Circular Economy

Growing demands for resource efficiency, sustainability, and security of supply are increasing the need for industry-ready solutions to ensure a functioning circular economy. Materials, components, and products should be used for as long as possible, reliably assessed, and, whenever possible, reused, repaired, or recycled into high-quality products.

At the same time, complex material flows, new material combinations, and high quality requirements present companies with major challenges. To make informed decisions about reuse, refurbishment, recycling, or alternative recovery methods, the condition, composition, and quality of materials and products must be precisely assessed.

Therefore, non-destructive testing methods, smart sensor technology, data fusion, and AI-supported evaluation methods are becoming increasingly important, particularly for plastics, secondary metals, solar modules, machine components, and composite materials.

Our Solution: Sensor and Data Systems for the Circular Economy

Fraunhofer IZFP supports industry, the waste management sector, recycling companies, manufacturers, and operators with intelligent sensor and data systems for the evaluation, sorting, and quality assurance of materials, components, and products.

The combination of nondestructive testing, sensor-based material characterization, data management, and machine learning provides a reliable basis for decision-making to support sustainable and economically viable circular processes.

Our solutions specifically address a focus on sensor-based methods for characterizing complex material streams, AI-supported classification of recyclable materials, and non-destructive condition assessment of products and components throughout their lifecycle. This enables materials to be managed more effectively within the circular economy, rejects to be reduced, and recycling processes to be made more efficient.

  • the contactless identification and sorting of materials,
  • the assessment of product and material conditions,
  • quality assurance for recycled materials and secondary raw materials,
  • decisions regarding reuse, refurbishment, and recycling, and
  • the environmental and economic evaluation of processes and technologies.

Benefits for You

  • Greater resource efficiency through in-depth material and condition assessment
  • Improved sorting and recycled material quality
  • Reduced material losses and less waste
  • Data-driven decisions on reuse, refurbishment, and recycling
  • Support with sustainability and regulatory requirements
  • Development of customized, industrial-grade sensor and data systems for your circular processes

Our Solutions

 

Ultrasonic-based measurement system for detecting inclusions in molten aluminumAloX

 

An innovative approach to sorting black plasticsThermoSort

Public Research Projects in the Field of Circular Economy

 

DiGreeS

User-friendly digital platform for connected steel production

 

ECO²

Providing methods for the comprehensive assessment, evaluation, and optimization of environmental and economic impacts

 

K3I-Cycling

AI-driven optimization of the plastic packaging recycling process

 

Re-Machine

The project paves the way for a circular economy for machine parts

 

ReSolar³

Digitization and optimization of the circular economy for photovoltaic systems using smart sensors

 

Waste4Future

Fraunhofer Flagship project “Waste4Future”: From waste to raw material—green molecules for the chemical industry

Publications & Press Releases on the Topic of the Circular Economy

Reliable and precise detection of inclusions in aluminum melts using ultrasound

May 27, 2026

© Fraunhofer IZFP / Uwe Bellhäuser
Tailored to the industry’s specific requirements: AloX at SENSOR+TEST 2026 in Nuremberg.

At SENSOR+TEST, the international trade fair for sensor, measurement, and testing technology, the Fraunhofer Institute for Nondestructive Testing IZFP in Saarbrücken will showcase its “AloX” measurement system—winner of the Joseph-von-Fraunhofer Prize—which enables the rapid, continuous, and precise determination of the level of non-metallic inclusions in aluminum melts. This addresses a key challenge in aluminum casting, as non-metallic inclusions have a decisive impact on the quality of the resulting components, and the increasing use of secondary aluminum further exacerbates this issue. Experts from Fraunhofer IZFP will present the efficient and cost-effective “AloX” system from June 9 to 11, 2026, at SENSOR+TEST in Nuremberg (Nuremberg Exhibition Center, 1-317/Hall 1). Please read more...

Efficient and single-variety recycling of black plastics

March 3, 2026

© Fraunhofer IZFP / Uwe Bellhäuser
Black plastics sorted efficiently: Fraunhofer IZFP presents AI-supported thermography sorting demonstrator at SOLIDS & RECYCLING-TECHNIK 2026 in Dortmund.

At the trade fair duo for the bulk solids, process, and recycling industries, the Fraunhofer Institute for Nondestructive Testing IZFP from Saarbrücken will be exhibiting a demonstrator that, for the first time, characterizes and sorts black plastics by type using active thermography and machine learning. This addresses a key problem in the circular economy: black plastics that have historically been excluded from mechanical recycling because of missing or prohibitively expensive sorting technologies can, in the future, remain within the circular material flow as valuable resources. Experts from Fraunhofer IZFP will present the sorting demonstrator from March 18 to 19, 2026, at SOLIDS & RECYCLING-TECHNIK in Dortmund (Dortmund Exhibition Center, Hall 4, Booth D47). Please read more...

Aluminum production — ultrasound reliably detects inclusions: Fraunhofer IZFP research team receives the Joseph von Fraunhofer Prize 2025

June 4, 2025

© Fraunhofer / Piotr Banczerowski
Dr. Thomas Waschkies and Andrea Mross received the Joseph von Fraunhofer Prize for 2025 for developing the “AloX“ mobile ultrasound-based measuring system.

Thanks to its physical properties, aluminum plays a major role in the circular economy and achieving climate neutrality. High material quality is crucial during processing, as any contamination present in the aluminum during smelting diminishes the quality of finished components. Unlike existing methods of analysis, the ultrasound-based AloX measuring system from the Fraunhofer Institute for Nondestructive Testing IZFP can detect existing inclusions not only reliably but also quickly and at low cost. The team of researchers was presented with the Joseph von Fraunhofer Prize for 2025 for developing this innovative tool. Please read more...

Digital production platform aims to make steel production more sustainable and energy-efficient

November 4, 2024

Digitale Produktionsplattform soll die Stahlproduktion nachhaltiger und energieeffizienter gestalten
© Adobe Stock / MP Studio
The innovative digitalization solutions used are intended to improve the product quality of the steel products and the raw material and energy efficiency of the manufacturing process, thereby increasing their recyclability.
© European Union
The project “DiGreeS“ is funded by the European Union under the “Grant Agreement ID: 101178079“.

The transition to environmentally friendly and low-carbon steel production in Europe requires a considerable reorganization and restructuring of steel production processes. This applies in particular to the implementation of new and innovative steel production methods. To plan and manage these enormous challenges and ensure sustainable steel production, a user-friendly digital platform for networked steel production is to be developed as part of the EU project “DiGreeS”*  –under the leadership of the Fraunhofer IZFP in Saarbrücken – with a total of 11 European partners from industry and research. The European Union is funding the project with around 5 million euros. Please read more ...

5 million euros for the circular economy: Saarland invests in research collaborations

Saarbrücken, May 2, 2024

© MWIDE / C. S.
Symbolic handover of the cheque to Fraunhofer IZFP and htw saar by Ministers Jürgen Barke and Jakob von Weizsäcker

The transformation fund will be used to finance the establishment of two cooperative research groups in close cooperation between Saarland University of Applied Sciences (htw saar) and the Fraunhofer Institute for Nondestructive Testing IZFP. The focus is on researching new methods to conserve resources in industrial production through closed-loop processes. After the start-up phase, the new research fields will be permanently based at the Fraunhofer IZFP in Saarbrücken in future. Please read more ...