the  Collective  Research, 
pan-European  approach,  combining  the  unique  competences 
of a range of research institutions, industrial associations plus 
the participating SMEs themselves. While a common research 
methodology  will  be  employed  to  address  the  pan-European 
problems of occupational health associated with mechanisation, 
the tailored solutions provided will reflect regional differences. 
A large body of European forestry contractors will maximise the 
uptake of good ergonomic working practices. Additionally, the 
COMFOR project will develop research and knowledge transfer 
capacities in the field of Work Science and contribute to mutual 
standards  required  by  the  European  market  for  products  and 
services. 

Overall, the adoption of ergonomically efficient ways of working 
proposed  by  the  COMFOR  project  will  improve  the  well-being 
and  economic  performance  of  European  forestry  operations 
businesses. 
long  term,  this  should  considerably 
strengthen  the  forestry  workforce  and  the  sustainability  of 
forestry-dependent rural communities in general. 

In  the 

this situation.

Due  to  a  range  of  financial,  social  and  cultural  pressures, 
forest  operations  businesses  have  shown  a  reluctance  to 
adopt  ergonomically  efficient  methods  of  working.  Despite 
regional differences in economy and culture, these businesses 
face  the  same  constraints  all  over  Europe.  Consequently, 
the  pan-European  problem  of  poor  occupational  health  and 
economic performance calls for a collective solution. Designed 
to  maximise  the  impact  of  its  results  on  forestry  SMEs  by 
transforming research into practical applications, the COMFOR 
project  aims  at  solving  the  underlying  problem  of  knowledge 
transfer at the European level.

Same problems in varying conditions
Given the fact that forestry contractors are not in a position to 
undertake research and development themselves, the COMFOR 
consortium  will  undertake  a  3  year  pan-European  project  of 
integrated  work  science  research  linked  to  the  most  effective 
ways  of  transferring  knowledge  to  these  businesses.  The 
research  topics  will  focus  on  new  research  into  the  impact  of 
structural change across the European wood supply chain, the 
economic  benefits  of  ergonomic  investment,  and  the  learning 
patterns  of  SMEs.  The  main  output  of  the  project  will  be  an 
innovative  knowledge  transfer  package  for  the  improvement 
of health and performance. The package will be customised for 
SMEs operating in three European regions: North, West Central, 
and East Central Europe. 

The  global  yet  local  context  of  the  forestry  sector  means  that 
its  characteristics  vary  in  different  parts  of  Europe.  This  calls 
for regional expertise in tackling the problems of occupational 
health and knowledge transfer. Still, there are many similarities 
across the continent. For instance, forestry contractors employ 
the  same  machines,  are  mostly  micro-businesses  and  rely  on 
only one or two large customers. Furthermore, they all have to 
adopt new standards regarding certification and environmental 
regulations.  As  a  consequence,  forestry  operations  SMEs 
throughout  Europe  face,  or  will  face,  similar  challenges, 
including occupational health problems associated with capital 
intensive modes of production. 

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Collective Research Volume 3

“The COMFOR project aims at solving the 
underlying problem of knowledge transfer at 
the European level.”

Project title
Collective work science approach to solving the common 
problems of occupational health and performance in European 
forest operation SMEs (COMFOR)

Contract number
30300

Duration
36 months

Global project costs
€2 184 734

EC contribution
€1 647 545

Contact Person
Contact Person
Edgar Kastenholz
European Network of Forest Entrepreneurs e.V.
Rütteberg 10
D-79294 Sölden
Germany
Email: edgar.kastenholz@enfe.net 

Participants
1. European Network of Forest Entrepreneurs (DE)
2. Qualifizierungsfonds Forstwirtschaft e.V. (DE)
3. Swedish University of Agricultural Sciences (SE)
4. Warsaw Agricultural University (PL)
5. Albert-Ludwigs-Universität Freiburg (DE)
6. Forestry Commission Scotland (UK)
7. Association Forêt Cellulose (FR)
8. Kuratorium für Wald und Forstarbeit (DE)
9. Delo – Organisationsberatung (DE)
10. Hudson Consulting Ltd (UK)
11. Waldwirtschaft Jacob OHG (DE)
12. Sundgaubois (FR)
13. Harper Harvesting & Transport (UK)
14. Dyduch C. sp zo.o (PL)
15. Il Forest (RO)
17. Wand Enterprises (IR)
18. Gebr. Zweverink BV (NL)
19. Metsäurakointi Piirainen oy (FI)
20. Dunbergs Skogsservice AB (SE)
21. Gorhin Ltd (BG)
22. Forest Research Institute of Poland (PL)

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4/16/07   12:26:45 PM

 
 
 
 
 
 
 
 
 
 
 
LONG LIVE THE CRAB

CrustaSea

“The project partners are seeking to enhance 
the level of innovation and technology 
exploitation in accordance with 
toughening global competition.”

European  SMEs 
crustaceans  sector  are 

the 
increased 
from  North  America  and  Asia.  To 
safeguard  the  jobs  attached  to  this  rural  business,  these 
SMEs need to improve their structural deficiencies and regain their 
competitiveness. A high level of mortality (10-50%) of live crustaceans, a 
very costly transportation method and an outdated grading system are key issues 
that need to be addressed. The CrustaSea initiative has been set up to counter these 

involved 
facing 

competition 

in 

deficiencies by improving the infrastructure of the European crustacean fishery sector.

The  CrustaSea  project  aims  to  reduce  or  even  eliminate 
mortality  and  quality  loss  after  capture  and  also  to  expand 
market  opportunities  for  live  crustaceans  from  Europe.  The 
project partners are seeking to enhance the levels of innovation 
and  technology  exploitation  in  accordance  with    toughening 
global competition. This will be achieved through new technical 
solutions  for  the  transport,  holding  and  grading  of  live 
crustaceans, especially crabs and lobsters.

From average to premium label
CrustaSea is working on several innovative concepts to improve 
the  efficiency  of  the  European  crustacean  fishery  sector.  The 
tools  developed  include  a  grading  technology  based  on  light 
transmission for specific use in crustacean processing plants. 
A  new  water  treatment  system  seeks  to  improve  the  animal 
welfare  at  holding  stations,  especially  to  reduce  ammonia 
concentration in holdingwater.

Plenty of room for improvement
Costs  related  to  the  mortality  of  live  crabs  are  estimated  at 
€11.09 million a year. The quality loss problem due to insufficient 
grading can decrease sales value by €0,60 per kg, resulting in 
a  further  reduction  of  value  by  €12  million.  With  a  total  loss 
of  9.5%  of  the  complete  commodity  value,  the  economical 
potential for improvements in the live crustacean sector seems 
obvious.

Improving  the  grading  system,  water  treatment  method,  and 
transportation  technology  of  live  crustaceans  implies  an 
enhanced understanding of the biological factors and technical 
standards involved. Another topic is the market segmentation 
related to quality and freshness, which has an impact on pricing. 
The  CrustaSea  consortium  aims  to  expand  technological 
knowledge and raise awareness about market opportunities in 
order to develop Best Practice. This double goal will be reached 
through targeted research in both fields, and the results will be 
disseminated beyond the consortium.

Transportation  and  holding  boxes  will  be  designed  for 
applications  in  both  dry  and  wet  conditions  with  bivalve 
commodity  to  ease  drainage  and  water  circulation.  Thanks 
to  a  sophisticated  stacking  system,  they  will  reduce  the 
manual handling. The consortium is furthermore working on a 
technological solution to reduce water consumption of transport 
and holding systems to 40% instead of the 50% needed today. If 
successful, such a solution would not only significantly reduce 
transport  and  holding  costs,  but  also  generate  more  profit 
thanks to the increased transport capacity of ships and trucks.

The knowledge gathered by the CrustaSea consortium will be used 
to develop innovative technologies that will also have applications 
in other sectors such as the aquaculture sector and the farming of 
crustaceans. But above all, these technologies will be protected 
by  intellectual  property  rights.  This  measure  will  ensure  a  long-
term  competitive  advantage  of  European  SMEs  over  their  global 
competitors,  whether  they  are 
involved  in  the  catching, 
trading, transportation 
or processing of live 
crustaceans.

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Collective Research Volume 3

“CrustaSea is working on several innovative 
concepts to improve the efficiency of the 
European crustacean fishery sector.”

Project title
Development of Best Practice, grading and transportation 
technology in the crustacean fishery sector (CrustaSea)

Contract number
30421

Duration
36 months

Global project costs
€2 500 000

EC contribution
€1 700 000

Contact Person
Leif Harald Hanssen
Norwegian Seafood Association
Dronningensgate 7
7000 Trondheim
Norway
Tel. (+47) 73 84 14 00
Fax: (+47) 73 84 14 01
Email: leif.harald.hanssen@nsl.no  
Website: www.nsl.no 

Project website
www.crustasea.com 

Participants
1. Norwegian Seafood Association (NO)
2. Federation of Icelandic Seafood Processing Plants (IS)
3. Welsh Federation of Fishermen’s Associations Ltd. (UK)
4. Portuguese Association of Fisheries Traders (ANCIPA/ACOPE) (PT)
5. Isumar SRL (IT)
6. Hitramat AS (NO)
7. Vinnslustöðin ehf. (IS)
8. McBrideFishing Co Ltd. (IE)
9. Killibegs Electrical Refrigeration Services Ltd. (UK)
10. Sæplast Dalvik ehf. (IS)
11. The National Institute of Technology (NO)
12. Møre Research (NO)
13. Pera Innovation Ltd. (UK)
14. Vestmannaeyjar Research Centre (IS)
15. Centro Tecnólogico del Mar, Fundación CETMAR (ES)
16. National Research Institute on Agriculture and Fisheries 
Research, Instituto Português de Investigação das Pescas e do 
Mar (IPIMAR) (PT)

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4/16/07   12:27:02 PM

 
 
 
 
 
 
 
 
 
 
 
BURNING AWAY CARCINOGENIC 
DIOXINS
“The danger with dioxins lies in the fact that even 
a small exposure can, if regular, originate 
cancers.”

DIOFUR

Human  health. 

Industrial  activity 
means currently some kind of risks. Nowadays 
dioxins are focused as an objective to avoid because 
they are related to cancer. Good prevention remains, however, 
a better solution than the best cures. The danger with dioxins lies in 
the fact that even slight exposure can result in cancers, if this exposure is 
regular. The DIOFUR project originated with the intention to study and introduce 

new measures aimed at reducing the level of dioxins produced in ferrous foundries.

Dioxins are toxic organic chemicals, produced principally as a 
result of human activity, such as waste incineration, pesticide 
production or even cigarette smoke and car exhausts. Dioxins 
are  deposited  on  land  and  water,  where  they  can  remain  for 
exceedingly long periods of time. Animals accumulate dioxins 
through  exposure  or  consumption  of  contaminated  food. 
Through each link of the food chain, the concentration levels of 
these toxic chemicals increase, and consequently the risk to the 
final consumers — frequently humans — likewise increases.

Despite the fact that the foundry sector is not the main dioxin 
producer, as many other industries, also some foundries emit 
dioxin  levels  above  the  legally  authorised  values  (as  set  by 
the  Incineration  Directive,  2000/76/EC,  concerning  integrated 
pollution  prevention  and  control).  Furthermore,  the  European 
Integrated Pollution Prevention and Control Bureau (EIPPCB, in 
Seville),  has  emphasised  the  need  for  a  better  understanding 
of the contribution of the process parameters to the formation 
of dioxins. This requires the monitoring of dioxin emissions for 
various installations and under varying conditions. Because of 
that need of measurements results in addition to the fact that 
rotary  furnaces,  electric  arc  furnaces  and  cupolas  are  a  good 
representation of the European furnaces and that they have the 
highest emissions, DIOFUR project team has focused its work to 
the measurement in these furnaces.

Trying to avoid a worst-case scenario
Dioxins  could  be  a  by-product  of  ferrous  foundries.  They 
originate  in  the  metal-melting  process,  while  burning  coal, 
coke and fuel oils, which can contain chloride ions and organic 
carbon. The presence of oxygen and of catalysts such as copper 
are also factors inducing dioxin formation. When the elements 
mentioned  above  are  placed  together,  and  exposed  with  a 
sufficient residence time to temperatures ranging from 250 to 
450 °C, the conditions for dioxin emissions are possible.

The  DIOFUR  project  team  follows  a  two-step  approach  in 
reducing  dioxin  emissions  below  an  acceptable  toxicity  level. 
Indeed, due to the very nature of the process, one single step 
would be insufficient.

Specifically,  the  first  step  is  the  optimisation  of  process 
parameters, in order to avoid the dioxin formation conditions. 

For example, during melting processes, when the temperatures 
in  the  furnace  reach  850  °C,  dioxins  are  destroyed;  however, 
when the temperature drops to between 250 and 450 °C, in the 
cooling phase, new dioxins can be formed. 

A  second  step  is  necessary  in  order  to  achieve  the  required 
emission reduction. Modified end-of-pipe techniques, such as 
carbon activated and sorbent injection, will be used to capture 
or retain the dioxins after the cooling phase. Adapting existing 
foundries to include these measures should be both simple and 
affordable for most SMEs.

One small giant step for foundries
DIOFUR  aims  at  a  sector-wide  reduction  in  dioxin  emissions. 
There  are  approximately  800  furnaces  in  European  foundry 
SMEs,  representing  80%  of  the  companies  in  the  sector.  The 
project builds on the experience and knowledge of its members, 
who are experts in iron and steel foundries, environmental and 
foundry researchers, and equipment manufacturers.

are 

those 

The  16  partners  concerned  will  contribute  with  the  creation 
of  a  ‘good  practice  book’  to  widely  disseminate  best  practice 
guidelines  to  as  many  foundries  as  possible.  This  approach 
will  raise  awareness  of  this  vital  issue;  it  will  also  contribute 
to reducing the cancer risk for workers and, to a wider extent, 
for  the  population  in  general. 
Foundry 
workers 
predominantly 
at risk of exposure; 
any 
in 
represents  an 
improvement 
health 
of 
and 
safety 
s t a n d a r d s 
work. 
at 

emissions 

reduction 

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4/16/07   12:27:08 PM

 
 
 
 
 
 
 
 
 
 
 
the 

areas 
Moreover, 
foundries 
neighbouring 
also  benefit  from  the  reduction  in  dioxin 
production, as fewer particles representing a potential 
risk will be dispersed in the atmosphere.

will 

DIOFUR  will  have  a  positive  impact  on  public  health,  hard-
working in its own sector by eliminating the carcinogenic dioxins 
produced in foundry processes.

Collective Research Volume 3

“The areas neighbouring foundries will also 
benefit from the reduction in dioxin 
production, as fewer particles 
representing a potential risk will be 
dispersed in the atmosphere.”

Project title
Dioxins in cupolas, rotary and electric arc furnaces — 
emissions free melting practices in foundries (DIOFUR)

Contract number
30298-2

Duration
30 months

Global project costs
€2 878 936

EC contribution
€1 606 067

Contact Person
Antton Meléndez
Casting Technologies
Fundación Inasmet-Tecnalia
Mikeletegi Pasealekua, 2
20009 San Sebastián
Spain
Tel. (+34) 943633065
Fax: (+34) 943627727
Email: antton.melendez@inasmet.es 
Web: www.inasmet.es 

Participants
1. Fundación Inasmet (ES)
2. Centre Technique des Industries de la Fonderie (FR)
3. Istytut Odlewnictwa (PL)
4. Vlaamse Instelling vdoor Technologisch Onderzoek (BE)
5. Asociación de Fundidores del País Vasco y Navarra (ES)
6. Odlewnicza izba Gospodarcza (PL)
7. Deutscher Giebereiverband (DE)
8. Européenne SEA (FR)
9. Fiday Gestion (FR)
10. Zaklady Metalurgiczne Pomet SA (PL)
11. Guivisa S.L. (ES)
12. Fundiciones Infiesta S.A. (ES)
13. Fundiciones Fumbarri S.C.L. (ES)
14. Sider Progetti S.N.C. (IT)
15. NV Typhoon (BE)
16. NV Desotec Activated Carbon (BE)

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4/16/07   12:27:17 PM

 
 
 
 
 
 
 
 
 
 
 
THE ROAD TO STANDARDISED WINDOW 
PRODUCTION
“Individual designs will be made much easier, and 
SMEs will maintain their ability to satisfy their 
customers.”

The  European  labels  of  conformity, 
known  as  CE  markings,  are  a  guarantee  of 
quality and safety for goods produced and sold in the 
EU.  One  of  the  most  recent  CE-conformity  standards,  code-
named EN 14351-1, relates to window manufacturing; it stipulates that 
all window models put on sale, will have undergone a series of performance 
tests, within the next three years. However, some window-producing SMEs might 
struggle to cope with the new requirements, for financial reasons — and Ecwins may 
provide  these  companies  with  support  in  this  process,  through  the  development  of  new 

ECWINS

Life after Ecwins
The  project  has  intends  to  utilise  the  expertise  of  28  IAG, 
SMEs and RTD performers from 8 countries. The new software 
development will constitute a major task for the project team, 
which  will  dedicate  two  years  to  compiling  information  and 
testing the new models in real-life situations. The dissemination 
of project results and the organising of workshops and training 
for SMEs will require another year. The IAGs in the consortium 
also expect to set up a joint venture for managing the assessment 
tools and the derived intellectual property rights.

The impact of Ecwins will be felt long after the actual project’s 
completion,  with  enduring  effects  on  the  competitiveness 
and  sustainability  of  SMEs,  the  main  participants  in  window 
manufacturing  in  Europe.  The  window  producers  will  be 
simultaneously be able to reduce their costs and diversify their 
employment offers. 

Conversely,  customers  will  have  greater  choice  in  selecting 
windows that best suit their tastes, combined with confidence 
in the quality of their goods, wherever they shop.

tools.

The  conformity  standard  EN  14351-1,  requires  tests  ensuring 
that all windows and front doors produced in Europe have an 
adequate  and  uniform  level  of  comfort  and  safety.  However, 
these tests entail additional costs; small companies with limited 
resources  may  not  viably  be  able  to  withstand  such  expense. 
In  order  for  SMEs  to  avoid  the  financial  difficulties  stemming 
from  these  additional  costs  and  also  to  avoid  competitive 
disadvantages,  new  design  tools  are  needed.  Creating  a 
European CE-based assessment tool for flexible and innovative 
window systems is an ambitious goal for ECWINS.

Design made easy
ECWINS  proposes  to  develop  new  software  comprising 
two  prediction  models.  The  first,  an  elaboration  of  a  ‘CE-
Assessment-Model’  is  the  major  objective  of  the  project,  and 
it aims at simplifying the production of windows and avoiding 
the  need  for  full-size  testing.  This  model,  constructed  from  a 
database of all window profiles, designs and materials, informs 
users  whether  their  intended  products  are  compliant  with  CE 
requirements. The production of individual designs will be much 
easier, and SMEs will be able to maintain customer satisfaction, 
while simultaneously respecting international standards.

The  second  prediction  tool  will  be  designed  with  another 
objective.  Taking  into  account  particular  national  legislations 
and specific design traditions, the ‘European Window Interface 
Model’ simplifies a design of windows that can easily be applied 
to  buildings  in  different  countries.  Based  on  a  collection  of 
national  characteristics,  this  model  will  predict  if  a  window 
complies with specific legislations and building traditions of a 
country,  other  than  those  of  the  manufacturer.  This  flexibility 
in  adapting  products  to  other  regulations  may  expand  small 
companies, by creating new export market opportunities.

The possibility of using these two models (inserted in a unique 
software  package),  will  revolutionise  the  way  windows  are 
currently  designed.  Instead  of  building  costly  prototypes 
and  individually  testing  each  one  against  EU  and  national 
requirements,  the  manufacturer  can  concurrently  design,  test 
and  evaluate  the  qualities  and  defaults  of  a  virtual  window 
against its qualities and defaults.

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Collective Research Volume 3

“The impact of ECWINS will last far beyond 
the duration of the project, with enduring 
effects on the competitiveness and 
sustainability of the main actors 
of window manufacturing in 
Europe: SMEs.”

Contact Person
Helmut Haybach
Association of Wood joinery / Northrhine-Westfalia
Johannes-Schuchen-Str. 4
32657 Lemgo
Germany
Tel. (+49) 5261 9214-13
Fax (+49) 5261 9214-10
Email: Haybach@ECWINS.eu 

Project website
www.ecwins.eu 

Participants
1. Confederatie Bouw Vlaamse Schrijnwerkers (BE)
2. Normapme a.i.s.b.l. (BE)
3. European Builder Confederation (BE)
4. Confederation of Finnish Construction Industries (FI)
5. Confédération de l’Artisanat et des Petites Entreprises du 
Bâtiment (FR)
6. Fachverband des Tischlerhandwerks NRW (DE)
7. Országos Asztalos és Faipari Szövetség (HU)
8. Federazione Italiana delle Industrie del Legno, del sughero, 
del mobile e dell’Arredamento - Federlegno/Arredo (IT)
9. Latvijas Logu un Durvju Razotaju Asociacija (LV)
10. British Woodworking Federation (UK)
11. Valtion Teknillinen Tutkimuskeskus (FI)
12. University of West Hungary (HU)
13. Consiglio Nazionale delle Ricerche (IT)
14. Delft University of Technology (NL)
15. Netherlands Organisation for Applied Scientific Research (NL)
16. Domus Yhtiöt oy (FI)
17. Skaala Ikkunat ja ovet oy (FI)
18. Criaud (FR)
19. Eurl Desmedt (FR)
20. Kolb GmbH (DE)
21. Wigger Fenster + Fassaden GmbH & Co.KG (DE)
22. Helmut Damwerth GmbH & Co.KG (DE)
23. Theo Thesing GmbH (DE)
24. Széplaki Faipari Kft. (HU)
25. Holz Team Kft. (HU)
26. Nelss Logi SIA (LV)
27. Flora SIA (LV)
28. Boyland Joinery Ltd. (UK)

Project title
A European CE-based assessment tool for flexible and 
innovative window systems (ECWINS)

Contract number
30490

Duration
36 months

Global project costs
€3 344 532

EC contribution
€2 230 838

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4/16/07   12:27:28 PM

 
 
 
 
 
 
 
 
 
 
 
INJECTING NEW LIFE INTO PLASTIC 
MOULDING
“Emold participants intend to radically redefine 
the plastic injection process by introducing 
mechatronics into the moulding cycle.”

