Materials

Circular Economy in Practice:
Next-Generation Materials

At Lavaris, we specialize in recycling soft materials such as plastic, rubber, textiles, or biomass. We also handle hard materials like concrete, drywall, slag, and other construction and demolition waste.

We are capable of recycling less common materials such as tennis balls, fire hoses, or cigarette butts.

We convert all these materials into secondary raw materials that can be further used in the production of new products.

Lavaris has made a significant breakthrough in rubber material recycling by developing a unique technology that enables the efficient separation of textile cords from rubber. A previously unsolvable problem, where textile remnants contained more than 50% rubber and were unsustainably used as fuel, has been overcome. Our technology reduces the rubber content in textiles to less than 10%, opening up new possibilities for using these materials as secondary raw materials.

Another success is our Active Rubber Powder (ARP), which excels due to our advanced recycling technologies and methods, enabling the process of devulcanization and subsequent revulcanization. This powder with a porous surface can be mixed with new rubber and re-vulcanized, allowing its reuse without chemical additives. ARP brings significant savings to the industry and enhances production sustainability, which was recognized by winning first place in the "Waste to Resources" competition.

One of our most successful projects in rubber recycling involves recycling tires for Trelleborg. We are currently collaborating with Yokohama on recycling defective tires from production, transforming them into Active Rubber Powder (ARP) with a size of 250 µm. This exclusive product is packaged into small bags weighing 2–3 kg according to the production technologists' requirements. This packaged material is then added to new mixtures in tire production.

Our collaboration with Michelin and involvement in the WhiteCycle project further advances us in finding new ways to recycle complex materials and transform them into valuable raw materials for manufacturing new products. Through these efforts, Lavaris contributes to the development of the circular economy and a sustainable future.

Gypsum Board Recycling
Gypsum board waste presents a challenge in recycling due to the combination of gypsum and paper. We have developed advanced processing techniques for gypsum board scraps and demolition waste, allowing their reuse in construction materials. In collaboration with the Czech University of Life Sciences (ČZU), we are working on transforming paper waste from gypsum board into substrates. Our technology also includes smart containers and recycling lines with mills adapted for gypsum calcination, achieving high efficiency and added value for recycled products.

Concrete and Demolition Waste Recycling
Our technology for recycling concrete waste and bricks includes the production of recycled aggregate in various fractions, which is then used for manufacturing construction mixtures and lightweight aggregates. We utilize concrete recyclates in research projects focused on developing new building materials, such as floor fill mixtures. Recycling also involves processing slag and ash, contributing to sustainable management of demolition waste.

Mineral Thermal Insulation Recycling
In the field of mineral thermal insulation, such as blown insulation, we have developed mobile recycling lines that allow dust-free processing of materials directly on construction sites. This recyclate is further used as raw material for producing new insulation materials. We place special emphasis on processing mineral fibers and dust, which can be reused in various construction applications.

Glass Recycling
Our recycling technology is also focused on processing glass shards, particularly from photovoltaic plants. These shards are processed into high-quality recycled glass, which is then used in the production of building materials, ensuring the reuse of valuable glass raw materials and reducing the need for primary sources.

Project DECOMPOSE
One of our major projects is DECOMPOSE, aimed at minimizing the generation of construction and demolition waste and promoting its reuse. This project includes a detailed analysis of building decomposition, demolition waste recycling, and the development of methodological guidelines for legislative adjustments. The project results contribute to reducing the ecological footprint of the construction sector and support the sustainable use of secondary raw materials in construction.

We have achieved a significant breakthrough in cigarette filter recycling, where we successfully applied our innovative technology to transform this waste into new, useful materials. In collaboration with experts from TUL and VŠCHT, we developed a method for IMMINENT that allows cigarette filters to be recycled, deodorized, and used as materials such as padding for jackets or as agrotextiles in agriculture. This process not only reduces environmental impact but also creates valuable products from materials that would otherwise end up in landfills. Our solution is an example of the effective use of waste within the circular economy.

Our company specializes in the recycling of mineral wastes such as slag, fly ash, slag, and other construction and demolition materials that often end up in landfills without fully utilizing their valuable properties. In order to change this inefficient approach, we use advanced grinding and filtration technologies that allow processing of these materials even with high moisture content.

The Lavaris filtration system is designed to withstand high temperatures and the water vapor content generated during grinding. Additionally, our high-speed mill utilizes the generated heat to evaporate moisture during grinding, eliminating the need for pre-drying of the material and significantly reducing the energy consumption of the process. Together with our partners from the Czech Technical University (CTU), we are also working on a project that uses artificial intelligence and Industry 4.0 principles to ensure energy-efficient and environmentally friendly processing of these valuable mineral resources.

Our mobile recycling lines are capable of crushing plastic materials into micron-sized particles, which is highly efficient for their further use. This process also includes the production of microplastics, which are part of the unique international project Minagris. Thanks to our technology, we are able to achieve extremely fine grinding and separation of plastics, opening up new possibilities for recycling and the production of sustainable products.

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Materials

Circular Economy in Practice: Next-Generation Materials

Circular Economy in Practice:
Next-Generation Materials