The  variety  of  plastic  materials, 
specifications  and  applications  ensures  the 
viability of a range of different production techniques. 
Among those, plastic injection is one of the most commonly 
used and applies to the manufacturing of thermoplastic elements of all 
sizes, from small parts to entire car body panels. In the global marketplace, 
European SMEs involved in plastic injection are facing ever increasing challenges 
from their international rivals. To boost their competitiveness, European SMEs need 
newer and more efficient processes. Emold aims at following a total life cycle approach (from 
mould design to plastic production) to develop new ‘intelligent’ and ‘interoperable’ moulds, able 

EMOLD

to adapt in real time to the different demands of both customers and producers.

European plastic producers are at the cutting-edge of moulding 
technologies; however, cost and time effectiveness can further 
be improved. Emold participants intend to radically redefine the 
plastic injection process by introducing mechatronics into the 
moulding cycle. The challenge faced  by the  project  team  is  to 
create active and intelligent moulds that can be networked and 
that embed knowledge of different process parameters.

Parting away from tradition
The process of injection moulding was created in the middle of 
the  19th  century.  The  technology  used  nowadays  was,  for  its 
part,  introduced  in  1946  and  the  screw  injection  system,  via 
which plastic is heated, mixed and injected into a mould, has 
been maintained ever since.

In  injection  moulding,  molten  plastic  is  introduced  at  high 
pressure into a mould. The mould is a block of metal (steel or 
aluminium) hollowed-out to allow for the plastic to take shape. 
Once  the  molten  plastic  cools  down,  it  can  be  removed  from 
the mould. Great care is taken to ensure the correct design and 
manufacture of moulds, which are expensive to produce and to 
modify, if necessary. 

intend 

to  make 

the  moulds 

Emold  participants 
‘more 
intelligent’ and able to adapt to changing circumstances. This 
will  be  achieved  by  introducing  mechatronics  in  the  moulds. 
Mechatronics is the combination of mechanics, electronics and 
software  engineering,  which  together  achieve  the  automation 
of  a  system.  In  practice,  the  new  generation  of  moulds  will 
include sensors and devices that will enable SMEs to monitor 
what is going on inside the mould in real time,. Depending on 
the situation, the characteristics of the mould can be adapted 
to modify the shape or other particulars of the injected plastic. 

The  next  step  for  Emold  will  be  to  integrate  the  mechatronics 
moulds  into  networks.  A  centralised  system,  at  the  heart  of 
which lies a server, will receive information from all the linked 
moulds,  even  if  they  are  thousands  of  kilometres  apart.  The 
Emold system sends information to mould-makers and injection 
moulders,  in  order  for  them  to  follow  the  process  and  make 
adjustments, if needed.

In time, this network will become a Knowledge-Based System 
(KBS),  that  will  pool  and  process  the  knowledge  embedded 

in  the  intelligent  moulds.  The  objective  of  this  information 
gathering  is  to  optimise  the  efficiency  of  processes  and  the 
design of future moulds.

Benefits of the new working model
The  strength  of  39  000  European  plastic  companies  (of 
which  85%  are  SMEs)  lies  in  the  top-end  technology  used. 
Nonetheless, in terms of injection moulding, processes can still 
be optimised to improve production by up to 25% and to reduce 
the final cost of parts.

By developing an intelligent network, Emold aims at reducing the 
number of faulty batches of products, by offering the possibility 
to modify the configuration of moulds to correct imperfections. 
The  development  of  new  moulds  is  expected  to  reduce  by  up 
to  30%  the  time  required  for  the  set-up  phase  of  production. 
The  moulds  themselves  are  manufactured  with  recycling  as  a 
key element: Emold participants are studying the possibility of 
re-using  mould  components  —  whereas  currently,  moulds  are 
discarded or melted away once their life-cycle ends.

Emold  introduces  a  new  concept  of  injection  moulding, 
placing  the  emphasis  on  intelligent  mechatronic  moulds.  The 
networking of these central elements of plastic manufacturing 
will enable all industrial actors to monitor moulding processes 
in  real  time  and  to  constantly  improve 
their  efficiency.  SMEs  and 
the  plastic  industry  in 
general  will  draw 
benefits 
Emold, 
consumers  will, 
p o t e n t i a l l y , 
better 
enjoy 
q u a l
i t y 
p r o d u c t s , 
available 
at 
lower costs.

from 
but 

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4/16/07   12:27:30 PM

 
 
 
 
 
 
 
 
 
 
 
Collective Research Volume 3

“The strength of 39 000 European plastic 
companies (of which 85% are SMEs) resides 
in the top-end technology used.”

Project title
Total life cycle approach for efficient and networking plastic 
injection moulding processes (EMOLD)

Contract number
30339

Duration
36 months

Global project costs
€3 727 418

EC contribution
€2 222 214

Contact Person
Alex Sancho
Fundació ASCAMM
Av. Universitat Autonoma, 23
08290 Cerdanyola del Valles
Spain
Tel. (+34) 935944700
Fax: (+34) 936929360
Email: alex@ascamm.com 

Project website
www.emold.eu 

Participants
1. Fundació ASCAMM (ES)
2. Federación Española de Asociaciones empresariales de 
Moldes y Matrices FEAMM (ES)
3. Gauge and Tool Makers Association (UK)
4. Vlams Kunststof Centrum (BE)
5. Eleda Cumsa (ES)
6. Plastia (ES)
7. MDE B.V. (NL)
8. Haidlmair GmbH (AT)
9. Sprint Tool & Die Ltd (UK)
10. Tecos (SI)
11. Elastopoli oy (FI)
12. FOS Messtechnik GmbH (DE)
13. Fundación Fatronik (ES)
14. TNO Science and Industry (NL)
15. Smithers Rapra Technology Ltd (UK) 
16. European Plastics Converters (BE) 
17.Razvojni Centre (SI) 
18. Podjetje ZA (SI)

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4/16/07   12:27:32 PM

 
 
 
 
 
 
 
 
 
 
 
PUSHING THE BOUNDARIES
OF MAINTENANCE
“New possibilities open up to such SMEs thanks to 
the increased affordability of mobile wireless 
devices with broadband access to the 
Internet.”

Field  Service 

(FSEs) 
represent a so-called ‘mobile workforce’: they 
spend most of their working day out of the office, on-
site.  Many  FSEs  are  employed  by  maintenance  and  repair 
companies,  of  which  many  have  a  limited  size:  currently,  more 
than  15  000  maintenance SMEs  operate  in  Europe.  It  is  crucial  for  these 
smaller businesses to have access to the most effective information tools. This is 
necessary to ensure that their FSEs are well prepared and able to provide the highest 
possible  service  quality  to  the  customers.  The  E-SUPPORT  initiative  has  been  set  up  to 

Engineers 

E-Support

develop a technical solution that will bring an unprecedented flexibility to this business area.

of Adaptive Learning and AI-based knowledge sharing features 
will clearly give E-SUPPORT the edge over current systems. 

A perfect match
The E-SUPPORT project will lead to a commercial product targeted 
and adaptable to any SME that has specific maintenance needs. 
E-SUPPORT’s  Multi  Agent  architecture  will  ease  future  system 
enhancement through reusable and structured learning objects, 
profile-based  itineraries,  and  agent-based  profile  matching. 
This technology is ideally suited for knowledge sharing in the 
maintenance industry, particularly for field engineers roaming 
around the world with wireless access to the system. In short, 
the perfect virtual assistant for Field Service Engineers is about 
to be born.

European maintenance associations and SMEs have expressed 
a  need  to  provide  their  FSEs  with  an  affordable,  flexible  and 
easy to use system to get on-site, remote and timely access to 
accurate technical data. Current systems are still insufficient in 
terms of data retrieval and/or management. Moreover, they are 
quite bulky and therefore impractical in field situations or where 
hands-free  operation  is  required.  The  mobile  nature  of  FSEs’ 
work furthermore requires e-learning platforms that would allow 
maintenance SMEs to rapidly and remotely train their FSEs on 
new or modified machinery, parts, etc. New possibilities open 
up to such SMEs thanks to the increased affordability of mobile 
wireless devices with broadband access to the Internet.

Anywhere, anytime
Only large companies have access to costly tools and elaborate 
information  systems,  far  beyond  the  scope  of  SMEs.  Taking 
up  this  challenge,  the  E-SUPPORT  project  is  developing  novel 
intelligent  agent-based  technology  to  deliver  two  systems 
specifically adapted to the business needs of SMEs. These two 
systems rely on a web-based application accessible via mobile 
devices.  The  first  one,  ‘FSE-assistant’,  will  support  corporate 
knowledge  management  and  deployment  with  utility  tools 
like  PDF  documents,  CAD  files,  emails,  Word  documents  and 
training  videos.  The  second  one,  an  open  e-learning  system 
named  ‘FSE-master’,  will  integrate  processes,  templates  and 
web-based  tools  to  create  a  flexible  and  adaptable  training 
program.  Both  systems  will  be  easy  to  operate,  maintain  and 
configure. On top of that, they will be low cost.

There is a growing focus on the customer, on added value and 
effective service in business today. This has an important impact 
on the competitiveness of thousands of European SMEs involved 
in  maintenance  and  repair  of  industrial  plants,  machinery  or 
buildings.  These  SMEs  have  to  rely  even  more  on  the  quality 
and  reliability  of  the  on-site  service  delivered  by  their  FSEs. 
Like their larger competitors, SMEs are seeking ways to equip 
their FSEs to become more productive by providing them quick 
access to user manuals, technical drawings, etc. while on site. 
The  novelty  of  E-SUPPORT  will  be  to  overcome  the  limitations 
identified  in  existing  Computer  Maintenance  Management 
Systems:  support  of  real  mobility  on  the  field  (access  from 
smartphones,  PDAs  and  laptops),  use  of  document  retrieval 
techniques based on Artificial Intelligence (AI), implementation 

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4/16/07   12:27:35 PM

 
 
 
 
 
 
 
 
 
 
 
Collective Research Volume 3

“The novelty of E-SUPPORT will be to overcome 
the limitations identified in existing 
Computer Maintenance Management 
Systems.”

Contact Person
Felip Miralles
Project Manager & Research Engineer
Centre de Recerca i Investigació de Catalunya (CRIC)
Travessera de Gràcia, 108
08012 Barcelona
Spain
Tel. (+34) 93 204 99 22
Fax: (+34) 93 204 98 66
Email: felip.miralles@cric.cat 
Website: www.cric.cat

Participants
1. Norwegian Federation of Food and Drink Industry (NO)
2. Feltalálói és Kutató Központ Kft (HU)
3. Comitato Nazionale Italiano per la Manutenzione (IT)
4. PIMEC, Micro, Petita i Mitjana Empresa de Catalunya (ES)
5. Slovenské centrum produktivity (SK)
6. Nederlandse Vereniging voor Doelmatig Onderhoud (NL)
7. Asociatia Generala a Inginerilor din Romania (RO)
8. Airat, SA (ES)
9. Merusa mantenimiento y servicios, S.A. (ES)
10. Zanziservizi S.p.A. (IT)
11. Combustibili Nuova Prenestina Srl. (IT)
12. BASS, s.r.o. (SK)
13. Traduco Asset Management bv (NL)
14. Theia Tecnologies, SL (ES)
15. I+ S.r.l. (IT)
16. Kern International NV (BE)
17. Tekever, s.a. (PT)
18. Electronic Systems Design Ltd (MT)
19. GAMO a.s. (SK)
20. SIMPPLE SL (ES)
21. D’Appolonia S.p.A. (IT)
22. Malta Industrial Innovation for SMEs (MT)
23. Centre de Recerca i Investigació de Catalunya, S (ES)

Project title
A knowledge transfer and on-site information agent driven 
access system for SME field service engineers (E-Support).  

Contract number
30386

Duration
36 months

Global project costs
€3 056 943 

EC contribution
€1 784 157 

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4/16/07   12:27:41 PM

 
 
 
 
 
 
 
 
 
 
 
FILTERING TOXIC SPENT 
METALWORKING FLUIDS
“The goal of this project is to … develop a 
technique which can effectively treat 
complex spent metalworking fluids 
(MWFs).”

FILTER

companies 

Engineering 

an 
essential pillar of the EU economy, since they 
are  represented  by  nearly  375  000  companies  and 
20  million  workers.  Like  many  other  sectors,  engineering 
specialists  face  tough  competition  from  Far-East  countries  where 
labour  costs  are  very  low.  In  addition,  ever-tightening  EU  legislation  on 
waste  disposal  is  another  factor  that  has  contributed  to  20%  of  engineering 
workshops  going  out  of  business  in  the  past  5  years. The  Filter  project  proposes  to 
introduce a solution for the disposal of toxic spent metalworking liquids, and to reduce the 

are 

associated disposal costs.

Filter  aims  to  create  new  recycling  opportunities  for  spent 
metalworking fluids (MWFs), to replace the current practice of 
discharging  them  into  sewers.  Each  year,  four  billion  litres  of 
MWFs are disposed of in the EU. The goal of this project is to 
reduce this quantity by 50% by the development of a two-stage 
treatment system and new recycling opportunities.

New solutions for a recurrent problem
Engineering companies use MWFs during machining processes 
for lubrication and cooling purposes. Due to the very nature and 
application of these fluids, they can only be used for a limited 
period of time — this is generally confined to 1 year.

The  Filter  consortium  comprises  13  institutions,  inclusive  of 
IAGs, SMEs and RTD performers. Representing the interests of 
the whole engineering sector, the project team is developing a 
new disposal technique, based on a two-stage approach. 

The first stage aims to enhance separation membranes, in order 
to  separate  water  from  various  components  of  spent  MWFs 
(bacteria,  mineral  oil,  metal  parts,  etc).  The  second  phase 
includes  a  ceramic  photo-catalytic  oxidation  process,  which 
will polish up the recovered water.

Washing away external competition
The Filter team has divided the work among its members, so as 
to achieve the best possible results and ensure that its findings 
are  shared  with  the  other  industry  participants.  For  instance, 
RTD  performers  draw  on  their  knowledge  to  help  SMEs  build 
the disposal technology. Likewise, at the end of the chain, IAGs 
promote the technology and train future users in the engineering 
sector.

Initially,  the  objective  is  that  the  Filter  product  assumes  a 
moderate  market  penetration  of  only  2%.  Although  this  may 
appear  modest  in  terms  of  percentage,  the  market  share 
translates into EUR 32 million of disposal cost savings. If more 
SMEs — who account for 90% of the companies in engineering 
—  adopt  Filter,  many  more  millions  can  be  saved.  These 
economies will have long-lasting effects. For instance, industry 
competitiveness could be improved, and the pressure from low 
labour and production cost countries will be more lightly felt. 

It is significant that the Filter technology will also have a positive 
impact on the environment, in enabling engineering companies 
to comply with EU legislation on pollution and waste disposal.

Facing  up  to  the  challenge  of  improving  the  competitiveness 
of  European  engineering  SMEs,  Filter  proposes  a  novel  way 
to  address  an  environmental  problem  with  few  or  no  current 
solutions.  In  creating  a  new  recycling 
process,  Filter  will  certainly 
boost 
sector,  and  improve 
its 
position.

the  engineering 

financial 

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Collective Research Volume 3

“… the Filter technology will also have a positive 
impact on the environment.”

Project title
A total metalworking fluid disposal technology (FILTER)

Contract number
30364

Duration
36 months

Global project costs
€2 038 153

EC contribution
€1 153 651

Contact Person
Gary Booton
Engineering Employers Federation
Broadway House
Tothill Street
London
SW1H 9HQ
United Kingdom
Email: GBooton@eef-fed.org.uk

Participants
1. Irish Engineering Enterprise Federation (IE)
2. Engineers Employers Federation (UK)
3. Federation of Estonian Engineering Industry (EE)
4. Lenntech Water Treatment & Air Purification Holding BV (NL)
5. Scientific-Lab. Glass AB (SE)
6. Bayer-Wood Technologies Ltd (UK)
7. Aceites Lubricantes Sash SL (ES)
8. Johnson and Allen Ltd (UK)
9. Notech AS (NO)
10. Talleres Ruiz Sociedad Anónima (ES)
11. Adrem Parnu AS (EE)
12. Pera Innovation Limited (UK)
13. Teknologisk Institutt AS (NO)

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4/16/07   12:27:51 PM

 
 
 
 
 
 
 
 
 
 
 
MORE FLEXIBILITY FOR METAL FORMED 
COMPONENTS
“For Flexform participants, the solution for the 
future of special vehicle manufacturers is 
‘dieless’ Incremental Sheet Forming.”

unique  production  processes  due  to 

The  special  vehicle  sector  requires 
its 
specific technical challenges that cannot be dealt with 
using  mainstream  manufacturing  methods. Special  vehicles 
are mainly hand-made on a small-scale production based on craft 
skills, but the Flexform project aims at encouraging a shift towards a less 
resource-dependent  manufacturing  process.  To  support  the  move  towards  a 
more efficient, reliable and profitable technique, the project team aims to improve the 
knowledge of an emerging technology for sheet metal shaping: Incremental Sheet Forming. 

FLEXFORM

Flexform 
is  a  consortium  pooling  the  competence  and 
experience  of  19  participants,  among  which  are  SMEs,  IAGs 
and RTD performers in the fields of special vehicle production 
and  metal  technologies.  The  participants  will  encourage  the 
adoption of ‘dieless’ Incremental Sheet Forming by the industry 
and develop software tools to facilitate the change in production 
methods.

To support the adoption of ISF technology, Flexform participants 
will design a computer assisted engineering and manufacturing 
(CAEM)  algorithm  to  allow  for  the  easier  design  of  parts.  The 
input  of  all  consortium  participants  will  be  crucial  to  gain  a 
better understanding of the requirements of the industry, which 
will determine the rules and procedures that are to be used in 
ISF development. 

ISF will result in cost reductions in product manufacturing and 
in tooling needs. In terms of time economy, the Flexform team 
expects reductions of up to 60% in product development time 
and 50% as far as manufacture is concerned. Although Flexform 
focuses on special vehicles, the ISF technology could also have 
significant applications in other industries, such as aerospace, 
naval and railway construction and even furniture and medical 
device manufacturing.

Moving  away  from  a  manual  manufacturing  process  towards 
an  automated  and  computer  assisted  process  will  be  the  key 
for  the  continued  success  of  special  vehicle  producers.  The 
competitiveness  of  these  producers  will  be  reinforced,  with 
the more effective production of vehicles corresponding to the 
diverse demands of customers.

Special market niches
‘Special vehicles’ are limited production cars with less than 2 
000 units produced yearly. Examples of special vehicles include 
ambulances,  funeral  cars,  buses,  coaches,  military  vehicles, 
cleaning vehicles, sports cars and cars for disabled people. In 
Europe, nearly 120 000 special vehicles of all types are produced 
yearly. There are 2 500 European SMEs involved in this sector, 
with a business volume of EUR 4 billion and approximately 75 
000 employment positions. 

Currently, the demand for special cars is on the increase, and 
production  difficulties  have  arisen.  Indeed,  hand-made  craft 
production has high costs because it is very specific. Producers 
find  it  difficult  to  respond  to  escalating  and  fluctuating 
customer demands while at the same time managing complex 
supply chains. The competitiveness of EU SMEs in this sector is 
dependent on their ability to adopt an innovative, more flexible 
and automated high-value production method.

The new method will reduce manufacturing time and be more 
effective and reliable. As a result, the profitability for SMEs will 
increase:  faster  production  means  more  production  capacity, 
hence,  more  profits.  For  Flexform  participants,  the  solution 
for  the  future  of  special  vehicle  manufacturers  is  ‘dieless’ 
Incremental Sheet Forming.

Challenging production solutions
‘Dieless’  Incremental  Sheet  Forming  (ISF)  is  a  technique  used 
to  shape  sheet  metal  components,  based  on  an  incremental 
process  of  small  successive  deformations  and  on  rapid 
manufacturing  techniques.  These  techniques  are  normally  used 
for producing complex shapes in steel and aluminium. One of the 
particularities of ISF is that it allows for the production of parts that 
are not symmetrical.

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4/16/07   12:28:00 PM

 
 
 
 
 
 
 
 
 
 
 
Collective Research Volume 3

“Although Flexform focuses on special vehicles, 
the ISF technology could also have significant 
applications in other industries.”

Contact Person
Project Co-ordinator: Felip Esteve
Asociación Española de Rapid Manufacturing (ASERM)
Av. Universitat Autónoma 23
08290 Cerdanyola
Spain
Email: rd-projects@aserm.net 

Technical Co-ordinator: Benjamin Cavallini
ASCAMM Technology Centre
Parc Tecnologic del Valles
08290 Cerdanyola del Valles
Spain
Email: bcavallini@ascamm.com

Project website
www.flexform.org

Participants
1. ASERM - Asociación Española de Rapid Manufacturing (ES)
2. Sernauto - Asociación Española de Fabricantes de Equipos y 
Componentes para Automoción (ES)
3. GTMA - Gauge and Toolmakers Association (UK)
4. FOSTA - Forschungsvereinigung Stahlanwendung e.V. (DE)
5. TECOS - Slovenian tool and die development centre (SI)
6. AIMME - Asociación de Investigación de la Industria 
Metalmecánica, afines y conexas (ES)
7. CETIM - Centre Technique des Industries Mécaniques (FR)
8. Planchisteria Bergadana, S.L. (ES)
9. Ecoroll AG Werkzeugtechnik (DE)
10. Société de Recherches et Réalisations Automóviles (FR)
11. EDEATECH - Engenharia e Tecnologia, S.A. (PT)
12. Quantech ATZ (ES)
13. FormTech GmbH (DE)
14. Industrias Puigjaner S.A. (ES)
15. Drescher Karosseriebau GMBH (DE)
16. Fundació ASCAMM (ES)
17. RWTH-IBF - Institut für Bildsame Formgebung, Rheinisch-
Westfälische Technische Hochschule Aachen (DE)
18. CIMNE - Centre Internacional de Métodos Numéricos en 
Enginyeria (ES)
19. GIP Institut Supérieur d’Ingénierie de la Conception (FR)

Project title
Development of a new flexible manufacturing process for 
low series production of metal parts for custom and special 
vehicles (FLEXFORM)

Contract number
30273

Duration
36 months

Global project costs
€3 288 472

EC contribution
€2 176 908

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4/16/07   12:28:05 PM

 
 
 
 
 
 
 
 
 
 
 
HOME SWEET NETWORKED HOME

Flexonline@home

“Until now … PLC has not been adopted as a 
mainstream solution, mainly because of 
electro-magnetic (EM) problems.”

electronic 

Computers, 

gadgets 
and  anything  automated  have  become 
indispensable  companions  for  many  people;  but 
have  we  become  dependant  on  technology,  or  can  we  still 
use it to our benefit? Is technology useful and does it improve our 
quality of life? The members of the Flexonline@home consortium believe 
that  technology  can  indeed  improve  our  lives,  for  example  by  allowing  us  to 
communicate  more  easily. To  this  end,  the  team  is  developing  a  new  power  supply 
system, which will make home networking affordable for a large proportion of EU citizens. 
At the same time, the project will enable European SMEs to overcome the skilled labour shortage 

Building on the network knowledge
Flexonline@home  is  not  just  a  project  aimed  at  developing  a 
product  and  making  profit  out  of  it  —  although  the  resulting 
power  supply  will  find  its  way  into  the  market  in  the  months 
following  completion  of  the  project.  In  fact,  the  project  goes 
beyond that: for the team, it is crucial to spread the findings of 
the research to electricity, IT and building SMEs. 

The  project  findings  will  be  published  in  journals  and  at 
conferences.  The  knowledge  created  will  be  protected  by 
patents,  but  the  emphasis  will  be  placed  in  training  and 
transferring  knowledge  to  professionals.  This  stage  of  the 
project is of vital importance to solve the skilled labour crisis 
hitting the electricity sector.

Technology  is  generally  used  to  solve  the  problems  and 
difficulties  people  face 
lives.  Flexonline@home, 
in  their 
however, goes further and kills two birds with a stone, solving 
two problems with a single solution. By developing a new PLC 
power supply, the project paves the way for home networking 
for the general public, while at the same time overcoming the 
skilled labour shortages hampering the EU electricity sector.

affecting the electricity sector.

Flexonline@home  gathers  the  skills  of  10  RTD  performers, 
IAGs  and  SMEs,  specialising  in  electronic  components  and 
systems.  The  aim  of  the  project  is  to  develop  a  cost  efficient, 
reusable  and  innovative  power  supply  system  that  will  allow 
for the generalisation of Power Line Communication (PLC). The 
PLC idea is to use the power supply cables as a communication 
network. In practice, Internet, telephone and television can be 
transmitted via electrical cables normally used to convey power. 
Until now, however, PLC has not been adopted as a mainstream 
solution, mainly because of electro-magnetic (EM) problems. 

The use of PLC in houses can drastically reduce the time needed 
for  wiring  and  the  costs  of  cabling  installations.  A  significant 
cabling  price  reduction  could  lead  to  a  reduction  in  the  price 
of  new  houses  and,  at  the  same  time,  enable  more  people  to 
improve their houses with home networking capabilities. In the 
information era, enabling people to connect to the wider world 
can add to their quality of life.

Automation for the people
Despite  the prospects  for PLC in terms  of home networking  and 
automation,  the  technology  needs  to  be  further  developed. 
The  project  team  aims  at  improving  the  knowledge  of  factors 
influencing high-speed PLC in planar copper conductors, such as 
the  choice  of  materials,  the  distance  of  transmission  and  radio 
frequency radiations. This understanding of different factors will 
allow Flexonline@home participants to create a novel arrangement 
of copper conductors and insulators, as well as a differential mode 
transmission to reduce EM interference and electronic smog. 

The  project  participants  also  aim  at  improving  the  network 
bit  rate  capacity  and  transmission  by  protecting  it  from 
external  interference,  such  as  radio  signals.  If  successful, 
the  performance  enhancement  will  exceed  all  current  and 
foreseeable state-of-the-art solutions.

Although the Flexonline@home research is being conducted to 
improve the use of PLC in newly built or renovated houses — for 
example,  to  enable  the  installation  of  automation  systems  to 
assist elderly people living alone — further applications can be 
found in offices, scientific laboratories and hospitals. 

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Collective Research Volume 3

“The performance enhancement will exceed all 
current and foreseeable state-of-the-art 
solutions.”

Project title
Development of a cost efficient, innovative, reusable, 
integrated power supply system, enabling interference free 
high speed power line based communication architecture for 
the affordable smart house.
(Flexonline@home)

Contact Person
John Tebbit
Construction Products Association
26 Store Street
WC1E 7BT London
United Kingdom
Email: jtebbit@constprod.org.uk 

Contract number
30313

Duration
36 months

Global project costs
€1 860 736 

EC contribution
€1 075 412

Participants
1. Construction Products Association (UK)
2. European Association of Electrical Contractors (BE)
3. TSE spol. S.r.o (CZ)
4. EC Systems Sp. z o.o (PL)
5.0 Mosaic Ventures Limited (UK)
6. SC IPA SA CIFATT (Romania)
7. Navtel Systems (FR)
8. Innowacja Polska sp. z o.o. (PL)
9. FlexPower Lighting System Limited (UK)
10. Centre de Recerca I Investigació de Catalunya, S.A. (ES)

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4/16/07   12:28:16 PM

 
 
 
 
 
 
 
 
 
 
 
A SMOOTH RIDE TOWARDS 
EURO-ECO-LABELS
“In comparison to mineral oils, bio-lubricants are 
much greener.”

IBIOLAB

Pollution 

global  warming 
and 
constitute  serious  threats  to  our  environment 
and  therefore  to  our  very  existence  as  well.  To  date, 
most  environment-sensitive  research  has  focused  on  the 
development of new fuels, and this ‘bio’ or ‘green’ effort is now also 
being oriented in the direction of other heavy polluters, such as lubricants. 
The  project  aims  to  support  SMEs  in  the  creation  of  new  bio-lubricants,  with 
increased performance levels and lower production costs, which will comply with the 

Euro-eco-label requirements.

The Euro-eco-labels, as established by EC Regulation 1980/2000, 
apply to a variety of products such as hydraulic oils, chainsaw 
oils, grease and de-moulding agents. These lubricants, mainly 
based on mineral oils, are used in the automotive industry and 
generally  for  transport  applications.  Surprisingly,  only  a  few 
products  have  been  awarded  those  quality  labels  as  of  yet. 
IBIOLAB  aims  to  significantly  increase  the  proportion  of  bio-
lubricants in the market (currently at just 2%), and to encourage 
SMEs to apply for Euro-eco-labels.

How good is green?
Mineral  oils  are  the  mainstream  lubrication  solution  for 
industries.  Their  high  availability  and  low  costs  ensure  their 
market  position,  but  even  so,  they  remain  high-risk  products 
with  a  negative  impact  on  the  environment;  water  and  soil 
contamination and CO2 emissions are examples of this effect. 
Bearing  in  mind  that  nearly  a  third  of  lubricants  finally  settle 
in the ecosystem, it is easy to understand how some countries 
have progressively grown more attached to bio-lubricants.

In comparison to mineral oils, bio-lubricants are much ‘greener’. 
Indeed, they are based on vegetables or re-used frying oils, and 
not on fossil fuels. The main disadvantages of green lubricants 
are the production costs and the lower performance levels, two 
aspects  that  IBIOLAB  aims  to  improve  through  an  enhanced 
understanding  and  optimising  of  the  existing  manufacturing 
processes.

(emulsions,  maleinisation) 

The  project  team  intends  to  develop  new  processes  and 
techniques 
the 
performance  of  lubricants.  Moreover,  researchers  plan  to  use 
new  vegetable  oils,  additives  and  even  frying  oils  to  reduce 
production costs. The evaluation of the results of this work will 
also  take  into  account  the  environmental  lifecycle  of  the  bio-
lubricants.

to  advance 

Pioneering innovation shared
The knowledge acquired by IBIOLAB will be beneficial to all SMEs 
involved in the lubricant production sector. The team of 4 IAG, 
12 SMEs and 6 RTD performers from 7 European countries will 
hold training sessions and organise communication campaigns. 
As  a  result,  the  knowledge  base  will  be  expanded,  and  the 
project consortium hopes to encourage further development of 
bio-lubricants. This communication is expected to provide and 
promote a better awareness of the criteria and benefits of Euro-
eco-labels, thus encouraging SMEs to apply for the labels.

The economic potential of a labelled product is not insignificant; 
it places the product above the competition. In the long term, 
the position of bio-lubricants could improve dramatically, in a 
market which, in 2001, saw a consumption of nearly 5 million 
tons of lubricants in Europe alone.

IBIOLAB targets the labelling of at least one generic bio-lubricant 
for  each  of  the  applications  indicated  in  the  Euro-eco-label 
regulation: two-stroke oil, grease application, hydraulic fluids, 
chainsaw  oils  and  concrete  release  agents.  These  products 
will  showcase  the  inherent  properties  of  bio-lubricants,  and 
highlight their readiness to replace mineral oils.

Provided  that  the  ambitious  project  objectives  are  achieved, 
IBIOLAB  will  play  a  key  role  in  surpassing  the  cost  and 
performance 
restricting  the  penetration  of 
bio-lubricants 
market.

into  the 

currently 

barriers 

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Collective Research Volume 3

“IBIOLAB targets the labelling of at least one 
generic bio-lubricant for each of the 
applications indicated in the Euro-eco-
label regulation.”

Contact Person
Carinne Alfos
ITERG
Rue Gaspard Monge
Parc Industriel Bersol 2
33600 Pessac
France
Tel. (+33) 556 360044
Fax: (+33) 556 365760
Email: c.alfos@iterg.com
Website: www.iterg.com 

Project website
www.ibiolab.com (under construction)

Participants
1. Centre Technique Industriel des Professions de Corps Gras 
(ITERG) (FR)
2. The Seed Crushers’ and Oil Processors’ Federation of the EU (BE)
3. Valorisation de la Biomasse asbl (BE)
4. Organisation Nationale Interprofessionnelle des Oléagineux (FR)
5. AGRAGEX (ES)
6. Ets Albert Mauran et Fils S.A. (FR)
7. Lubrix S.A. (BE)
8. Baraldi Lubricanti (IT)
9. Doimak S.A. (ES)
10. Zero Waste (FR)
11. Vandeputte Oleochemicals S.A. (BE)
12. Brugarolas S.A. (ES)
13. Sogelub (BE)
14. Natoil (CH)
15. RS Clare (UK)
16. Abamotor Energía SL (ES)
17. Panolin A.G. (CH)
18. BFB Oil Research S.A. (BE)
19. University of Gembloux — Chimie Biologie Industrielle (BE)
20. Institut National Polytechnique de Toulouse — Laboratoire 
de Chimie Agro-Industrielle — UMR 1010 INRA INPT (FR)
21. BAM (DE)
22. Fundación Tekniker (ES)

Project title
Improvement of bio-lubricant manufacturing and development 
thanks to the obtaining of Eco-labels in a wide range of 
industrial sectors (IBIOLAB)

Contract number
030307

Duration
36 months

Global project costs
€3 443 907

EC contribution
€2 181 818

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4/16/07   12:28:28 PM

 
 
 
 
 
 
 
 
 
 
 
SMALL COMPANIES, VAST 
COMPETENCIES
“An Intellectual Capital Statement (ICS) enables 
decision-makers to visualise ‘intangible’ 
resources that are essential for the 
success of their company.”

InCaS

Company-specific 

is 
generally referred to as Intellectual Capital (IC); 
it pertains to intangible assets, namely non-monetary 
assets that cannot be seen, touched or physically measured. 
The InCaS initiative aims to support Intellectual Capital Statement 
(ICS) as a management tool that would enable European SMEs to detect 
and communicate their Intellectual Capital, and to take improvement measures 
accordingly. To this end, the project will implement ICSs in several European SMEs, 

knowledge 

relying on a consolidated methodology.

Intellectual  Capital  (IC)  can  prove  particularly  useful  in  the 
development, production and selling of a company’s products 
and  services.  It  covers  a  diversified  knowledge  area,  ranging, 
for instance, from staff qualification and motivation, leadership 
and  management  structures,  to  organisational  capacities 
or  relations  to  the  market.  Overall,  IC  can  serve  as  a  crucial 
resource  in  gaining  an  advantage  over  competition,  and  in 
ensuring  the  future  success  of  a  business.  However,  such  a 
powerful resource naturally requires an appropriate operating 
instrument.

The  Intellectual  Capital  Statement  (ICS)  makes  it  possible 
to  assess,  report  and  develop  an  organisation’s  Intellectual 
Capital, to monitor critical success factors systematically, and 
to  support  strategic  core  competencies.  It  can  thus  help  to 
decrease operational and strategic risks, serving as a suitable 
basis for strategic decisions and organisational development. 
The InCaS consortium will assemble SMEs and IAGs from five 
European countries, in a bid to develop and implement an ICS 
method  able  to  meet  the  specific  requirements  of  European 
SMEs. 

From scattered approaches to a global 

methodology

ICS  methods  and  guidelines  have  been 
While  different 
developed  and  tested 
in  several  European  countries,  a 
harmonised approach at EU level has not yet been accomplished. 
The  scattered  knowledge  gained  from  the  various  national 
approaches  needs  to  be  accumulated  at  a  scientific  level. 
Accordingly, the InCaS consortium is basing its research work 
on the differing ICS approaches, intending to identify common 
ground,  as  well  as  cultural  differences  and  national  and 
branch-specific  requirements.  The  derived  consolidated  ICS 
methodology  will  set  pre-normative  standards  for  assessing 
and reporting Intellectual Capital in European SMEs. 
Focusing on five core branches of SME activity, the InCaS project 
partners are seeking to simplify the procedure, by providing a 
manageable implementation procedure. In order to render this 
suitable for SMEs, a practical approach is paramount, as is the 
maximum  benefit  possible  from  improving  the  exploitation  of 
existing  Intellectual  Capital,  and  revealing  unused  innovation 
potential.  Commencing  with  50  pilot  implementations  in  six 

European countries, the methodology developed by InCaS will 
lead to the creation of practical ICS guidelines that will enable 
SMEs across Europe to implement ICSs unaided.

Setting the standards for success
A  software  compendium  (ICS  Toolbox)  will  support  SME 
users  during  the  ICS  implementation  process,  while  a  central 
database (InCaPedia) will compile data relating to all aspects of 
ICS generation and its use in relation to SMEs. The development 
of branch-specific ICS elements will facilitate ICS comparability 
(ICS  Harmonisation),  while  the  minimal  requirements  for  IC 
reporting  will  be  determined  (IC  Benchmarking).  Based  on 
representative  empirical  data,  a  bottom-up  contribution  to 
standardisation will be supported. The developed approach will 
be tested and evaluated, so as to guarantee proof of concept. 
This  will  assist  in  maximising  the  dissemination  impact, 
expected to extend to over 1 000 European SMEs.
‘Intangible’  resources,  such  as  trade  secrets,  copyrights, 
patents, or trademarks, can be essential for business success. 
With  ICS,  decision  makers  in  European  SMEs  will  have  an 
efficient tool with which to visualise these assets. Ranging from 
increased transparency regarding knowledge and competences 
(the so called ‘soft’ success factors), to systematic research of 
market niches, the advances engendered by ICS are potentially 
crucial. 

consolidated 

The 
I C S     m e t h o d o l o g y 
established by InCaS will 
be the cornerstone in 
a unified approach 
Intellectual 
of 
C a p i
t a l 
a s s e s s m e n t 
reporting 
and 
European 
in 
In  an 
SMEs. 
that 
economy 
is 
increasingly 
k n o w l e d g e -
based, 
the InCaS concept can 
prove to be a vital step. 

adopting 

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Collective Research Volume 3

“… the methodology developed by InCaS will lead 
to practical ICS guidelines that will enable 
SMEs across Europe to implement an 
ICS on their own.”

Contact 
Person
Stefan Zickgraf
Confédération Européenne des 
Associations de Petites et Moyennes 
Entreprises 
Avenue de la Renaissance 1
B-1000 Bruxelles
Belgium
Email: stefan.zickgraf@cea-pme.org 

Participants
1. Confédération Européenne des Associations Petites et 
Moyennes Enterprises (EU)
2. Bundesverband mittelständische Wirtschaft - 
Unternehmerverband Deutschland e. V. (DE)
3. Gospodarska Zbornica Slovenije (Slovenia)
4. Polska Konfederacja Pracodawcow Prywatnych Lewiatan (Poland)
5. Association Française des Dirigeants d’Entreprise en Europe (FR)
Foment del Treball (Spain)
6. Helmut Beyers GmbH (DE)
7. JRC Capital Management Consultancy & Research GmbH (DE)
8. PASS Stanztechnik (DE)
9. Malergeschäft Bethel-Eckerts (DE)
10. Balance Technologie (DE)
11. DYNAXO Sp. Z.o.o (PL)
12. ARR S.A. w Koninie (PL)
13. GARTEN POLSKA (PL)
14. MarCo Ltd spolka z ograniczona odpowiedzialnoscia (PL)
15. NEXBAU mgr inż. Roman Bauta (PL)
16. KAC d.o.o. (SI)
17. Industrijska oprema Brežice d.o.o. (SI)
18. Glotta Nova, Center za pravo učenje in poučevanje d.o.o. (SI)
19. INTER DISKONT d.o.o. EXPORT - IMPORT (SI)
20. LE-TEHNIKA Podjetje za proizvodnjo in trgovino z 
elektrotehničnimi izdelki, d.o.o. (SI)
21. Sisteplant SL (ES)
22. FORMACIÓN DIGITAL, SL (ES)
23. VERTISUB, S.L. (ES)
24. Asociación Industrial de Optica, Color e Imagen (ES)
25. SIDASA (ES)
26. Business and Development Learning Institut (FR)
27. Castlink Services (FR)
28. PROJIRIS (FR)
29. Cortel (FR)
30. Vendee Mecanique Industry (FR)
31. Fraunhofer Institut für Produktionsanlagen und 
Konstruktionstechnik (DE)
32. Technische Universität Berlin (DE)
33. London School of Economics and Political Science (UK)
34. Universitat Politècnica de Catalunya (ES)
35. ARC Systems Research GmbH (AT)
36. Intangible Asset Consulting (AT)
37. Wissenskapital Entwicklungsunternehmen GmbH (DE)
38. UNIC Universal Networking Intellectual Capital AB (SE)
39. Univerza v Mariboru (SI)

Project title
Intellectual Capital Statement – Made in Europe (InCaS)

Contract number
30485

Duration
30 months

Global project costs
€3 217 472

EC contribution
€1 985 087

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4/16/07   12:28:42 PM

 
 
 
 
 
 
 
 
 
 
 
THE TEXTILE INNOVATION CATALYST

INNOTEX

“The main objective of the initiative is to create 
an IT based toolbox, to prevent and alleviate 
manufacturing defects.”

Quality  is  the  recurring  theme  of  the 
EU textile industry and the key to the success 
of  the  nearly  200  000  companies  involved.  In  order 
to  maintain  the  qualitative  edge  and  to  gain  a  competitive 
advantage by standing out from low-quality rivals, European SMEs are 
constantly trying to boost the performance of their production processes. 
The Innotex project aims at developing new software facilitating the optimisation 
of existing manufacturing processes for textiles. The software will be integrated into 
the production chain and support manufacturers in eliminating the root causes of quality 

defects.

Innotex is a project involving 26 partners from seven countries. 
The  main  objective  of  the  initiative  is  to  create  a  software 
‘toolbox’ for preventing and alleviating manufacturing defects. 
However,  project  participants  will  go  further,  with  the  results 
of  Innotex  expected  to  contribute  to  the  development  of  the 
European  technology  platform  for  the  future  of  textiles  and 
clothing.  Indeed,  the  optimised  processes  and  improved 
product  quality  can  ensure  the  long-term  competitiveness 
of  the  European  textile  industry  (which  is  the  second  largest 
exporter of textiles in the world), by ensuring more jobs, growth 
and export income for the EU.

The missing link
Innotex  will  mathematically  model  performance  indicators 
for  four  types  of  processes  including  polymer  extraction/
yarn  manufacturing,  dyeing,  finishing,  and  technical  fabrics 
manufacturing. These are among the most commonly used and 
better-known processes. The new software will be designed to 
optimise  all  the  production  stages,  and  offer  manufacturing 
operators  an  indication  on  how  to  minimise  the  risks  which 
potentially threaten product quality.

Technically speaking, the Innotex software will be an automated 
empirical  model,  able  to  construct  a  stochastic  model  linking 
process  data  to  quality  risks.  Using  a  self-learning  algorithm, 
the software can use recorded process data to produce a group 
of output variables, starting from a group of input variables. In 
practice,  the  software  will  process  the  input  variables  taking 
into account past process data. 

As a result, all the potential quality risks can be assessed. For 
example, in the course of a given process, an operator will be 
able to use the new software to pinpoint the source of a quality 
defect  and  to  optimise  all  the  control  parameters.  He  can 
also  compare  the  data  recorded  by  online  diagnostic  sensors 
against  the  control  parameters,  to  spot  and  solve  any  quality 
problem  that  might  arise.  Participants  at  Innotex  expect  the 
software to help operators establish the link between process 
data, recorded by sensors, and the quality risks to the textile 
product.

Practice makes perfect
Ultimately,  consumers  will  benefit  from  better  quality  textiles 
produced  by  SMEs  using  the  Innotex  software.  However,  the 
main beneficiaries from this project’s innovations are expected 
to  be  the  manufacturers.  Powerful  software  will  provide  a 
further  way  of  strengthening  the  position  of  European  SMEs 
against their competitors. 

Innotex  participants  are  planning  on  creating  a  European 
Competence  Group  to  disseminate  the  results  of  the  project 
and to train operators in using the software. This is necessary 
because  operators  and  production  managers  must  first 
familiarise themselves with the toolbox before they are able to 
use it effectively. 

Furthermore,  the  project  team  aims  at  making  the  Innotex 
software  able  to  connect  to  existing  Enterprise  Resource 
Planning  (ERP)  solutions,  which  are  often  used  by  textile 
companies. Compatibility with existing solutions and suitable 
training for operators pave the way for widespread usage of the 
Innotex software throughout the industry. A final contribution to 
the success of the Innotex toolbox is the importance given by its 
creators to the compliance of the software with ISO  standards, 
which have been widely adopted throughout the industry.

Innotex 

Generating  innovation  is  the  main  objective  of  the  Innotex 
toolbox.  By  simplifying  the  detection  of 
quality  defect  risks  in  textile 
manufacturing, 
will  provide  valuable 
support 
for 
textile 
European 
and 
industry 
strengthen 
its 
position  in  the 
global market. 

the 

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4/16/07   12:28:46 PM

 
 
 
 
 
 
 
 
 
 
 
Collective Research Volume 3

“… the powerful software will provide an 
additional means of strengthening the 
position of European SMEs against their 
rivals.”

Contact Person
Christian Bernardin
Centexbel-Verviers
Avenue du Parc, 38
4650 Herve
Belgium
Email: cb@centexbel.be 

Project website
www.innotex-cr.org

Participants
1. CENTEXBEL — Centre scientifique et technique de l’industrie 
textile belge(BE)
2. Technofi S.A. (FR)
3. Miriad Technologies S.A. (FR)
4. Datatex S.R.L. (IT)
5. Institute of Textile Materials Engineering (PL)
6. TECMINHO (PT)
7. INNOVATEXT — Textile Engineering and Testing Institute Co. 
(HU)
8. Centrocot (IT)
9. LEITAT — Laboratorio de Ensayos e Investigaciones Textiles 
del Acondicionamiento Tarrasense (ES)
10. FEBELTEX — Federatie van de Belgische textielbedrijven (BE)
11. ATP — Associação Textil e Vestuário de Portugal (PT)
12. PIOT (PL)
13. TMTE (HU)
14. UNITEX — Associazione Nazionale per l’Unificazione nel 
settore Tessile – Federata all’UNI (IT)
15. FNAETT — Federación Nacional de Acabadores y Tintoreros 
(ES)
16. EURATEX — European Apparel and textile Organisation (BE)
17. Verstraete-Hahn (BE)
18. Dyvertex S.P.R.L. (BE)
19. ETEVIMOL — Empresa textile de Vilar do Monte, Lda. (PT)
20. ATB — Acabamentos Textéis de Barcelos, Lda. (PT)
21. Eurohod Textil LTD (HU)
22. AR-POL (PL)
23. Lariofil S.R.L. (IT)
24. Antonio Aspesi S.R.L. (IT)
25. Tejidos Estambril, S.A. (ES)
26. Industrial Neotex, S.A. (ES)

Project title
A tool box to catalyse continuous process INNOvation within 
the TEXtile manufacturing lines in Europe (INNOTEX)

Contract number
30312

Duration
36 months

Global project costs
€3 422 145

EC contribution
€1 860 078

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4/16/07   12:28:55 PM

 
 
 
 
 
 
 
 
 
 
 
A NEW PERSPECTIVE FOR MACHINING

KnowEDM

“The Know EDM methodology is expected to 
generate a 50% lead-time reduction and 
a 30% cost reduction for the whole 
European tool making sector.”

Currently,  the  European  tool  and 
precision  manufacturing  sector  accounts  for 
some 4 500 SMEs, employing a total of 110 000 people 
and achieving a turnover of approximately EUR 9 billion. But 
Europe’s market share in this field is being threatened by low-wage 
countries, putting 44 000 jobs at risk. In spite of this, decision makers are 
reluctant to innovate. In addition to this, unpleasant working conditions make 
the  tool  manufacturing  sector  unpopular  for  young  people  The  KnowEDM  initiative 
has  been  set  up  to  address  these  issues  and  improve  the  competitiveness  of  European 

precision engineering.

The  structural  deficiencies  of 
the  European  machining 
sector  come  at  a  cost.  So  far,  the  making  of  mould  tools  and 
precision engineering components has been a labour intensive, 
craftsmanship based activity. Qualified personnel are urgently 
needed in highly specialised areas, like computer aided design 
and manufacturing (CAD/CAM) – methods which are essential 
for  a  sector  that,  until  now,  has  made  little  effort  to  attract 
young and skilled technicians.

Furthermore,  one  of  the  most  important  machining  processes 
in  precision  manufacturing,  Electrode  Discharge  Machining 
(EDM),  lacks  the  capability  to  offer  a  reliable  machining  time 
calculation. Consequently, it is impossible to optimise the total 
manufacturing  process,  reduce  costs  and  shorten  the  period 
between  start  and  completion  of  production  (i.e.  the  lead 
time). 

Competitors from Asian countries may compensate for similar 
technical  limitations  with  lower  manufacturing  costs,  using 
smaller wage packets. For the European sector however, the only 
way to counter this tendency is to save costs and attain shorter 
delivery times, through innovation. This is what KnowEDM is all 
about.

Getting to KnowEDM
By gathering 20 SMEs from all parts of Europe, the KnowEDM 
consortium  aims  to  develop  an  integrated  EDM  technology, 
for  the  design  and  manufacture  of  moulds  and  precision 
components.

Electrode Discharge Machining is a machining method primarily 
used  for  hard  metals  or  those  that  would  be  impossible  to 
‘machine’ with traditional techniques. The term ‘machining’ has 
broad applications and refers to all types of metal removal and 
cutting processes. Examples of traditional machining techniques 
include turning, boring, milling, drilling, and grinding. Because 
it  has  the  capability  to  cut  and  carve  small  or  odd-shaped 
angles, intricate contours or cavities into extremely hard steel 
and  exotic  metals,  EDM  is  the  most  appropriate  machining 
method for the mould-making tool and dye industries.

The solution developed by the KnowEDM consortium consists 
of  a  knowledge-based  system,  structured  around  ‘expert’ 

software. The system will handle automated calculation of EDM 
time, automated design and manufacturing proposals for EDM-
electrodes,  and  provide  a  computer-based  design  review  of 
mould tools. This methodology is expected to generate a 50% 
lead-time  reduction  and  a  30%  cost  reduction  for  the  whole 
European tool making and precision engineering sector.

Craftsmanship goes high tech
The  KnowEDM  system  will  comprise  three  software  modules, 
conceived  to  provide  an  accurate  EDM  time  estimation, 
automate  electrode  design  and  manufacturing,  and  optimise 
the  choice  between  2  manufacturing  processes,  EDM  or  HSM 
(High  Speed  Mill).  While  the  support  of  the  HSM  process 
will  improve  machining  for  parts  of  particular  geometry,  the 
seamless  transition  between  both  methods  will  allow  for  an 
advantage of speed, over the competition.

Thanks  to  its  knowledge-based  concept,  the  modular  system 
will further communication between product designers, mould 
manufacturers  and  injection  moulders.  Moreover,  the  quality 
of  manufactured  moulds  will  be  improved,  and  the  costs  and 
delivery times reduced. The modules will not only be beneficial 
to  mould  makers  and  manufacturers  of  precision  engineering 
products,  but  also  to  other  sectors  applying  EDM  technology 
(e.g. the aerospace, automobile and electronics industries).

the 

Overall, 
the  goal  of 
project  is  to  encourage 
a  transition  from  a 
labour- intensi ve 
to  a  knowledge-
i n t e n s i v e 
w o r k i n g 
sector. 
This 
will  not  only 
the 
increase 
technological 
requirements, 
but 
also 
enhance 
prestige  of 
professions  involved. 
Indeed,  entry 

level  to 

the 

the 

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encompass 

these professions 
will 
also 
university  graduates.  Their  task  will 
be  to  adapt  the  modular  system  to  specific 
applications,  which  will  take  place  in  programming 
departments rather than in noisy toolshops. Away from an old-
fashioned image, the European tool and precision manufacturing 
sector will become more attractive, thus more able to deal with 
its current and future recruitment needs.

KnowEDM brings new possibilities and a great deal of potential 
to  help  European  machining  retain  a  competitive  edge  over 
global competition.

Collective Research Volume 3

“KnowEDM’s goal is to create a transition from 
a labour intensive to knowledge intensive 
working sector.”

Project title
Automated knowledge based EDM technology for integrated 
toolmaking and high precision components (KnowEDM)

Contract number
30238

Duration
36 months

Global project costs
€3 791 000

EC contribution
€2 328 000

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Contact Person
Han Oosterling
TNO Science & Industry
De Rondom 1
PO box 6235
5600 Eindhoven
The Netherlands
Tel. (+31) 40 2650 551
Fax: (+31) 40 2650 945
Email: han.oosterling@tno.nl
Website: www.tno.nl

Project website
www.knowedm.com
www.knowedm.eu

Participants
1. TNO, Netherlands Organisation for Applied Scientific 
Research (NL)
2. Metaalunie (NL)
3. Stowarzyszenie Inzynierow i Technikow Mechanikow Polskich 
— Towarzystwo Przetworcow Tworzyw Wielkoczasteczkowych (PL)
4. Federación Española de Asociaciones Empresariales de 
Moldes y Matrices (ES)
5. Gauge & Toolmakers Association (UK)
6. NC Gesellschaft e.v. (DE)
7. Gereedschapsmakerij WINTERS B.V.B.A. (BE)
8. Materialise N.V. (BE)
9. Zwicker Systems GmbH (DE)
10. Gereedschapmakerij van Wijnen (NL)
11. Perspa B.V. (NL)
12. CCIM Competence Center for Innovative Manufacturing (NL)
13. Procesos Tecnicos del Molde, S.L. (ES)
14. COPROIN-Condés Procesos Industriales, S.L. (ES)
15. Zeeko Limited (UK)
16. PP Injection Moulds and Mouldings LTD (UK)
17. Missler Software (FR)
18. Buckinghamshire Chilterns University College (UK)
19. Katholieke Universiteit Leuven (BE)
20. IDEKO S. Coop. (ES)

sme.brochure.collec.2.indd   37

4/16/07   12:29:07 PM

 
 
 
 
 
 
 
 
 
 
 
PICKING THE RIGHT FRUIT FOR 
THE RIGHT JUICE
“The starting point for a good apple juice is… 
good apples.”

LOWJUICE

Fruit 

juicy 
juice  production 
business, but it is not always a sweet one. The 
competition  from  countries  making  low  cost  juices, 
as  well  as  the  increase  in  the  consumption  of  other  non-
alcoholic beverages put a strong pressure on sectors such as apple 
juice production. Facing up to the challenge of strengthening the position 
of EU producers, Lowjuice will answer consumer demands for healthier products 
by developing novel processes for better and more varied apple juices with less sugar 

is  a 

and more fibre.

The Lowjuice project draws on the experience of 15 partners to 
develop  a  new  way  of  producing  apple  juice.  The  members  of 
the consortium are specialists in the fields of apple production, 
juice processing and also enzyme supply and filter technology, 
all the elements the project needs to achieve its mission.

Overall,  the  project  aims  at  producing  apple  juices  suiting 
consumer  taste,  but  with  50%  less  sugar  and  increased 
fibre  content  to  provide  a  good  share  of  recommended  daily 
intakes.  These  improvements  must  not  stretch  the  total  cost 
of  production  by  more  than  20%.  Lowjuice  will  introduce  a 
combination  of  measures,  such  as  the  right  choice  of  apples 
and modified filtration systems.

Making the right choices
The  starting  point  for  a  good  apple  juice  is…  good  apples. 
Instead  of  following  the  frequent  practice  of  using  apples 
rejected from the fresh market to make juice, Lowjuice will use 
tailor-grown high quality apples. The combinations of high acid 
and low acid apples, harvested at an early stage, result in lower 
sugar in fruits. In time, Lowjuice will lead to the establishment 
of a grower’s guide for low sugar juice apples.

This project will achieve the required sugar reduction by using 
enzymatic  conversion.  Enzymes  are  proteins  that  act  on  fruit 
sugars  (i.e.  sucrose,  glucose),  converting  them  into  polyols, 
which  have  a  higher  level  of  sweetness  —  and  thus  reduce 
the need for sugars in the juice. Enzymes will also be selected 
for  their  ability  to  process  fibres  such  as  pectin.  The  removal 
of fibres before pressing makes for an easier juice extraction. 
Lowjuice  plans  to  re-introduce  the  fibres  at  a  later  stage  of 
production, in order to make juices healthier for consumers.

Participating teams target the development of two techniques. 
The  first  technique  is  tangential  cross-flow  osmatic  filtration 
and  allows  for  the  removal  of  compounds  that  might  be  in 
excess  and  for  the  adjustment  of  sweetness  levels.  The  other 
technique  relies  on  a  modified  venturi  system,  to  reintroduce 
fibres into the processed juice.

All  the  choices  made  during  the  project  are  aimed  at  achieving 
better juices with less sugar. The progress made by Lowjuice will 
enable the preparation of more varieties of juice and even ‘100% 

juices’ (i.e. with less than 10% sugar), currently not present in the 
European market.

A healthy industry
A push for better juice quality will move the technological barriers (i.e. 
the limited ability to reduce sugars) and open up new doors for the 
creation of new juice varieties. Due to this diversification effort, the 
position of EU producers will be strengthened, in a juice market valued 
at over EUR 18 billion (for 2001). Fruit juices represent a good share of 
the European market for non-alcoholic beverages, estimated at EUR 
52.5 billion for 2003, in a global market of nearly EUR 150 billion.

The  evolution  induced  by  Lowjuice  will  also  have  an  impact 
on  other  actors  of  the  industry,  such  as  biotechnology  firms 
developing enzymes or SMEs supplying filter equipment. The new 
methods will be disseminated and over 6 000 SMEs could benefit 
from the progress made by this initiative. New patents may also be 
registered for the sugar and fibre processes.

Furthermore, it is important to highlight that project participants 
intend  to  achieve  their  objectives  without  significantly  raising 
the costs of juice production, in order for the finished products to 
remain accessible for consumers.

from 

pressures 

production 

competition 

Lowjuice is a valuable project for the progression and competitiveness 
of  the  EU  fruit  juice  sector,  which  faces 
internal 
demanding consumers and 
external 
from  countries  with 
low 
The 
costs. 
technological 
developments 
enabled by this 
have 
project 
potential 
the 
to 
reinforce 
the  position  of 
European  SMEs  in 
the long term.

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Collective Research Volume 3

 “A push for better juice quality will move the 
technological barriers (i.e. the limited ability 
to reduce sugars) and open up new 
doors for the creation of new juice 
varieties.”

Project title
Novel processes for reducing sugar and adding fibre to 
natural apple juices for increased public health and increased 
competitiveness of the European fruit juice industry 
(LOWJUICE)

Contract number
30379

Duration
36 months

Global project costs
€1 948 483

EC contribution
€1 185 353

Contact Person
Berit Bull-Gjertsen
The Federation of Norwegian Food & Drink Industry
Essendropsgate 6
0305 Oslo
Norway
Fax: (+47) 23088720
Email: berit.bullgjertsen@nbl.no 

Participants
1. The Federation of Norwegian Food & Drink Industry (NO)
2. Federación Española de industrias de alimentación y 
bebidas (ES)
3. Danish Fruit, Vegetable and Potato Board (DK)
4. Biozoon GmbH (DE)
5. Lerum Fabrikker AS (NO)
6. Alberta (EL)
7. Galilee Flavours Ltd (IL)
8. Targi Tarimsal Girisim Sanayii ve Ticaret AS (TR)
9. Erik Lolle (DK)
10. Athanasaki Brothers (EL)
11. Cooperativa Frutos del Campo Kumix (ES)
12.  Maquinaria Energesa S.L. (ES)
13. Troyka Mkine Gida Sanayii Danismanlik ve Pazarlama Ltd 
Sirketi (TR)
14. PERA Innovation Limited (UK)
15. The Norwegian Food Research Institute (Matforsk AS) (NO)
16. National Agricultural Research Foundation (EL)
17. University of Applied Science Weihenstephan (DE)

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4/16/07   12:29:16 PM

 
 
 
 
 
 
 
 
 
 
 
THE WROUGHT CHOICE FOR 
MAGNESIUM PARTS
“In the forging industry … SMEs have identified a new 
specialisation opportunity that will ensure their 
survival: magnesium forging.”

MAGFORGE

The global marketplace offers almost 
unlimited  economic  opportunities  for  SMEs, 
but it also puts extreme pressure on small companies 
to compete with rivals from every corner of the globe. Many 
European  businesses  are  obliged  to  cut  costs  in  order  to  survive 
against  producers  from  countries  with  very  low  labour  and  production 
costs. In the forging industry, which directly accounts for 135 000 jobs in Europe, 
SMEs have identified a new opportunity in specialisation that will ensure their survival 
i.e. magnesium forging. MagForge is a project destined to support the industry in its quest 

for innovation and manufacturing enhancement, focusing on lightweight components.

Forging a new reputation
In the forging industry, steel is the principal material, followed 
by  aluminium.  MagForge  participants  focus  on  yet  another, 
albeit  still  underexplored  alternative  forging  material,  which 
is  magnesium.  The  project,  if  successful,  will  have  developed 
new  processes,  enabling  high-volume  applications  with  a 
massive  50%  cost  reduction  over  current  production  prices. 
Price reduction will be an important asset, adding to the already 
important  weight  advantage  of  magnesium  over  steel  and 
aluminium. As a matter of fact, magnesium is 75% lighter than 
steel and 35% lighter than aluminium.

These  impressive  qualities,  if  applied  to  a  wide  range  of 
products,  could  reinforce  the  position  of  magnesium  in  the 
forging  sector.  The  project  team  will  devise  benchmark  parts, 
which will be used to measure the performance of magnesium 
against aluminium, and which will validate the newly developed 
processes. In order to facilitate the spread of magnesium and its 
qualities and potential, the knowledge developed by MagForge 
will  be  disseminated  to  industrial  associations  and  forging 
SMEs, as well as to material producers and end-users.

MagForge  hopes  to  provide  the  forging  industry  with  tailored 
and  cost-effective  technologies  for  the  manufacturing  of 
magnesium-forged  components.  These  developments  are 
expected  to  offer  SMEs  the  opportunity  to  produce  high-
volume  magnesium  applications,  thus 
strengthening 
of  European  companies 
in  the  global  forging 
market.

the  position 

Forging  companies  mainly  work  with 
their  automotive 
counterparts  who,  due  to  environmental  and  fuel-efficiency 
concerns,  require  lightweight  parts.  This  requirement  opens 
up  new  horizons  for  forging  SMEs,  with  the  possibility  of 
replacing the prevailing steel forging with new materials, such 
as magnesium. 

The  challenge  is  for  Europe’s  1  000  forging  SMEs  to  produce 
high  volumes  at  low  costs.  However,  before  it  is  feasible  to 
produce magnesium parts within this context, MagForge must 
first  develop  new  technologies  and  improve  knowledge  of 
materials,  processes  and  tools.  The  project’s  23  participants 
aim to produce demonstrator components for showcasing the 
added-value of their research.

Pushing the material limits
Magnesium forging can be done using a variety of techniques, 
from  closed-die  forging  to  coining,  impact  extrusion  and 
spinning. The production of cast parts (melted into a mould) is 
widespread, but wrought products are now raising interest as 
well. Indeed, wrought magnesium parts can be shaped into more 
formats,  and  are  also  stronger  and  more  ductile.  Particularly 
important  for  the  automotive  industry  is  the  performance  of 
wrought parts in terms of crash-relevant components.

In order to achieve a satisfactory level of performance for wrought 
magnesium parts, the MagForge project team aims to optimise 
the  production  processes  throughout  the  whole  processing 
chain.  The  main  research  areas  are  materials,  processes 
and  components  to  be  developed.  The  project  consortium  is 
developing  new  materials,  based  on  new  alloys,  to  improve 
forge  ability  of  the  substance  and  its  mechanical  properties. 
MagForge  also  focuses  on  the  actual  forging  processes,  by 
improving  knowledge  on  the  interrelations  between  alloy 
composition, processing temperature and part deformation, as 
well as on post-forging processes such as machining and heat 
treatment. New processes are expected to contribute to better 
quality  magnesium  parts,  and  could  sustain  the  cost-cutting 
efforts the industry has to make.

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Collective Research Volume 3

“The project team will elaborate benchmark 
parts, which will be used to measure the 
performance of magnesium against 
aluminium.”

Contact Person
Wilhelmus Hubertina Sillekens
Netherlands Organisation for Applied Scientific Research 
(TNO)
PO Box 6235
5600 HE Eindhoven
Netherlands
Tel. (+31) 402650475
Fax: (+31) 402650945
Email: wim.sillekens@tno.nl

Project website
www.magforge.eu

Participants
1. Netherlands Organisation for Applied Scientific Research, 
TNO (NL)
2. GKSS-Forschungszentrum Geesthacht GmbH (DE)
3. Association Française de Forge (FR)
4. Deutsche Gesellschaft für Materialkunde e.V. (DE)
5. Confederation of British Metalforming (UK)
6. Czech Forging Industry Association (CZ)
7. Romanian Forging Society (RO)
8. Slovenian Tool and Die Development Centre (SI)
9. Asociación Española de Fabricantes de Equipos y 
Componentes para Automoción (ES)
10. Gospodarsko Interesno Združenja ACS, Automotive Cluster 
of Slovenia (SI)
11. Nonferro Metaalnijverheid N.V. (BE)
12. Forgialluminio 3 s.r.l. (IT)
13. Leiber Poland Sp. Z o.o. (PL)
14. SC Bimetal SA Bucharest (RO)
15. Kovinar D.O.O (SI)
16. Pressmetall AB (SE)
17. Duroc Tooling i Robertsfors AB (SE)
18. MAT PlasMATec GmbH (DE)
19. Soraluce Sociedad Cooperativa (ES)
20. University of Ljubljana – Faculty of Mechanical Engineering (SI)
21. IDEKO Sociedad Cooperativa (ES)
22. University “POLITEHNICA” of Bucharest – Faculty of 
Materials Science and Engineering (RO)
23. Svensk Verktygsteknik AB (SE)

Project title
Magnesium forged components for structural lightweight 
transport applications (MAGFORGE)

Contract number
30208

Duration
36 months

Global project costs
€2 900 000

EC contribution
€1 700 000

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4/16/07   12:29:31 PM

 
 
 
 
 
 
 
 
 
 
 
MELTING PROCESSING 
INCONVENIENCE AWAY
“The project focuses on improving rotational 
moulding processes, by developing two new 
retrofit tools.”

MICRO-MELT

Plastic  is  ubiquitous  and  contained 
in almost every item we use in our daily lives. 
The market for these products is, therefore, extremely 
varied in terms of quantity, quality and types of products. SMEs 
dominate  the  European  plastic  sector  but  face  tough  competition 
from Far East countries, which produce low cost plastics. The competition 
is  such  that  only  an  increased  understanding  and  development  of  plastic 
processing  can  ensure  the  survival  of  European  manufacturers.  Micro-Melt  aims  at 
advancing the state of the art of rotational moulding and to contribute to the sustainability 

Two steps, three effects
Micro-Melt  envisions  the  development  of  two  new  retrofit 
devices.  The  first  is  a  microwave-heating  system,  which  will 
reduce  energy  consumption  by  70%.  The  second  is  a  cooling 
system,  which  is  placed  inside  a  mould  and  accelerates  the 
cooling process - reducing the overall processing cycle time by 
50%. As well as reducing energy consumption and production 
times, the two new devices will also contribute to improving the 
quality of plastic parts.

To date, rotomoulding has been limited to low cost applications, 
but the substantial developments that Micro-Melt is aiming for 
could change the situation. The scientific advances achieved by 
the researchers involved in the project could have direct positive 
effects on the quality of products and on the competitiveness of 
SMEs and the plastic sector as a whole. The position of European 
SMEs  could  be  strengthened  in  terms  of  their  ability  to  offer 
high-quality products at low prices and at faster delivery rates.

Micro-Melt  will  deploy  all  the  efforts  required  to  achieve  its 
main objective, the introduction of new methods for improving 
rotomoulding  processes  and  to  help  European  SMEs  achieve 
even greater competitiveness.

of European plastic manufacturers.

Micro-Melt brings together the expertise and experience of 14 
participants, consisting of SMEs, IAGs and RTD performers. The 
project focuses on improving rotational moulding processes by 
developing two new retrofit tools: a microwave heating tool and 
an internal mould-cooling device. These retrofit devices can be 
applied to existing mouldings and machinery, and are expected 
to  reduce  energy  costs  and  processing  times.  According  to 
the  project  team  they  will  also  contribute  to  a  significant 
improvement in the quality of parts.

The importance of being plastic
Household  items,  working  equipment,  toys,  vehicles  and  a 
wide range of other objects are mostly made of plastic. Plastic 
parts are, for the main part, produced by moulding, a process 
consisting  of  shaping  material  using  a  model  frame,  called  a 
mould. The mould is a hollow element, filled with liquid plastic, 
which  will  give  the  material  the  required  shape.  Rotational 
moulding,  or  rotomoulding,  is  used  to  produce  hollow  one-
piece  parts,  such  as  kayaks,  bins  and  containers.  Such  parts 
are easier to produce with plastic than with metal, and are also 
cheaper, lighter and more durable.

In rotomoulding, plastic is placed, at low pressure, on a rotating 
mould  (with  biaxial  rotation).  The  four  phases  of  the  process 
include  loading  the  plastic  powder  in  the  mould,  heating  and 
rotation,  cooling,  and  finally  the  removal  of  the  newly  formed 
part. Once the plastic powder is poured in the mould, the heat 
melts it, while the rotational movement fills the mould evenly. 
During the cooling phase, the plastic solidifies and adopts the 
shape of the mould under the effect of fans. As the part cools 
down, it shrinks and can be easily removed.

This moulding technique is cheaper than injection moulding, for 
example, because it uses moulds that are cheaper to produce. 
In  recent  years,  rotomoulding  techniques  have  evolved  and 
technology  now  allows  for  the    process  to  be  monitored. 
Operators  no  longer  have  to  guess  whether  a  part  is  ready  or 
not.  However,  the  process  remains  very  lengthy  and  energy-
hungry. Micro-Melt responds to industry needs for shorter and 
more energy-efficient processing methods.

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Collective Research Volume 3

“The position of European SMEs could be 
reinforced in terms of their ability to offer 
high-quality products at low prices and 
at faster delivery rates.”

Project title
Development of advanced retro-fit processing technologies 
for rotational moulding to reduce product cost and processing 
time and increase surface performance (MICRO-MELT)

Contract number
30434

Duration
36 months

Global project costs
€2 548 978

EC contribution
€1 450 082

Contact Person
Mercia Gick
The British Plastics Federation
6 Bath Place, Rivington Street
EC2A 3JE London
United Kingdom
Email: mgick@bpf.co.uk 

Participants
1. Pera Innovation Limited (UK)
2. The British Plastics Federation (UK)
3. Association of Rotomoulders Ireland Limited (IE)
4. Association of Rotational Moulding (Central Europe) (DE)
5. Gisip AB (SE)
6. PPA Teo Limited (IE)
7. Neale Plastics Limited (UK)
8. Frigel Firenze S.r.l. (IT)
9. Ernst Reinhart GmbH (DE)
10. SPI Play (Europe) Limited (UK)
11. Balmoral Group Ltd (UK)
12. Mauk & Esslinger GmbH (DE)
13. The Queen’s University Belfast (UK)
14. Fraunhofer-Gesellschaft zur Förderung der angewandten 
Forschung e.V. (DE)

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4/16/07   12:29:46 PM

 
 
 
 
 
 
 
 
 
 
 
CORRUGATED BOARD TOP MODEL 
BOXES
“The main difficulty for package manufacturers is 
to predict the properties of paper products 
based on heterogeneous source 
materials.”

To  most  people,  a  cardboard  box 
is  just  a  folded  piece  of  tough  paper,  useful 
for storing and transferring goods. For the producers 
of  packages,  however,  the  preparation  and  modelling  of 
performance  of  corrugated  boards  is  a  tough  technical  challenge 
demanding intensive research. This is mainly due to the fact that different 
types of forest-based and recycled fibres are used in the fabrication process. The 
Modelpack project is developing new software to simplify the design and manufacture 

MODELPACK

of fibre packages — with the overall objective of assisting European SMEs in the sector.

raw material, as suited to the specifications of the desired final 
product. Modelpack will be a pioneering project, in the sense 
that  it  will  be  the  first  scientific  attempt  at  developing  such  a 
prediction tool. 

Helping SMEs go global
The Modelpack software will contribute to the optimisation of 
all the production stages, from the preparation of paper to final 
fibre  products.  This  innovative  project  expects  to  explore  the 
scientific and technical link between paper properties and the 
properties of corrugated boards. 

To  this  end,  the  consortium  is  gathering  information  on 
the  existing  raw  materials  used  by  packaging  companies 
throughout Europe, with a view to constructing a database. A 
classification of paper grades will be determined, based on their 
primary properties and production methodologies. Drawing on 
professional  working  practices,  the  project  team  will  define  a 
quality  prediction  system.  Prior  to  production,  manufacturers 
will  be  able  to  predict  the  packaging  quality,  with  regards  to 
feasibility, costs, profits and energy input.

Use of the new prediction software will allow even the smallest 
firms  to  improve  and  refine  products,  thus  satisfying  global 
market  demands,  and  creating  commercial  opportunities  for 
the  optimised  and  standardised  goods 
sector.

The  European  corrugated  board  market  is  a  very  demanding 
sector.  On  the  one  hand,  customers  demand  performing 
products  with  the  lowest  possible  costs.  On  the  other  hand, 
the relevant legislation requires manufacturers to use recycled 
paper  fibres  in  the  fabrication  processes.  As  a  result,  small 
manufacturing  companies  struggle  to  combine  raw  materials 
with  dissimilar  characteristics  and  to  produce  goods  with 
homogenous properties.

Modelpack, combining the efforts of 15 RTD performers, SMEs 
and IAGs, hopes to strengthen the position of European SMEs 
in  the  global  packaging  market.  The  competitiveness  of  the 
corrugated  goods  sector  has  been  hampered  by  the  lack  of  a 
quality prediction tool; this project aims to address this issue. 
The  tool  will  evaluate,  in  advance,  which  materials  should  be 
used  and  in  which  proportions,  in  order  to  obtain  the  best 
possible final product.

Harmonised heterogeneity
The main difficulty for package manufacturers lies in predicting 
the  properties  of  paper  products,  based  on  heterogeneous 
source  materials.  Forest-based  materials,  traditionally  the 
main  source  of  paper,  are  slowly  being  phased  out  of  fibre 
package-making.  The  obverse  of  this  is  that  recycled  paper 
is  becoming  an  increasingly  important  source  material.  An 
additional problem lies in the fact that manufacturers purchase 
the raw materials for processing on a local basis. Consequently, 
materials  produced  in  different  places  tend  to  have  disparate 
quality  characteristics,  and  manufacturers  need  to  take  this 
factor into account when preparing the final products.

Therefore,  manufacturers  would  welcome  the  opportunity  to 
predict how the two types of materials — recycled and forest-
based  —  can  be  combined  to  satisfy  consumer  demands. 
Consumers  require  corrugated  products  with  homogeneous 
qualities. They would not accept that two examples of the same 
box,  prepared  by  the  same  company  for  the  same  use,  have 
different resistance, texture or stiffness characteristics.

The diversity of source materials is a reality that manufacturers 
must contend with. The solution to the heterogeneity challenge 
is  the  development  of  a  prediction  tool;  this  would  enable 
selection  of  the  characteristics  and  percentages  of  the  ideal 

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Collective Research Volume 3

“Drawing on professional working practices, the project 
team will define a quality prediction system.”

Project title
Advanced quality prediction tool for knowledge-driven 
packaging design and manufacturing in European SMEs 
(MODELPACK)

Contract number
030299

Duration
36 months

Global project costs
€2 471 245

EC contribution
€1 744 762

Contact Person
Prof. Dr. Jose-Vicente Oliver
Asociación de Investigación y Desarrollo de la Industria del 
Mueble y Afines (AIDIMA)
Technology Park of Valencia
Benjamin Franklin 13 Str.
46980 Valencia
Spain
Tel. (+34) 96 1366070
Fax: (+34) 96 1366185
Email: joliver@aidima.es 

Project website
www.modelpack.org 

Participants
1. AIDIMA – Asociación de Investigación y Desarrollo de la 
Industria del Mueble y Afines (ES)
2. FEFCO IA (BE)
3. Innovawood Limited (IE)
4. Cartonajes Santorroman S.A. (ES)
5. Envases Industriales del Cartón Ondulado S.A. (ES)
6. Ondupack S.A.(ES)
7. Haitoglou Hartel S.A. (EL)
8. BESKID (PL)
9. Francisco Vento S.A. (ES)
10. PAKA (DE)
11. Hellenic Foreign Trade Institute — Hellenic Packaging 
Institute (EL)
12. Aristotle University of Thessaloniki (EL)
13. COBRO — Polish Packaging Research and Development 
Centre (PL)
14. STFI-PACKFORSK (SE)
15. Universidad Complutense de Madrid (ES)

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4/16/07   12:29:55 PM

 
 
 
 
 
 
 
 
 
 
 
‘FARM PREGNANCY TESTS’ FOR CATTLE

OVULTEST

“For years, farmers have relied on their experience 
and observation skills to detect heat in 
cattle.”

Artificial  insemination  is  a  ‘miracle’ 
technique for individuals who cannot conceive 
naturally. For dairy cattle, however, insemination is a 
management technique, which allows farmers to control and 
induce pregnancy, a sine qua non for milk production. The Ovultest 
project has been set up with the objective of developing a new biosensor 
for ovulation detection, aimed at improving the success rates of inseminations. 
The new detection method will have a significant economic impact on dairy farming 

in the EU.

The  Ovultest  biosensor  is  being  developed  by  a  multinational 
team  of  18  RTD  centres,  IAGs  and  SMEs,  with  comprehensive 
experience in the fields of electronics, information technologies, 
livestock and dairy farming. The scientific research is expected 
to  lead  to  the  production  and  commercialisation  of  a  new 
multianalyte analyser. This instrument will be able to determine 
ideal insemination times and to detect pregnancy, by means of 
an analysis of the hormonal presence in milk.

Traditional heat detection methods
For  years,  farmers  have  relied  on  their  experience  and 
observation skills to detect heat in cattle — this indicates the 
period of sexual receptivity, which occurs approximately every 
21 days, with a duration of 6 to 30 hours. 

The main disadvantage of this method is that it is particularly 
time-consuming:  each  observation  requires  approximately  20 
minutes, and must be performed 3 to 4 times a day. Furthermore, 
efficient heat detection can only be achieved by farmers with a 
good understanding of cow behaviour; they need to sense the 
animal’s  nervousness  and  increased  activity.  Some  farmers 
keep  records  of  fertility  events  and  use  pedometers,  but  the 
latter technique is still far from reliable.

Unreliable heat detection leads to poorly timed inseminations, 
and  consequently  results  in  lower  conception  rates.  Ovultest 
aims  to  solve  this  problem,  by  developing  a  biosensor,  which 
is  able  to  measure  the  levels  of  progesterone  and  estradiol 
hormones  in  milk.  These  hormones  are  produced  at  different 
junctures  of  the  cow’s  oestrus  cycle;  a  combined  analysis  of 
hormone levels allows for the prediction of the best insemination 
times.

Current test procedures for the  monitoring  of hormonal levels 
in  milk,  such  as  ELISA  tests  (Enzyme-Linked  Immuno  Sorbent 
Assay),  are  not  widely  implemented,  because  they  require 
skilled technicians, are time-consuming and are not adaptable 
to automation. 

Pregnancy checks made easy
An invaluable asset for the Ovultest biosensor will be its ease of 
use, and also its ability to determine heat periods and pregnancy, 
with unprecedented levels of rapidity and accuracy. The biosensor, 
or  analyser,  will  also  prove  its  worth  in  identifying  certain 
reproductive disorders. For example, the analyser will be able to 
identify anoestrous cows, and monitor postpartum ovarian status, 
thanks to a strategically scheduled analysis calendar, defined by 
intelligent software.

Ovultest will be an extremely useful tool for the 600 000 SME dairy 
farmers across Europe. For example, a dairy-farm with a herd of 100 
cows could save up to EUR 15 000 per year, merely by being able to 
predict ovulation times accurately. The failure to detect heat and 
pregnancies,  and  the  consequent  miscalculated  inseminations, 
account for nearly 90% of unsuccessful inseminations — a problem 
for which Ovultest will offer a solution. 

The  economic  benefits  of  the  analyser  could  contribute  to  the 
survival  the  European  dairy  industry,  which  between  1990 
and 2000 lost half of its farmers. This sector is still, despite the 
difficulties it encounters, one of the largest food exporters in the 
EU, worth nearly EUR 4 billion a year. With the progress achieved 
by Ovultest, the productivity of dairy cows, both in terms of milk 
production and delivery of calves, could be greatly improved.

The  Ovultest  analyser  will  not  replace 
routine  veterinary  pregnancy 
examinations.  However, 
it  will  allow  for  easier 
heat and pregnancy 
detection, 
the 
replacing 
need  for  labour 
i n t e n s i v e 
obser vations 
with innovative 
technology.

by 

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Collective Research Volume 3

“An invaluable asset for the Ovultest biosensor 
will be its ease of use and ability to 
determine heat periods and pregnancy 
with unprecedented levels of 
rapidity and accuracy.”

Project title
Improving profitability of dairy SMEs through developing, 
validating and promoting the use of a biosensor for ovulation 
detection (OVULTEST)

Contract number
30377

Duration
36 months

Global project costs
€2 728 500

EC contribution
€1 819 740

Contact Person
Estela Pacheco
Centre de Recerca i Investigació de Catalunya S.A.
C/ Travessera de Gràcia, 108
08012 BARCELONA
Spain
Tel. (+34) 93 204 9922 
Fax: (+34) 93 204 9866
E-mail: estela.pacheco@cric.es

Project website
http://www.cric.es

Participants
1. Centre de Recerca i Investigació de Catalunya S.A. (ES)
2. Irish Cattle Breeding Federation Society Ltd (IE)
3. Animal Breeder’s Association of Estonia (EE)
4. Associazione Italiana Allevatori (IT)
5. Holstein (UK)
6. South Eastern Cattle Breeding Society Ltd (IE)
7. Piistaoja Katsetalu OÜ (EE)
8. Pölva Agro OÜ (EE)
9. Società Cooperativa ‘Carlo e Pasquale Siciliani’ (IT)
10. Gesund Lanbruk AB (SE)
11. Joan Furroy Bernatallada S.L. (ES)
12. Aberekin S.A. (ES)
13. Applied Research using Omic Sciences S.L. (ES)
14. Electronic Systems Design Ltd (MT)
15. Lea Biotech s.r.l. (IT)
16. Institut de Recerca I Tecnología Agroalimentaria (ES)
17. Centre for Chemistry and Chemical Engineering (SE)
18. Malta Industrial Innovation for SMEs Ltd (MT)

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EARLY WARNING SURVEILLANCE
FOR MILK
“The implementation of this system enables dairy 
farmers to reduce economic losses resulting 
from delayed detection of diseases.”

Milk  production 

the  most 
important  agricultural  activity  in  the  majority 
of EU Member States, representing some 14% (EUR 38 
billion) of the total value of agricultural production. With EU 
consumers placing increasing importance on food safety, traceability, 
food quality and animal welfare it is essential that a quick, easy to use, 
portable and cost effective microbiological analyser for pathogen detection in 
dairy herds is made available across the EU. This would lessen the crippling effects of 
animal disease, avoid unnecessary extra work and veterinary fees and ultimately safeguard 

is 

PATHOMILK

the future of the EU dairy industry.

The  Pathomilk  project  aims  to  tackle  this  EU-wide  problem 
through  the  development  of  a  state-of-the-art  veterinary 
surveillance  system  that  enables  simple,  affordable  on-site 
diagnosis  of  diseases.  The  implementation  of  this  system 
enables  dairy  farmers  to  reduce  economic  losses  resulting 
from delayed detection of diseases. These measures also help 
to  keep  outbreaks  under  control,  facilitate  the  production  of 
high quality milk and ensure the health and safety of European 
consumers.

Milking the industry dry?
Despite  the  importance  of  the  EU  dairy  industry,  most  small 
farms have fallen on hard times with many going out of business 
altogether,  mainly  due  to  low  milk  prices.  Improving  current 
pathogen  detection  systems  would  enable  even  the  smaller, 
more vulnerable dairy farms to produce milk of improved safety 
and quality, as well as enabling the early detection of disease 
outbreaks. Such improvements would boost the competitiveness 
and public image of the EU dairy sector through the reduction of 
disease-related costs. 

In  addition  to  the  potentially  devastating  economic  impact, 
several pathogens affecting dairy herds are also dangerous to 
humans. Some are often present in raw milk and dairy products, 
affecting  cheeses  such  as  brie,  camembert,  roulé,  semi-soft 
farmhouse  cheeses  and  unpasteurised  milk.  Pasteurisation 
results in a dramatic reduction of milk-borne disease outbreaks 
but  consumption  of  raw  or  inadequately  pasteurised  milk 
has  been  associated  with  several  outbreaks  of  intestinal 
infections. 

Flexibility, speed and accessibility
Most  detection  techniques  only  detect  one  pathogen  at  a 
time through blood  samples and the  farmer may have to wait 
for  several  days,  even  weeks,  before  getting  the  results  of 
the  tests.  Pathomilk  aims  to  develop  a  rapid  multi-pathogen 
analyser for detecting the most common pathogens in milk, thus 
avoiding blood sampling. Efficient detection from samples will 
be possible through the use of an innovative biosensor based 
on a DNA-hybridisation method and utilising Surface Plasmon 
Resonance (SPR) technology. 

Dairy  SMEs  and  associations  are  conscious  of  the  benefits  of 
a  fast,  reliable  and  cost-effective  technology  for  the  accurate 
detection  of  pathogenic  microorganisms.  To  ensure  the 
Pathomilk  system’s  development  and  effective  dissemination 
of the results, a number of associations from different Member 
States have established a consortium that will raise awareness 
and ensure appropriate training to maximise the benefits such 
technology brings. 

This support is vital. With the future of SME dairy farms at stake, 
it is increasingly important that adequate on-farm controls are 
developed  that  will  enable  farmers  to  produce  safer  milk,  to 
make their businesses competitive and to ensure the safety of 
consumers across Europe and beyond.

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Collective Research Volume 3

“With the future of SME dairy farms at stake, it is 
increasingly important that adequate on-farm 
controls are developed which will enable 
farmers to produce safer milk.”

Contact Person
Serafin Gutierrez
Centre de Recerca i Investigació de Catalunya, S.A.
Travessera de gracia 108
08012 Barcelona
Spain
Email: serafin.gutierrez@cric.es 

Project website
http://pathomilk.cric-projects.com

Participants
1. Centre de Recerca i Investigació de Catalunya, S.A. (ES)
2. Associazione Italiana Coltivatori (IT)
3. LEICAR — Associação dos Produtores de Leite e Carne (PT)
4. Lleters de Catalunya, Llet Nostra, SCCL (ES)
5. Royal Association of British Dairy Farmers (UK)
6. IBIS Technologies (NL)
7. Genescore (FR)
8. Vitaltech Ibérica S.L. (ES)
9. Applied Research using OMIC Sciences S.L. (ES) 
10. Výskumný ústav mliekarenský — Dairy Research 
Institute (SK)
11. MILCOM a.s. — Dairy research Institute (CZ)
12. National Milk Records PLC (UK)
13. Sociedad Agropecuária Vilamorim LDA (PT)
14. Torre in Pietra Sant´Angelo (IT)
15. Figli Bigaran (IT)
16. LEICARCOOP — Cooperativa dos Produtores de Leite CRL, (PT)
17. Gesund Lanbruk HB (SE)
18. Industrias del CADI (ES)
19. KE & LRC Edwards (UK)
20. Feltalálói És Kutató Központ Szolgáltató Korlátolt (HU)
21. Institut de Recerca I Tecnologia Agroalimentaria (ES)
22. Institute of Photonics and Electronics (CZ)

Project title
Providing milk supply chain with a rapid, portable and cost 
effective biosensor for multipathogen detection in milk 
(PATHOMILK)

Contract number
30392

Duration
36 months

Global project costs
€2 788 967

EC contribution
€1 784 750

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4/16/07   12:30:14 PM

 
 
 
 
 
 
 
 
 
 
 
A BOOST FOR THE PLASTICS INDUSTRY

PEPT-Flow

Plastic  extrusion 

“The modular design of twin-screw extruders 
allows a significant flexibility in process set-
up and operation, enabling the engineer 
to tailor the processing and mixing 
environment to suit specific 
hardware requirements.”

the  most 
important processing technology for plastics, 
accounting for more than 30% of all plastics made in 
Europe. Due to its process design flexibility and high-mixing 
efficiency, twin-screw extrusion is widely recognised as a key future 
technology in this sector. But there is a fundamental lack of quantitative 
and qualitative knowledge on this subject, which proves to be a major barrier 
to the advancement of twin-screw extrusion as an industrial standard. The PEPT-Flow 
project has been set up to address this limitation, through the use of an innovative flow-

is 

of the system. A key feature of the PEPT technique is that the 
gamma photons are able to penetrate relatively thick layers of 
steel,  thereby  enabling  the  analysis  of  processing  equipment 
operated  under  realistic  industrial  conditions,  such  as  high 
pressure and temperature. 

The  knowledge  base  and  tools  established  by  the  PEPT-
Flow  project  are  expected  to  have  a  significant  impact  on  the 
competitiveness  of  SMEs  throughout  the  European  plastic 
sector.  This  will  result  in  the  improvement  of  simulation  and 
modelling  software,  as  well  as  in  knowledge-based  machine 
design,  optimisation  and  validation.  In  addition,  new  process 
launches  will  be  reduced  in  time  and  cost,  and  energy  will 
be  conserved  thanks  to  improved  material  properties  and 
production.

All in all, the project is expected to considerably improve machine 
design and materials. Therefore, PEPT-Flow will not only generate 
better  services  and  provide  more  added  value,  but  will  also 
contribute to the sustainability and competitiveness of a European 
industry sector led by SMEs.

analysis technique.

Throughout the plastics sector, twin-screw extruder technology 
is  widely  used  for  processes  such  as  polymer  blending, 
compounding and reactive processing. The modular design of 
twin-screw extruders allows a significant flexibility in process 
set-up  and  operation,  enabling  the  engineer  to  tailor  the 
processing  and  mixing  environment  to  suit  specific  hardware 
requirements.  However,  this  diversity  in  machine  design, 
combined  with  the  complexity  of  the  processing  environment 
and the limitations of existing flow analysis techniques, has led 
to a significant knowledge gap.

Bridging gaps
Consequently,  while  guidelines  exist  for  process  set-up  and 
optimisation,  machine  designers  and  end-user  processors 
are  primarily  limited  to  the  experience  and  expertise  of  the 
technologist, or to time-consuming trial and error attempts. To 
overcome  this  hurdle,  the  PEPT-Flow  consortium  relies  on  an 
innovative flow-analysis technique — ‘Positron Emission Particle 
Tracking’ (PEPT) — that will be applied to an experimental twin-
screw  extruder.  The  process  is  being  tested  under  realistic 
industrial conditions.

In  time,  the  PEPT  technique  is  expected  to  enable  detailed 
non-invasive  quantitative  and  qualitative  investigation  of  the 
flow behaviour and mixing mechanisms within the twin-screw 
process. This is to determine the influence of machine design, 
process operation and polymer system properties. The results 
generated shall be used to establish knowledge-based machine 
design  criteria  and  operation  guidelines.  They  will  also  assist 
in developing, optimising and validating both new and existing 
commercial simulation and modelling software.

Going with the flow
PEPT  uses  positron-emitting  tracer  particles  that  cause  the 
rapid release of collinear back-to-back gamma photons, which 
are detected by carefully positioned positron imaging cameras. 
Triangulation  of  successive  photon  pairs  reveals  the  particle 
location in three dimensions. The tracer particle position data 
can then be processed to yield flow analysis information such 
as  trajectory  plot  movement,  time-averaged  velocity  vectors 
and  spatial  residence  time  distribution  plots.  The  gathered 
information provides insight into the flow and mixing behaviour 

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Collective Research Volume 3

“The knowledge base and tools established 
by the PEPT-Flow project are anticipated 
to have a significant impact on 
the competitiveness of SMEs 
throughout the European 
plastic sector.”

Contact Person
Gary Foster
Rapra Technology
Shawbury
Shrewsbury
Shropshire
SY4 4NR
United Kingdom
Tel. (+44) 1939 252482
Fax: (+44) 1939 251118 

Participants
1. Smithers Rapra Ltd (UK)
2. Fraunhofer-Gesellschaft zur Forderung der angewandten 
Forschung e.V. (DE)
3. The University of Birmingham (UK)
4. Technische Universiteit Eindhoven (NL)
5. Camera di Commercio, Industria, Artigianato e Agricoltura di 
Milano (IT)
6. British Plastics Federation (UK)
7. Italian Plastics and Rubber Processing machiniery and 
moulds manufacturers association (IT) 
8. Gesamtverband Kunststoffverarbeitende Industrie e. V (DE)
9. The Polymer Machinery Manufacturers and Distributors 
Association Ltd. (UK)
10. Turkish Plastics Industry Association (TR)
11. Rondol Technology Ltd. (UK)
12. Treffert S. A. S. (FR)
13. Vamp Technologies S.p.A. (IT)
14. EXTRICOM GMBH Blach Extruder& Components (DE)
15. DG Tec S.A.S. (FR)
16. ICMA San Giorgio (IT)
17. Centro Europeo Sviluppo Applicazioni Plastiche (IT)
18. Ion PhaseE Oy (FI)
19. Sciences Computers Consultants (FR)
20. MAPEA (FR)
21. RCT SRL. (IT)

Project title
Innovative Polymer Flow Visualisation for Optimised Machine 
Design, Improved Mixing and Material Properties, Process 
Efficiency and Energy Reductions (PEPT-Flow)

Contract number
30191

Duration
36 months

Global project costs
€3 351 561

EC contribution
€2 182 667

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4/16/07   12:30:25 PM

 
 
 
 
 
 
 
 
 
 
 
FROM TRIAL AND ERROR TO STATE
OF THE ART
“In term, the measures developed by the 
Pro4Plast partners are expected to cut the 
time to market by 50% and to achieve a 
cost reduction of 30%.”

Injection moulding of plastic products 
is  used  in  the  production  of  a  vast  range  of 
items, appliances and consumer goods. At the moment, 
the design of plastic products and moulds is based largely on 
craftmanship and empirical knowledge, while simulation techniques 
are used only in critical cases. The Pro4Plast initiative is the first European 
collaboration  that  aims  to  place  the  process  on  more  of  a  scientific  footing. 
Assembling industry associations, research providers and participants from the entire 
supply chain of the EU plastic industry, the project aims to improve the competitiveness of 

Pro4Plast

European SMEs in the field. 

Injection  moulding  is  a  widespread  manufacturing  technique 
used  to  produce  thermoplastic  parts.  During  the  process, 
molten plastic is injected at high pressure into a mould, which 
is  the  inverse  of  the  product’s  shape.  Injection  moulding  is 
contingent on the material characteristics, the product design 
and the process parameters. Typical items produced using this 
technique include car bumpers, interior and exterior car parts, 
fuel  systems  parts,  and  electric  or  electronic  appliances  like 
washing machines, TV sets and hi-fi systems. 

In  fact,  injection  moulding  is  the  most  common  production 
method  for  plastic  products.  However,  the  current  product 
development  process,  with  its  standard  approach  of  trial 
and  error,  is  in  dire  need  of  change.  Trial  and  error  involves 
selecting  a  possible  solution  to  a  problem,  applying  it  to  the 
problem  and,  if  unsuccessful,  selecting  or  generating  another 
possibility  that  is  subsequently  tried.  The  process  ends  only 
when  a  possibility  yields  a  solution.  This  approach  has  its 
shortcomings: it makes no attempt to discover why a solution 
works, and moreover, it only produces one solution (there may 
be more than one accessible), which is therefore not necessarily 
the best obtainable result.

The Pro4Plast project has been set up to negotiate the transition 
towards  a  more  precise  methodology  in  the  field  of  injection 
moulding  product-development-process.  If  successful,  the 
initiative could constitute a vital step for approximately 40 000 
European SMEs.

Big market, facing an even bigger challenge
The  European  injection  moulding  and  mould-making  industry 
has  an  annual  turnover  of  EUR  150  billion  and  employs  1.5 
million  people,  mainly  in  medium-sized  companies.  Although 
the European plastics industry is still the worldwide technology 
leader,  it  is  already  losing  5%  annually  to  low-wage  countries 
with  less  costs  and  shorter  development  times.  Today,  only 
these  countries  can  develop  and  produce  simple  plastic 
products at competitive prices. If European SMEs in the plastics 
sector are to maintain their competitiveness, they will need to 
produce  complex  and  highly  functional  parts,  using  both  fast 
and cost effective means. To this end, the Pro4Plast project is 
seeking  to  advance  the  state  of  the  art  in  injection  moulding, 
by developing a systematic approach to the production process 

and especially to the product-development process for complex 
parts.

Plastic  products  are  becoming  progressively  more  complex; 
this provides several reasons justifying why the trial and error 
method  is  increasingly  inefficient  for  product  development 
and problem solving. The first is that this method requires an 
injection  mould  to  be  conceived  and  manufactured  for  each 
new  design  of  a  plastic  product.  Subsequently,  production 
tests  need  to  be  performed  to  evaluate  both  injection  mould 
functionality  and  plastic  part  quality.  Finally,  the  process  of 
optimising parts, moulds and production processes, generates 
multiple iterations in the product development process, until an 
optimised  solution  is  obtained.  Consequently,  this  procedure 
requires extensive funding and considerable time.

Tackling the “time is money” issue
Pro4Plast  is  developing  an  enhanced  injection  moulding 
simulation software that will render fastidious trials and testing 
obsolete.  Another  powerful  tool  currently  under  development 
is  the  Product  Development  Guidance  System  (PDGS).  This 
flexible, affordable software tool will enable SMEs to establish 
themselves as ‘strategic development and production partners’, 
able to produce highly functional and complex parts at low cost 
and within a short period of time. Tailor-made for the necessities 
and  possibilities  of  European  SMEs, 
the  software’s  systematic 
approach  will  assist  in 
generating 
productivity 
employee 
and 
in 
machine 
de v e l o p me n t 
and production.

greater 
per 

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new 

product 

The 
development  process  will  be 
supported  and  promoted  by  a  new  training 
model, 
completed, the tools developed by the Pro4Plast partners are 
expected to cut the time to market by 50%, and to achieve a cost 
reduction of 30%. 

‘PDGS  certification’.  Once 

leading 

to  a 

Overall,  the  measures  implemented  by  the  Pro4Plast  project 
have  the  potential  to  reinforce  the  position  of  the  European 
plastic  industry  against  its  low-wage  competitors.  Moreover, 
the project’s outcomes could effectively help to ensure Europe’s 
continued leadership, in the field of plastic production.

Project title
New product development guidance system (PDGS) for 
complex injection moulded plastic parts by enhanced 
injection moulding simulation and material data measurement 
applicable by SMEs (Pro4Plast)

Contract number
30205

Duration
36 months

Global project costs
€4 450 097

EC contribution
€2 813 846

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Collective Research Volume 3

“If European SMEs in the plastics sector are to 
succeed in competition, they will need the 
endeavour to produce complex and 
highly functional parts in a fast and 
cost effective way.”

Contact Person
Georg Wilhelm Crößmann 
GKV Gesamtverband Kunststoffverarbeitende Industrie e.V.
Am Hauptbahnhof 12
60329 Frankfurt/M.
Germany
Tel. (+49) 69 2710536
Fax: (+49) 69 239836
Email: wcroessmann@gkv.de 

Project website
www.pro4plast.net 

Participants
1. Gesamtverband Kunststoffverarbeitende Industrie e.V. – GKV (DE)
2. Vereinigung zur Förderung des Instituts für 
Kunststoffverarbeitung in Industrie und Handwerk an der 
RWTH Aachen e.V. (DE)
3. Italian plastics and rubber processing machinery and 
moulds manufacturers’ association (IT)
4. Fundación AITIIP (Asociación de Investigación Taller de 
Inyección de la Industria) (ES)
5. Slovenska Asociacia Spracovatelov Plastov A Vyrobcov 
Specialneho Naradia (SK)
6. Association of the Hungarian Plastics Industry (HU)
7. GIZ GROZD PLASTTEHNIKA (SI)
8. Polish Plastics Converters Association (PL)
9. Clusterland Oberösterreich GmbH (AT)
10. PKT Präzisionskunststofftechnik GmbH (AT)
11. Dollwin Tooling B.V. (NL)
12. Kunststoff-Technik Schmoelln GmbH (DE)
13. Weißer + Grießhaber GmbH (DE)
14. Awender Kunststofftechnik GmbH (AT)
15. Centro Europeo Sviluppo e Applicazioni Plastiche (IT)
16. Ingeniera Computerizada de Molde S.L. (ES)
17. Polycom Skofja Loka, d.o.o (SI)
18. Miraplast Hungaria KFT (HU)
19. Termoplast Lisova Plastü (CZ)
20. ESOX-Tooling Spol s.r.o. (SK)
21. Polyconcent Plastic Engineering and Development (AT)
22. Simcon Kunststofftechnische Software GmbH (DE)
23. Netherlands Organisation for Applied Scientific Research 
– TNO (NL)
24. Rheinisch-Westfälische Technische Hochschule Aachen (DE)
25. Montanuniversität Leoben, Institut für 
Kunststoffverarbeitung (AT)
26. Universidad de Zaragoza - Otri (ES)
27. Slovenian Tool and Die Development Center (SI)
28. ASK Altmann Systemengineering Kunststofftechnik (DE)

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4/16/07   12:30:36 PM

 
 
 
 
 
 
 
 
 
 
 
SCRAPING OFF DISEASES FROM SHEEP 
POPULATIONS
“The visible symptom in infected animals is 
itching, which causes them to scrape off 
their fleece against fences or rocks; 
hence the name, scrapie.”

feature 

Free-roaming  sheep  are  common 
landscapes,  but 
in  Mediterranean 
behind  the  bucolic  beauty  of  these  scenes  lies  an 
invisible  threat  by  a  distinct  enemy  —  scrapie. This  disease 
spreads among flocks and herds and contaminates milk and dairy 
products. Dairy SMEs need effective tools to enable the regular control and 
risk assessment of scrapie in milk. The RISKSCRA project is aiming at achieving 
the scientific and technological objective of improving the safety of sheep milk-based 

RISKSCRA

Risk quantification
RISKSCRA  will  create  new  analytical  tools  and  test  their 
effectiveness  throughout  the  production  chain  of  sheep  dairy 
products.  The  research  will  benefit  all  stages  of  production, 
from  breeding  to  dairy  product  preparation.  Enhancing  risk 
control  methods  ensures  the  safety  of  milk  products  —  the 
principle concern for manufacturers wishing to fulfil consumer 
demands for safe foods.

Safer  food  products  can  have  a  direct  economic  impact  by 
allowing dairy SMEs to promote their products in new markets. 
Quality  attributes  can  be  put  forward  under  the  umbrella  of 
‘scrapie-free’ products, and goods sold on wider European and 
international  markets.  Research  results  will  be  disseminated 
via  training  courses  to  give  SMEs  tailored  support  for  better 
assimilation  of  new  technology  and  knowledge.  Training  is 
intended  to  provide  dairy  producers  and  sheep  breeders  with 
greater incentives for achieving commercial success.

The  new  RISKSCRA  analytical  tools  are  expected  to  enable  a 
reliable assessment and quantification of scrapie risks in sheep 
dairy  products  in  the  Mediterranean  area.  The  project  team 
aims at reconciling economic development with environmental 
local  producers  to  succeed  with 
sustainability,  enabling 
disease-free food products in demanding markets.

products from the Mediterranean area.

The European sheep population had reached nearly 90 million 
by  the  end  of  2004.  Mediterranean  countries  are  the  main 
producers, with two thirds of total production. The dairy sheep 
industry  represents  a  strategic  sector  for  Mediterranean 
agriculture  (in  Sardinia,  for  example,  sheep  breeding  is  the 
principal  activity)  but  the  vulnerability  of  herds  to  some 
diseases is a worrying factor.

Transmissible spongiform encephalopathy (TSE) diseases, such 
as  scrapie,  are  of  major  concern  to  breeders  and  sheep  dairy 
SMEs.  The  industry  needs  tools  to  prevent  scrapie  infection. 
RISKSCRA is a project with the objective of enabling the dairy 
sector  to  quantify  and  manage  the  risk  of  contamination. 
The  work  involves  12  partners  from  the  Mediterranean  basin 
including  Croatia,  Greece,  Italy  and  Spain  who  will  tackle 
complex issues requiring a combined level of human resources, 
equipment and facilities that are far beyond the capabilities of 
individual participants. 

Scrapie-free flocks
The  RTD  oriented  tasks  focus  on  the  current  knowledge 
regarding the genetic background of this particular form of TSE, 
in order to introduce a technique or device for detecting scrapie-
susceptible genotypes in milk. 

Scrapie is a degenerative disease, affecting the nervous system 
of  sheep  and  goats.  The  visible  symptom  in  infected  animals 
is itching, which causes them to scrape off their fleece against 
fences or rocks; hence the name, ‘scrapie’. Like other TSE forms, 
such  as  bovine  spongiform  encephalopathy  or  BSE,  scrapie 
is caused by a proteinaceous infectious agent, called a prion. 
After  a  long  incubation  period  in  the  host  sheep,  the  disease 
spreads destroying tissues and organs.

This TSE is transmissible among sheep and goats but it has not 
yet been confirmed whether it can be passed on to other animals 
or humans. The spreading mechanism is not yet fully understood 
and more research is needed. A better understanding of these 
mechanisms  is  of  particular  importance  in  the  context  of 
RISKSCRA, which focuses on free-flocking herds,  which move 
around without any particular  restraint. 

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Collective Research Volume 3

“Enhancing risk control methods ensures the 
safety of milk products — the major concern 
for manufacturers, wishing to fulfil 
consumer demands for safe foods.”

Project title
Dairy products in Mediterranean sheep populations: 
quantification of scrapie risk (RISKSCRA)

Contract number
30278

Duration
24 months

Global project costs
€1 540 000

EC contribution
€1 053 000

Contact Person
Riccardo Aleandri
Istituto Sperimentale Italiano “Lazzaro Spallanzani”
La Quercia
26027 Rivolta d’Adda — Cremona
Italy
Tel. (+39) 036378883
Fax: (+39) 036337047981
Email: riccardo.aleandri@istitutospallanzani.it

Participants
1. Istituto Sperimentale Italiano “Lazarro Spallanzani” (IT)
2. Consorzio Tutela Formaggio Pecorino Romano (IT)
3. Chios Sheep Breeders’ Cooperative “Macedonia” (EL)
4. Consejo Regulador del Queso Zamorano (ES)
5. Hijos de Salvador Rogriguez (ES)
6. Quesos Campostera (ES)
7. F.lli Pinna Industria Casearia SpA (IT)
8. Agriexport Sardegna Coop srl (IT)
9. Istituto Zootecnico Caseario per la Sardegna (IT)
10. Departamento Producción Animal Facultad de Veterinaria, 
Universidad de León (ES)
11. Animal Science Department, Faculty of Agriculture, 
University of Zagreb (HR)
12. School of Veterinary Medicine, Aristotle University of 
Thessaloniki (EL)

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4/16/07   12:30:47 PM

 
 
 
 
 
 
 
 
 
 
 
GETTING A RAW DEAL

SAFECHEESE

“The primary objective of the Safecheese project 
is to develop a barrier to prevent pathogenic 
bacteria from growing in raw milk 
cheeses.”

Raw  milk  cheeses  made  in  the  EU  are 
appreciated  by  consumers  all  over  the  world. 
But unfortunately, every year people fall ill owing to the 
consumption of cheese made from non-pasteurised milk, which 
often gives these products bad publicity. Thousands of European SME 
cheese producers make cheese from raw milk, which has a unique taste and 
quality; however, it often fails to enter the market, because it lacks the adequate 
pathogenic barrier that a pasteurisation process would provide. It is impossible to eliminate 
occasional contamination of non-pasteurised milk with harmful bacteria, even when dairy farms 
adhere  to  strict  clean  milking  and  cooling  procedures.  Current  EU  legislation  calls  for  measures 
ensuring that all food made available to consumers should be safe to eat. This legislation, coupled with 
consumer choice issues and the continued success of the cheese production industry, has induced those 
involved in the Safecheese project to explore safer means of producing raw milk cheese.

A cultural clash ?
The  Safecheese  project  aims  to  develop  a  specific,  mixed 
protective  culture  of  lactic  acid  bacteria,  making  it  possible 
for  raw  milk  cheese  producers  to  deliver  safer  cheese, 
without compromising on taste. This protective culture will be 
characterised  according  to  its  protective  properties,  and  then 
produced  in  a  pilot  plant,  with  selected  protective  cultures 
added to the starter culture. Once the cheeses are successfully 
produced and certified, cheese makers across the EU can begin 
to introduce potential protective cultures.

Safecheese  aims  to  help  SMEs  in  the  sector  to  become  more 
competitive,  by  reducing  costs,  adding  value  and  boosting 
consumer  confidence.  Milk  and  cheese  producers  combined, 
employ an estimated 910 000 people across the EU, often in rural 
areas.  It  is  anticipated  that  the  sector  will  grow  substantially, 
once  the  average  EU  consumer  is  reassured  concerning  the 
health  risks  of  raw  milk  cheese,  and  the  increased  safety  of 
the products on the shelves. Cheese producers frequently find 
it  difficult  to  adhere  to  safety  regulations,  while  attempting 
to  maintain  traditional  production  methods  and  customer 
satisfaction. Through its research and development activities, 
however, the Safecheese project strives to strike this delicate 
balance. 

The  primary  objective  of  the  project  is  to  develop  a  barrier 
that will prevent pathogenic bacteria from growing in raw milk 
cheeses.  This  will  be  achieved  through  the  development  of  a 
protective  culture  of  lactic  acid  bacteria,  originating  from  raw 
milk cheese. This protective culture would subsequently prevent 
the growth of pathogenic bacteria, ultimately resulting in safer 
cheese  from  non-pasteurised  milk,  for  EU  consumers.  The 
project’s general aim is to expand the current understanding of 
microbiological  growth,  affecting  both  the  wanted  lactic  acid 
bacteria,  and  the  unwanted  pathogenic  bacteria  in  raw  milk 
cheeses. This information would contribute to food safety in a 
cost-effective way, while respecting consumer preferences for 
natural foods.

Feeling bleu: Safeguarding consumer health
The lack of a pathogenic barrier is frequently a factor preventing 
pan-European  and  global  distribution  of  raw-milk  cheeses. 
It  is  consequently  necessary  that  EU  producers  explore  and 
develop the means to produce safer cheese. Food safety is an 
increasingly important public health and consumer concern, as 
problems with food safety transpire; worldwide, governments  
are redoubling their efforts to safeguard both consumer health 
and the sector itself.

The  general  public  is  aware  of  pathogenic  bacteria  such  as 
Salmonella,  Listeria  and  E.coli,  but  food  borne  diseases  are 
still  chronically  under-reported,  even  though  it  is  estimated 
that these illnesses are responsible for the annual loss of one 
million  working  days.  There  is  therefore  a  perceptible  need 
to  produce  safer  raw  milk  cheese,  with  a  lower  risk  of  food 
borne  diseases  for  the  consumer.  Milk  pasteurisation  forms 
a  barrier  that  destroys  the  pathogenic  bacteria  in  milk,  but  it 
can also spoil the characteristic taste and flavour of cheeses. 
Consequently,  a  technology  which  conserves  the  renowned 
flavour  of  these  European  cheeses,  while  also  ensuring  the 
safety of EU citizens, needs to be developed. This technology 
would be applied by thousands of SMEs in the raw milk cheese 
sector, by augmenting existing production methods. 

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Collective Research Volume 3

“Lack of a pathogenic barrier often prevents pan-
European and global distribution of raw-milk 
cheeses.”

Project title
A barrier for preventing pathogenic bacterial growth in cheese 
from non-pasteurised milk (SAFECHEESE)

Contract number
30285

Duration
36 months

Global project costs
€1 450 000

EC contribution
€725 000

Contact Person
Dr Frøydis Bjerke
Matforsk AS
Osloveien 1,
N-1430 Aas, 
Norway
Tel. (+47) 64 97 04 81
Fax: (+47) 64 97 03 33
Email: safecheese@matforsk.no 

Participants
1. Matforsk AS (NO)
2. Norsk Gardsost (NO)
3. Consorzio del Formaggio Parmigiano-Reggiano (IT)
4. Food Processing Faraday Partnership Ltd (UK)
5. Kaanlar Gida Sanayi Ve Ticaret A.S. (TR)
6. Muto Giuliana Liugina (IT)
7. Theodorou Mochlaki Bros Partnership Company (EL)
8. Northumberland Cheese (UK)
9. CoProLAt Societa Cooperative (IT)
10. Coquard (FR)
11. Pera Innovation Limited (UK)

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4/16/07   12:31:01 PM

 
 
 
 
 
 
 
 
 
 
 
A SAFER WORKING ENVIRONMENT

SAFEWORKER

“… the car repair sector faces a serious skills 
shortage.”

European 

industrial  SMEs  operate 
in  competitive  markets.  To  achieve  success, 
business  practices  must  be  constantly  improved  e.g. 
by  developing  new  production  techniques  and  identifying 
better  materials.  One  aspect  they  cannot  neglect  is  the  safety  of 
their workers. European legislation imposes strict health and safety rules 
to reduce, amongst other things, the amount of occupational exposure to certain 

chemical substances. 

In the vehicle repair industry, the use of certain filler materials 
traditionally  used  for  car  body  repair  has  created  a  situation 
where  workers  are  exposed  to  styrene  vapour  which  is  given 
off by the styrene containing compounds used in this sector. In 
order to reduce this exposure and improve working conditions, 
the Safeworker project aims to introduce styrene-free fillers to 
the car repair industry.

Volatile organic compounds (VOCs) such as styrene are currently 
used  in  polyester  repair  fillers.  However,  alternative  products 
are needed, as the 98/24 EC Directive lists strict rules on ‘the 
protection of the health and safety of workers from risks related 
to chemical agents at work’. 

Fulfilling the expectations of SMEs
The participants of Safeworker intend to share the development 
of the new filler with as many industrial participants as possible, 
thus allowing the whole car repair sector to benefit from it. 

Safeworker  can  have  a  significant  and  positive  impact  on 
more than 170 000 SMEs working in the car repair sector and 
represent 98% of the companies involved. First of all, healthier 
working conditions improve the quality of life for workers and 
improve  their  productivity.  The  filler  itself  will  allow  it  to  cure 
rapidly and the use of UV lamps will accelerate the turnaround 
of repairs and reduce costs, hence improving the productivity 
and revenues of the companies adopting the new technology.

The Safeworker consortium of 12 RTDs, IAGs and SMEs expects 
to  develop  new  body  repair  fillers  used  in  the  repair  of  dents 
and  damage  in  vehicle  bodies  which  will  reduce  or  eliminate 
exposure to styrene in this market sector. Each year, 100 000 
workers are affected by styrene, and nearly 300 000 tonnes this 
chemical is released into the atmosphere.

The  developments  introduced  by  the  Safeworker  project  are 
expected to have a positive impact on the situation of workers 
and  employers  in  the  car  repair  sector.  Workers  will  be  less 
exposed  to  hazardous  products  and  to  skin  and  respiratory 
diseases.  Employers  could  attract  more  skilled  people  and 
respond to the demands of a sector with increasing demand.

Looking Ahead
Styrene,  an  aromatic  hydrocarbon,  can  lead  to  problems 
associated  with  occupational  exposure,  such  as  dermatitis. 
In  Europe,  the  maximum  allowable  concentration  of  styrene 
vapour allowable in the workplace is controlled by legislation. 
Styrene  is  also  classified  by  the  International  Agency  for 
Research on Cancer (IARC) as a possible human carcinogen, so 
it is important to reduce its uses and applications by finding a 
suitable replacement.

As  a  result  of  the  dangers  presented  by  chemicals  used  in 
industry, the car repair sector faces a serious skills shortage. 
Indeed, workers are reluctant to follow the car repair professional 
path.  The  paradox  is  that  the  skills  shortage  comes  at  a  time 
when prospects for the repair market are at their highest. There 
are  over  180  million  cars  in  Europe,  with  an  average  increase 
of 2.3% annually, and the demand for repairs follows the same 
pattern of increase.

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Collective Research Volume 3

“… the skills shortage comes at a time when 
prospects for the repair market are at their 
highest.”

Project title
Reduction of Occupational Asthma and Dermatitis in the 
Vehicle Repair Industry (SAFEWORKER)

Contract number
30305

Duration
36 months

Global project costs
€2 466 713

EC contribution
€1 404 824

Contact Person
Paul Sherratt
Pera Innovation Limited
Nottingham Road
Melton Mowbray
Leics LE13 0PB
United Kingdom
Email: paul.sherrat@pera.com 

Project website
http://safeworker.pera.com

Participants
1. Pera Innovation Limited (UK)
2. Motorbranschkonsunt Aktiebolag (SE)
3. Retail Motor Industry Federation (UK)
4. Confederación Española de Talleres de Reparación de 
Automóviles y Afines (ES)
5. Uvasol Limited (UK)
6. Movac Group Limited (UK)
7. Proxima NTR (PL)
8. COLAS (E)
9. Glascraft (UK10 Fraunhofer-Gesellschaft zur Forderung der 
angewandten Forschung e.V. (DE)
11. Instituto Pedro Nunes, Associação para a Inovação e 
Desenvolvimento em Ciência e Tecnologia (PT)
12. Autobranchens Arbejdsmiljo (DK)

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4/16/07   12:31:14 PM

 
 
 
 
 
 
 
 
 
 
 
NOT EVERYTHING THAT GLITTERS
IS SAFFRON
“The adulteration of saffron in Europe, which has 
been noticeable in the latest decades, has 
caused the distrust of consumers.”

The  past  years  have  seen  a 
proliferation  of  fraudulent  practices  in  the 
saffron  spice  market.  This  phenomenon  is  due  to  a 
lack of technological standards applying to the detection of 
counterfeits:  despite  the  advances  achieved  in  the  unification  of 
authenticity  criteria,  some  technological  limitations  remain  unresolved. 
For instance, there is no definite proposal to modify the outdated test method 
established  by  the  International  Organisation  for Standardisation  in  2003,  which  is 
still the main tool used to counter saffron adulteration. European IAGs, SMEs and research 
institutes have therefore joined forces to create SAFFIC, a platform intended to develop a new 

SAFFIC

methodology that will improve international quality control norms.

Back to nature
In  order  to  simplify  the  quality  control  of  saffron  by  SME 
personnel,  the  technology  developed  by  the  SAFFIC  project 
partners, has to be more reliable and cost-effective than current 
techniques. To this end, near infrared spectroscopy — the study 
of interaction between light and matter — provides affordable 
and  fast  analyses,  not  necessitating  sample  pre-treatment. 
Moreover, this method can be easily combined with techniques 
currently in use, at saffron producing facilities. 

In addition, the introduction of Polymerase chain reaction (PCR) 
techniques for microbiological determination, makes it possible 
to  reduce  the  size  of  samples  and  to  analyse  several  strains 
concurrently. In addition to reducing costs, these methods will 
require less sample treatment and consequently less analysis 
time, laboratory equipments and consumable waste, but also 
less personnel training. 

Overall, the SAFFIC methodology will be more sensitive, accurate 
and  reproducible  than  the  current  testing  norm.  Beyond  the 
potential boost it may provide to the European saffron sector, 
SAFFIC  might  inspire  similar  initiatives  in  the  detection  of 
non-legal adulterants in foodstuff, thereby contributing to the 
overall quality of natural products from Europe.

Derived  from  dried  stigmas  of  the  Crocus  Sativus  Linneaus 
flower,  saffron  is  the  most  precious  and  expensive  spice 
worldwide.  It  is  also  one  of  the  few  spices  that  can  transmit 
three  different  sensory  properties  of  food:  colour,  taste  and 
aroma. These characteristics, combined with its unique taste, 
render  saffron’s  qualities  justly  appreciated.  However,  the 
adulteration of saffron in Europe — a marked development over 
the past decades — has caused distrust amongst consumers. 
As  a  result,  consumption  of  European  saffron  has  decreased 
in  favour  of  products  provided  by  countries  outside  the  EU. 
Considering the fact that European companies control over 90% 
of the global saffron market, the challenge they face is severe.

The  current  international  norm  (ISO)  regulating  the  purity  and 
quality of saffron, does not currently include any reliable analytical 
techniques  capable  of  detecting  basic  colorants  and  natural 
pigments. Nevertheless, a reliable tool applied to this task, would 
prove  invaluable  in  fighting  fraud  and  establishing  objective 
criteria of food quality. Furthermore, the test method established 
in 2003 (ISO/TS 3632), does not provide a tool that can determine 
microbiological  contamination,  so  as  to  assure  food  safety.  The 
necessity  for  a  new  testing  standard  is  compelling,  both  from  a 
market and a consumer-health perspective. 

Regaining consumers' trust
The SAFFIC consortium aims to modify the current ISO norm and 
introduce reliable standard procedures to fight fraud. Within this 
context, European SMEs could play a crucial role as controlling 
entities  of  saffron  quality.  An  efficient  control  mechanism  of 
synthetic colorants and pigments, would detect possible toxic 
effects of adulterated saffron thereby ensuring safety standards 
for consumers, as well as regaining their trust.

Although it is already possible to verify the authenticity of saffron 
by identifying the compounds responsible for colour, aroma and 
bitterness, the costs of current techniques is a factor rendering 
them  unsuited  to  SMEs.  Moreover,  the  choice  of  techniques 
varies from country to country. The SAFFIC methodology defining 
the criteria for purity, quality and food safety, will actually be the 
main tool supporting the competitiveness of European SMEs in 
the saffron sector. The project will unify these criteria, and will 
ultimately provide a unique methodology with the capacity to 
assess the authenticity of saffron. 

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Collective Research Volume 3

 “The SAFFIC consortium aims to modify the 
current ISO norm and introduce reliable 
standard procedures to fight fraud.”

 Project title
Methodologies for implementing International Standards for 
Saffron Purity and Quality (SAFFIC)

Contract number
30195

Duration
36 months

Global project costs
€2 762 312

EC contribution
€1 868 139

Contact Person
Juan Ramón Muñoz Montaño
Asociación Española de Elaboradores y Envasadores de 
Especias y Condimentos  
c/Felix Boix, 3 7 centro
Madrid
Spain
Tel. (+34) 913431184
Fax: (+34) 911412655
Email: jrmm@zurkor.com

Participants
1. Asociación Española de Elaboradores y Envasadores de 
Especias y Condimentos(ES)
2. Asociación Española de Normalización y Certificación (ES)
3. Societa Semplice su Zafferan (IT)
4. Asociatia Producatorilor, Prelucratorilor si Utilizatorilor de 
Plante (RO)
5. Krokos Kozani Cooperative of Safran (EL)
6. Hellenic Organization for Standardization (EL)
7. Consejo Regulador Denominación de Origen La Mancha (ES)
8. Verdú-Cantó Saffron Spain (ES)
9. Compañía Exportadora de Azafrán Español (ES)
10. Jesus Navarro, S.A. (ES)
11. Aromatic, A.B (SE)
12. Maria Carmine Ennas (IT)
13. Franco Curreli (IT)
14. Franco Sanna (IT)
15. Bakatzounis Markos Sons Aebe Vatero (EL)
16. S.C. Nutraceutical (RO)
17. Universidad de Castilla-La Mancha (ES)
18. Agricultural University of Athens (EL)
19. Instituto Técnico Agronómico Provincial de Albacete (ES)
20. Universidad Alcalá de Henares (ES)

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4/16/07   12:31:23 PM

 
 
 
 
 
 
 
 
 
 
 
SLIPPING WAS YESTERDAY

SlipSTD

“The production of safer flooring represents a big 
potential market for the ceramic floor tile 
industry.”

The societal and economical impacts 
of  slip  accidents  are  wide ranging. Accidents 
caused by slipping and tripping, are the most common 
cause  of  injuries  at  work.  Ninety-five  percent  of  major  slips 
result  in  broken  bones,  and  with  older  people  comprising  an 
increasing  section  of  the  population,  such  injuries  are  likely  to  become 
even more of an issue. Therefore, there is a pressing need to take action, and try 
to prevent slip accidents. This can be achieved by improving the slip resistance of shoes 
and floorings, and by maintaining clean surfaces without slippery interfacial contaminants. 
Designing, testing and installing safer flooring surfaces is a first task for enhancing safety. The 
SlipSTD project is focused on optimising the design of floor tiles and has been set up to stimulate this 

process at the EU level, and to help reduce the number of slip accidents.

Setting safety standards
SlipSTD is to create a reference database of validated surface 
profiles,  and  a  set  of  standard  surfaces  tested  with  different 
slip  resistance  characteristics.  This  will  provide  a  carefully 
defined,  reproducible  validation  tool 
for  slip  resistance 
measurements.  In  addition,  the  project  partners  will  publish 
a Publicly Available Specification (PAS), indicating the surface 
requirements  for  glazed  or  unglazed  ceramic  floor  tiles,  to  be 
classified as resistant. These results could be used in the future 
by the corresponding standardisation committees to help them 
to define this characteristic for ceramic tiles.

In short, SlipSTD will provide rules, guidelines and characteristics 
advising tile manufacturers how to best produce slip-resistant 
ceramic floor tiles, and earn the trust of consumers. The project 
will also provide architects with simple guidelines to generate 
confidence  in  designing  these  safer  floors.  Ultimately,  the 
outcomes  of  the  SlipSTD  project  are  expected  to  significantly 
reduce the number of slip accidents across Europe.

Although  numerous  safety  requirements  exist  for  other 
products,  there  are  currently  no  comprehensive  European 
manufacturing  guidelines  for  the  production  of  slip-resistant 
ceramic tiles, nor are there coordinated test methods to measure 
slip-resistance. For instance, the current standard defining the 
minimum requirements for ceramic tiles to be labelled with CE 
marking,  does  not  include  a  common  ‘European’  requirement 
for slip characteristics. 

Consequently, diverse national standard methods are still used 
to  assess  slip-resistance,  inevitably  leading  to  trade  barriers 
between European countries, owing to their diverging practices. 
In  the  absence  of  agreed  slip  requirements  harmonised  and 
validated tests, tile manufacturers tend to strive for innovative 
products  in  terms  of  aesthetic  appeal,  rather  than  focus  on 
improved health and safety performance. Still, the production 
of safer flooring represents a substantial untapped market for 
the European ceramic floor tile industry, which is dominated by 
SMEs.

Scratching the surface
Assembling  a  balanced  mix  of  end-users,  well-known  public 
bodies,  tile  manufacturers,  associations,  architects,  and 
European  Research  Centres,  the  SlipSTD  consortium  will  rely 
on this cross-disciplinary expertise. SlipSTD aims to reduce the 
number of slip accidents, by specifying the main floor surface 
characteristics  associated  with  engineering  slip  resistance 
floorings. 

A  multidisciplinary  approach  will  be  applied,  to  produce 
fundamental data concerning slip resistant surfaces, in terms 
of  the  topography  (micro  and  macro  structures)  and  the 
relevance of the surface structure in various environments. This 
methodology will include research on the tribological properties 
(friction, lubrication, wear) of ceramic tiles. It will also rely on 
computer  simulations  and  surface  science  to  design  surfaces 
with  graded  slip  resistance.  The  generated  knowledge  will 
provide sound guidelines that will assist manufacturers when 
designing improved slip resistant flooring tiles.

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Collective Research Volume 3

“SlipSTD aims at reducing the number of slip 
accidents by specifying the main floor 
surface characteristics associated 
with engineering slip resistance 
floorings.”

Project title
Development of Slip Resistance Standard Surfaces (SlipSTD)

Contract number
30287

Duration
36 months

Total project cost:
€2 140 769

EC contribution
€1 318 284

Contact Person
Dr Giuliano Tari
Manager, Technology Group
CERAM
Queens Road, Penkhull
Stoke-on-Trent
ST4 7DS 
England
Tel. (+44) (0) 1782 764240
Fax: (+44) (0) 1782 412331
Email: giuliano.tari@ceram.com  
Website: www.ceram.com 

Project website
www.ceram.com/projects/slipstd/index.html 

Participants
1. CERAM Research Ltd (UK)
2. UK Tile Association (UK)
3. Assiopastrelle (IT)
4. ASCER (ES)
5. ASPICER (PT)
6. Centre for Occupational Health (FI)
7. UK Health and Safety Executive (UK)
8. Royal Institute of British Architects (UK)
9. Forschungsinstitut für Anorganische Werkstoffe (DE)
10. Fraunhofer Institute — IPT (DE)
11. Finnish Institute of Occupational Health (FI)
12. Italian Ceramic Centre (IT)
13. Uppsala University (SE)
14. TopCer Lda (PT)
15. Dennis Ruabon Ltd (UK)
16. Cedir, Ceramiche di Romagna Spa (IT)
17. Alois Korzilius Interbau GmbH (DE)
18. Ceracasa SA (ES)

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4/16/07   12:31:33 PM

 
 
 
 
 
 
 
 
 
 
 
UNDERWATER PREVENTION AND 
DETOXIFICATION
“Most of the toxins are not fatal for shellfish 
(molluscs and crustaceans), but they can 
have distressing and even severe 
effects on humans.”

pertains 

Aquaculture 

the 
improvement  and  control  of  fish  production  of 
all types, and also to the attempt to ensure a permanent 
for  consumers,  without  over-fishing.  European 
aquaculture production is still marginal in the worldwide market, and 
protection against toxins is an issue requiring attention, if this market is to 
prosper. For instance, in shellfish culture (as with other intensive cultures such as 
poultry farming), the slightest contamination of a raft or tank can be disastrous for the 
production output. The SPIES-DETOX project aims to improve the early detection of algal toxins, 
and to define new protocols for the protection of shellfish aquacultures, thus protecting SMEs and 

supply 

to 

SPIES-DETOX

other stakeholders involved in the sector.

Most of the toxins are not fatal for the shellfish per se (molluscs 
and  crustaceans),  but  they  can  result  in  distressing  and  even 
severe effects on humans. Notably, some toxins are capable of 
causing diarrhoea, amnesia and even paralytic poisoning.

The SPIES-DETOX consortium draws on the expertise of 19 IAGs, 
SMEs and RTD performers in the fields of aquaculture and toxin 
research, from both the North Sea area and the Mediterranean. 
Their  mission  is  to  develop  new  methods  for  detecting  and 
eventually destroying the toxins found in shellfish that are bred 
in aquaculture. 

Mission: search and destroy
The key to effective destruction of contaminating toxins lies in 
the  reliability  and  performance  of  the  monitoring  system.  For 
SPIES-DETOX, the monitoring system will be based on a solid 
phase adsorption device. The device will contain a gel, to which 
toxins  will  attach.  The  existing  data  concerning  toxins  will 
enable the project team to configure the solid phase device and 
combine it with remote real-time samplers, placed underwater. 
The  team  expects  these  probes  to  eventually  become  the 
preferred  management  and  control  tools  for  the  aquaculture 
industry.

While  working  to  improve  detection  of  algal  toxins,  SPIES-
DETOX participants intend to investigate new protocols for the 
destruction of toxins. These protocols will be applied during the 
mechanical  washing/tumbling  phase,  during  which  shellfish 
are cleaned, before being packed and sold. 

The project team will also focus on the indispensable study of 
bacterial degradation of toxins. Whereas the cleaning protocols 
are  applied  during  processing,  bacterial  degradation  takes 
place while shellfish grow inside tanks or rafts. The bacteria are 
in fact fed via microcapsules to the molluscs and crustaceans; 
once released, the bacteria will destroy the toxins, in a biological 
process.

Controlling the future of aquaculture
Ultimately, the intention of the participants in SPIES-DETOX is 
to  eradicate  toxins  from  aquaculture.  To  achieve  its  goal,  the 
team  will  develop  tools  and  protocols  which  in  time  could  be 
widely adopted by the aquaculture industry. 

Once  the  new  technology  is  perfected,  dissemination  and 
training activities must be undertaken, so as to ensure that the 
knowledge acquired during the project is adequately distributed. 
On the one hand, dissemination will raise public awareness in 
relation  to  the  findings  of  the  project.  On  the  other,  training 
will  focus  on  transferring  scientific  intelligence  and  skills  to 
industrial  users  and  researchers.  Trained  industrials  will  be 
able to adopt the SPIES-DETOX device as an everyday control 
tool. As for researchers, they will be able to obtain cutting-edge 
information on toxins, and also to conduct further research in 
areas and subjects deriving from the results of this project.

European  SMEs  involved  in  aquaculture  are  far  behind  their 
Asian rivals, who produce 91% of all aquaculture fish (as noted 
in 2004, with regard to all fish types). Nonetheless, European 
producers are aiming for the best quality and safest products. 

By  developing  new  detection  and  detoxification  methods, 
SPIES-DETOX will not only reduce the risks of contamination for 
shellfish consumers, but will also contribute to the sustainability 
of the European aquaculture industry.

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Collective Research Volume 3

“The intention of the participants at SPIES-DETOX 
is to eradicate toxins from aquaculture.”

Project title
Active biological monitoring and removal of toxins in 
aquaculture ecosystems and shellfish — including the 
development of a solid-phase in-situ ecosystem sampler and 
detoxification of shellfish (SPIES-DETOX)

Contract number
30270

Duration
36 months

Global project costs
€3 064 287

EC contribution
€2 416 226

Contact Person
Alan Coghill
Orkney Fisheries Association
6, Ferry Terminal Buildings
Kirkwall Pier
KW15 1HU
Kirkwall
Orkney
United Kingdom
Email: dennis@researchrelay.com

Participants
1. Orkney Fisheries Association (UK)
2. Association of Scottish Shellfish Growers (UK)
3. Biomarin Vekst (NO)
4. ANFACO — Asociación Nacional de Fabricantes de Conservas 
de Pescados y Mariscos (ES)
5. Clew Bay Marine Forum Ltd (IE)
6. Association of Greek Shellfish Producers (EL)
7. Havbrukskompaniet AS (NO)
8. Hvalerskjell AS (NO)
9. Celtic Atlantic Salmon Ltd (IE)
10. Applied Enzyme Technology Ltd (UK)
11. Kvitsøy Edelskjell AS (NO)
12. Biosense Laboratories AS (NO)
13. Fisheries Research Services (UK)
14. National University of Ireland, Galway (IE)
15. Aristotle University of Thessaloniki (EL)
16. Scottish Association for Marine Science (UK)
17. Universidade de Santiago de Compostela (ES)
18. Central Science Laboratory (UK)
19. North Bay Shellfish Ltd (UK)

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FRESH FISH FROM THE FARM

SustainAqua

“ A lack of common best practices and the threat 
from low cost producers put European 
aquaculture farms under double 
pressure.”

In  the  last  30  years,  world  fish 
consumption has almost tripled, while roughly 
75% of the world’s most valuable marine fish stocks 
are either fished to the limits, or over-fished. It is estimated 
that  consumer  demand  will  rise,  and  therefore  sustainable 
alternatives for fishery must be developed worldwide, inclusive of Europe. 
The  freshwater  aquaculture  industry  is  certainly  a  promising  solution  to  the 
demand of European fish consumers, but it is hampered by an absence of harmonised 
sustainable best practice strategies, and also by competition from low cost fish producers 
from abroad. Moreover, European aquaculture farmers will need to adapt to new requirements in 

the fields of quality, environment and health. 

The taste of health
The consortium seeks to demonstrate that sustainably managed 
aquaculture systems have a positive effect on the taste of fish 
products and the quality of the fish meat. ‘Good fish taste’ is a 
crucial marketing criterion and, in this case, its accuracy will be 
verified through professional sensory tests. 

Sustainable farm management – Indicators 
and criteria

into  account  already  existing 

Taking 
indicator  systems, 
the  consortium  will  develop  a  practical  oriented  indicator 
and  criteria  system  for  sustainable  freshwater  aquaculture 
management.  The  team  intends  to  scientifically  contribute  to 
the development of Europe-wide discussions about sustainable 
quality  standards  and  to  give  recommendations  for  further 
research activities and co-operations.

Training european aquaculture farmers
More than 10 000 aquaculture farmers will directly benefit from 
the project results. Research organisations linked to the project 
will  train  their  partner  associations  which  in  turn  will  train 
their  member  SMEs  via  workshops  and  E-learning  seminars. 
Additionally a “practical guide for implementation of sustainable 
farm management” will be developed and ten 
different 
“regional  advisory  platforms 
for aquaculture farmers” 
be installed.

The  European  aquaculture  industry  has  made  substantial 
leaps of progress over the past decades. Dominated by SMEs 
(90%) and providing over 60 000 jobs, it is rightly considered 
a  significant  segment  of  the  EU  economy  and  global  fisheries 
sector.  However,  a  lack  of  common  and  sustainable  oriented 
best  practices  and  the  threat  posed  by  low  cost  producers 
from  Asia,  Latin  America  and  the  Caribbean,  place  European 
aquaculture farms under acute pressure.

In  addition,  further  problems  arise  as  a  result  of  the  adverse 
impact of the discharge of effluents, of the use of chemicals, of 
the limited number of different fish species or of dense stocking 
rates.  This  is  due  in  equal  measure  to  anticipated  restrictive 
European and national legislations, and to increased customer 
awareness generating new demand.  The SustainAqua initiative 
is set to address these issues, by improving both the knowledge 
base and the commercial performance and image of European 
freshwater aquaculture farmers.

Making nature profitable
The project consortium is developing and researching different 
options  for  upgrading  existing  aquaculture  farms  in  the 
direction  of  product  diversification,  quality  improvement  and 
optimisation of production processes. This will be done in five 
different  case  studies  in  Hungary,  Poland,  the  Netherlands, 
Denmark  and  Switzerland.  Each  study  represents  one  of 
Europe’s most relevant freshwater aquaculture fish species. 
The consortium intends to transfer the highly effective nutrient 
management  principles  of  natural  systems  into  competitive 
aquaculture  farm  strategies.  One  example:  alongside  the 
fish  production,  organic  material  will  be  exploited  as  far 
as  possible  for  the  production  of  marketable  products  like 
macroinvertebrates,  algae  or  plants  for  different  industrial 
applications.  Product  diversification  will  enable  fish  farmers 
to extend their customer range, produce for different demands 
and cope with market fluctuations. Besides, optimised nutrient 
chains reduce waste to nearly zero, avoid the implementation 
of  expensive  wastewater  treatment  and  filter  technologies, 
and  reduce  costs.  These  principles  will  be  tested  in  different 
extensive, semi-intensive and intensive aquaculture systems. 

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the 
European 

improving 
of 

Beyond 
competitiveness 
aquafarmers, the results of the SustainAqua 
project  are  also  expected  to  boost  employment 
throughout the European aquaculture production chain. Overall, 
SustainAqua  will  encourage  sustainable  development  in  rural 
areas and will support an environmentally sound, economically 
viable, European freshwater aquaculture.

Project title
Integrated approach for a sustainable and healthy freshwater 
aquaculture (SustainAqua)

Contract number
30384 

Duration
36 months

Global project costs
€3 301 493

EC contribution
€2 504 923

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Collective Research Volume 3

“The SustainAqua initiative is set to expand 
both the knowledge base, and the 
commercial performance and 
image of European freshwater 
aquaculture farmers.”

Contact Person
Ina Küddelsmann 
ttz Bremerhaven
Fischkai 1 
27572 Bremerhaven
Germany
Tel. (+49) 471 4832 171
Fax: (+49) 471 4832 129
Email: kueddelsmann@ttz-bremerhaven.de 

Project website
www.sustainaqua.org 

Participants
1. Verein zur Förderung des Technologietransfers an der 
Hochschule Bremerhaven e.V. (DE)
2. International Organisation for the Development of Fisheries 
in Eastern and Central Europe (DK)
3. Szarvasi Akvapark Egyesület (HU)
4. Verband der Deutschen Binnenfischerei e.V. (DE)
5. Vattenbrukarnas Riksförbund (SE)
6. Polskie Towarzystwo Rybackie (PL)
7. Organización de productores piscicultores (ES)
8. Österreichischer Fischereiverband (AT)
9. Su Ürünleri Tanitim Dernegi (TR)
10. The Danish Aquaculture Organisation (DK)
11. International Ecological Engineering Society (CH)
12. Teichwirtschaft Kainz (AT)
13. AquaBioTech Innovia Ltd. (MT)
14. Aranyponty Halaszati Rt. (HU)
15. Aquakultur Kahle (DE)
16. Hodowla Ryb “SALMO” (PL)
17. Liman Enegre Balikçilik Sanayii ve Ticaret Ltd. STI. (TR)
18. Viskwekerij Royaal B.V. (NL)
19. University of South Bohemia in Ceske Budejovice (CZ)
20. Wageningen University - Aquaculture and Fisheries Group (NL)
21. Polska Akademia Nauk, Zaklad Ichtiobiologii I Gospodarki 
Rybackiej (PL)
22. Martin-Luther-University Halle Wittenberg (DE)
23. Halászati és Öntözési Kutató Intézet (HU)
24. Danish Institute fro Fisheries Research (DK)

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BOUNCING BACK INTO BUSINESS

TECH-SPRING

“The idea behind TECH-SPRING is to produce a 
toolkit for innovation and for novel spring 
designs.”

Over  the 

last  decade, 

increasing 
globalisation has opened many new markets 
to  European  SMEs.  The  reverse  side  of  the  coin  is 
that European companies have not always managed to cope 
with the economic pressures from incoming competition, from Far 
East  countries  for  example.  For  spring  manufacturers,  for  instance,  the 
last 10 years have seen a decline in sales and revenue. Rising to the challenge 
of  reversing  the  situation  and  sending  European  business  to  the  top  of  the  market 
hierarchy, the TECH-SPRING project plans to introduce various technical advances to spring 

technology.

The  idea  behind  TECH-SPRING  is  to  produce  a  toolkit  for 
innovation and for novel spring designs. The toolkit is expected 
to  facilitate  the  manufacture  of  lighter  springs  with  improved 
performance and durability, coping with the requirements of the 
producers and customers. Using the toolkit, SMEs will be able 
to individualise their production strategy and their commercial 
approach to obtain the best possible economic results.

The spring revolution
The TECH-SPRING project is a programme of structured research, 
dissemination  and  training  activities.  The  dissemination 
stages  are  intended  to  raise  awareness  on  the  results  of  the 
project.  Potential  professional  users  will  benefit  from  the 
practical training sessions on using the toolkit when it becomes 
available.

Reflecting  the  ambition  of  revolutionising  the  whole  spring 
sector, the TECH-SPRING consortium pools the expert knowledge 
and professional experience of 10 participants. Their research 
activities will support over 600 spring manufacturing SMEs.

New tools for new prospects
TECH-SPRING  introduces  some  important  breakthroughs  for 
the spring sector. The first innovative aspects are knowledge-
related,  with  the  improved  understanding  of  residual  and 
applied  stresses.  Better  knowledge  forms  the  basis  on  which 
the prediction models for the optimisation of spring design are 
built. The toolkit created by the project team intends to include 
a  software  design  tool  to  enhance  the  quality  of  preparation 
work, prior to manufacturing stages. 

Two new methods will also be used. The first is a system using 
a camera and stroboscopic technologies, whereas the second 
is an adapted X-ray machine. Both methods should enable new 
methods of stress analysis to be used by the spring industry. 

The  project  team  also  plans  to  contribute  to  the  revision  of 
current EU and global standards for the production of springs.

The  project  participants  expect  the  toolkit  to  be  adopted  by 
European  SMEs,  to  increase  their  market  share  by  5%  in  the 
next five years. Such a market share increase would generate 
additional  revenues  of  EUR  114  million  a  year.  More  revenues 
could  be  followed  by  new  employment  opportunities,  with  a 
further 960 jobs being created.

Overall, TECH-SPRING will offer the ideal conditions for spring 
SMEs to add value to their products and to use fewer resources 
to  produce  more  and  better  springs.  The  added  value  means 
that  products  are  of  higher  quality  and  performance  and 
correspond  to  a  superior  level  of  specifications.  Importantly 
too, the new products will be available at competitive prices. All 
these aspects mean that European SMEs will be in a position to 
provide Large Enterprises, for example the automotive industry, 
with superior quality products.

European SMEs will draw on this project to gain an advantage 
over their competitors. The quality and 
costs  of  products  developed 
using  the  TECH-SPRING 
toolkit will contribute 
to 
increasing  the 
revenues of spring 
manufacturers.

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Collective Research Volume 3

“… SMEs will be able to individualise their 
production strategy and their commercial 
approach.”

Project title
Improving technical performance of springs through scientific 
understanding of dynamic stress profiles utilising advances 
in software design and measurement technologies (TECH-
SPRING)

Contract number
29743

Duration
36 months

Global project costs
€2 228 810

EC contribution
€1 234 191

Contact Person
Mark Hayes
Institute of Spring Technology Ltd
Henry Street
S3 7EQ
Sheffield
United Kingdom
Email: m.hayes@ist.org.uk

Participants
1. Institute of Spring Technology (UK)
2. Dutch Spring Association (NL)
3. ANCCEM (IT)
4. Turton Springs Limited (UK)
5. Mevis S.P.A. (IT)
6. Metalpol sp.J (PL)
7. Lake Image System (UK)
8. Peen Services (IT)
9. Innotec Forschungs und Entwicklungs (DE)
10. Joh. Pengg AG (AT)

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SUSTAINABILITY OUT OF THE BOX

TESS

“Because of the new legislation, there is a risk 
that some SMEs involved in the chemicals 
sector may become vulnerable 
and need to outsource their 
manufacturing to third 
countries.”

From  1st  June  2007,  a  major  new 
Directive  (2006/12/EC),  known  as  REACH 
(registration,  evaluation,  and  authorisation  of 
chemicals),  will  be  effective  in  the  EU.  The  new  law  will 
require  formal  approval  of  all  chemicals  which  are  stored,  used 
and manufactured in significant quantities, according to their health and 
ecological  impact.  The  costs  involved  in  carrying  out  these  tests  could  be  so 
substantial  that  some  smaller  manufacturers  might  be  forced  out  of  business.  The 
TESS  initiative  has  been  set  up  to  avoid  this  scenario.  Its  goal  is  to  solve  a  complicated 

situation by developing a simple tool. 

an  SME  context.  Furthermore,  the  project  partners  will  use 
screening and testing techniques to analyse the specific impacts 
of  chemical  toxicology  on  health  and  on  the  environment. 
Another research area will be ‘green chemistry’, with a special 
focus on its ecological and sustainable approach to the future 
of SME manufacturing. Finally, the practicalities of sustainable 
supply chains will be assessed.

Four research areas, several outcomes
The results and knowledge gathered through target research will 
be used in the development of the ‘TESS Toolbox’, which will be 
put in a real life context and tested by the six SMEs participating 
in the project. The seven IAGs involved will use their regional 
and  pan-European  networks  to  create  awareness  and  provide 
training to existing and potential toolbox users. The focus will 
be on SME users, but larger operators may also benefit from the 
compiled knowledge system.

In the closing weeks of 2006, the European Parliament passed 
a  finalized  legislation  to  provide  better  control  on  chemical 
manufacturing in Europe. From now on, firms will have to prove 
that the chemicals they manufacture are safe. To achieve this, 
the  new  legislation  requires  that  the  manufacturer  performs 
tests  and  declares  potential  dangers  before  certificates  of 
approval can be issued. Under REACH, chemicals of ‘very high 
concern’ will mean substances that may cause adverse effects 
on biological systems (toxic substances), cancer (carcinogens) 
or genetic mutation of living things (mutagens), to name a few.

There are about 30 000 different chemicals being produced across 
Europe, all of which need to be registered. Since the majority fall 
into the so-called Specialty and Fines Sector, this is where most of 
the testing needs to take place. The Speciality and Fines Sector, 
which is responsible for producing many key chemical ingredients, 
accounts for 20 000 SME manufacturers and blenders, representing 
94% of all manufacturers and formulators in Europe. These SMEs 
provide the ‘building blocks’ for the European manufacture of dyes, 
inks,  pigments,  pharmaceuticals,  surfactants,  food  additives, 
electronics, advanced materials, sensory products, etc. They also 
account for a contribution of EUR 157 billion per year to European 
Gross Value Added. 

Green, clean and affordable
Because of the new legislation, there is a risk that some SMEs 
involved  in  the  chemicals  sector  may  become  vulnerable  and 
need to outsource their manufacturing to Third Countries. TESS 
aims to avert this situation. Gathering SMEs and IAGs from eight 
European  countries,  the  project  aims  at  supporting  European 
SMEs  of  the  Speciality  and  Fines  Sector  in  cost-effectively 
updating to sustainable supply chains.

The  TESS  consortium  is  to  provide  advice  and  methodologies 
for  low  cost  compliance  to  SMEs  threatened  by  the  costs 
involved with the REACH legislation. To this end, the project is 
developing an online, self-help toolbox enabling these SMEs to 
identify gaps in their current level of preparedness for REACH. 
The TESS project partners will thereby focus on four principal 
areas of research. 

TESS will seek to gain in-depth knowledge of REACH legislation, 
which  will  be  evaluated  and  simplified  in  order  to  adapt  it  to 

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Collective Research Volume 3

“TESS is to provide advice and methodologies 
for low cost compliance to SMEs threatened 
by the costs involved with the REACH 
legislation.”

Project title
Toolbox to Evaluate Sustainable Systems (TESS)

Contract number
30234

Duration
36 months

Global project costs
€4 722 069

EC contribution
€3 654 679

Contact Person
David Boland
Chemicals Industries Association
Kings Building, Smith Square
SW1P 3JJ London
United Kingdom
Email: dave.boland@menza.co.uk 
Website: www.cia.org.uk

Participants
1. Chemicals Industries Association (UK)
2. European Chemical Industry Council (BE)
3. Federation of the Belgian Chemical Industries (BE)
4. Federchemica (IT)
5. Chemical Industry Federation of Finland (FI)
6. British Association for Chemical Specialties (UK)
7. Vereniging Van De Netherlande Chemische Industrie (NL)
8. Organica Feinchemie GmbH (DE)
9. PFW Aroma Chemicals BV (NL)
10. Arran Chemicals Ltd (IE)
11. Robinson Brothers Ltd (UK)  
12. Erchem (EL) 
13. Vantaco OY (FI)
14. Vickers Laboratory (UK)
15. University of Hull (UK)
16. Ghent University (BE)
17. VTT Technical Research Centre of Finland (FI)
18. City University of London (UK)

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UPSHIFTING THE EU GEAR INDUSTRY

X-Gear

“… Europe’s gear industry needs to implement 
major changes in gear design and gear 
manufacturing techniques.”

The 

mechanical 
European 
transmission  sector  employs  some  135  000 
people in SMEs, producing gears and gearing products. 
These  businesses  rely  on  traditional  technologies  and  are 
somewhat  reluctant  to  make  technical  innovations.  However,  end 
products using gears have become increasingly complex, making the use 
of  more  sophisticated  and  reliable  gears  a  necessity.  The  X-Gear  project  has 
been set up to help the European industry take on the challenges created by increased 

Sharing the progress
The  high  performance  gears  resulting  from  the  project  will 
be  characterised  by  a  number  of  advantages  compared  to 
standard  gears  produced  using  traditional  technologies  and 
heat  treatments.  These  advantages  will  include  an  improved 
efficiency  thanks  to  reduced  tooth-related  friction  losses  and 
an  increased  component  life  thanks  to  reduced  operating 
temperatures  under  full  load.  There  will  also  be  a  substantial 
reduction  in  lubrication  requirements.  New  developments  in 
air hardening steels, as opposed to quenched oil, will help to 
reduce the negative environmental impact of heat treatments. 
Another  aim  is  to  reduce  the  manufacturing  time  and  the 
number of process stages, especially for small batches of high 
performance gears.

Besides  addressing  these  strategic  objectives,  X-Gear  will 
develop  guidelines,  best  practices,  and  manufacturing  and 
design tools. These measures are to stimulate standardisation, 
harmonisation and facilitating of emerging technologies to the 
large, scattered European community of SMEs of the mechanical 
sector,  including  gear  and  machine  producers.  Overall,  the 
project  is  well  set  to  provide  the  European  subsector  of  gear 
manufacturing  with  the  tools  to  adapt  to  ever  toughening 
competition.

requirements on gear manufacturing. 

Mechanical Engineering, a domain where the EU has achieved a 
dominant position worldwide, is one of the most important and 
largest industrial sectors in Europe. In the related field of gear 
design and manufacturing, however, major changes have to be 
implemented in order to keep up with the evolving requirements 
of end products. In addition, European SMEs in the sector are 
increasingly challenged by China, due to the country’s enormous 
output of mechanical engineering equipment, which is growing 
much faster than in Europe.

A new generation of gears
To keep up with the growing competition, the X-Gear project is 
to  spread  and  standardise  novel  technologies  and  materials 
for a new generation of gears. The latter will be characterised 
by  higher  accuracy,  resistance,  reliability,  and  improved 
tribological  properties  (friction,  lubrication  and  wear).  Typical 
requirements in gear manufacturing are lighter weight, higher 
torque transmissions and quieter, more efficient gear trains. The 
X-Gear  partners  will  concentrate  on  the  automotive  and  wind 
energy  sectors,  thereby  focusing  on  helical  gears  only.  While 
the  automotive  sector  needs  more  cost-effective  processes 
due to a big market demand, the wind energy production sector 
needs to improve the reliability, noise and efficiency of turbine 
gearboxes.  New  materials  and  surface  treatments  will  be 
combined in a way to satisfy the constraints of both sectors.

The  project’s  research  activities  will  feature  an  innovative 
combination  of  new  surface  treatments  based  on  flame 
spraying,  physical  vapor  deposition  and  laser  shot  peening. 
New  materials  are  to  be  developed,  based  on  nanopowders, 
new direct hardening and air quenching steels, and advanced 
sintered  steels.  A  special  emphasis  will  be  put  on  detonation 
diamonds;  also  called  ultra  disperses  diamond  powders 
(UDDP), with a particle diameter of 4 to 6 nanometers. Markedly 
enhanced  properties  are  expected  from  the  exploitation  of 
novel coatings based on UDDP applied on the surface of gears. 
These properties will include a substantial improvement in wear 
reducing (from 2 to 10 times), increased micro hardness (from 
150 to 8000 kg/mm2), and an improved corrosion resistance.

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Collective Research Volume 3

“The X-Gear project is to spread and standardise 
novel technologies and new materials for a 
new generation of gears.”

Project title
Development of Gear Drive-Trains Based on New Materials and 
Novel Gear Systems (X-Gear)

Contract number
30433

Duration
36 months

Global project costs
€2 697 094

EC contribution
€1 872 586

Contact Person
Contact Person
Donato Zangani 
D’Appolonia S.p.A. 
Via San Nazaro 19
16145 Genova
Italy
Email: donato.zangani@dappolonia.it 

Project website
http://www.dappolonia-research.com/xgear/

Participants
1. D’Appolonia S.p.A. — Coordinator (IT)
2. BGA — British Gear Association (UK)
3. AGORIA ASBL — Mechanical and Mechatronic Engineering (BE)
4. AIMMAP — Association of the Metallurgical, Mechanical 
Engineering Sector in Portugal (PT)
5. STUME Scientific-Technical Union of Mechanical Engineering (BG)
6. Associazione Industriale di Massa Carrara (IT)za
7. ANEV — Associazione Nazionale Energia del Vento (IT) 
8. SIMP — The Association of Polish Mechanical Engineers and 
Technicians (PL)
9. CIM-mes project sp. Z.o.o.(PL)
10. Tecnogidue S.r.l. (IT)
11. Bierens Machinefabrieken b.v. (NL)
12. Brito Indústria Portuguesa de Engrenagens s.a. (PT)
13. Defawes ’96 NV (BE)
14. Technocontact International Ltd (BG)
15. Stam S.r.l. (IT)
16. Stresstech Oy. (FI)
17. Dendrit Ltd. (BG)
18. University of Newcastle upon Tyne — Design Unit (UK)
19. Space Research Institute — Bulgarian Academy of Sciences (BG)
20. Institute of Precision Mechanics (PL)

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