Chemical recycling chain for plastic cable waste – Prysmian and Versalis Signal Breakthrough for Europe as Chemical Recycling Chain for Plastic Cable Waste Advances Circular Economy Goals in Italy 24-12-2025
Chemical recycling chain for plastic cable waste
Prysmian, Versalis Launch Chemical Recycling Chain for Plastic Cable Waste in Italy
Prysmian and Versalis have announced a strategic partnership that could reshape how the cable industry manages plastic waste. The Italy-based collaboration establishes a dedicated chemical recycling supply chain for end-of-life and production cable plastics, addressing one of the sector’s most persistent environmental challenges. By combining industrial scale with advanced recycling technology, the project positions Italy as a testing ground for circular solutions that could later expand across Europe
The initiative arrives as pressure mounts on manufacturers to reduce waste, cut emissions, and comply with stricter European Union regulations on materials and product design. Energy infrastructure, in particular, faces growing scrutiny as grid upgrades and renewable energy expansion generate increasing volumes of complex plastic waste. chemical recycling chain for plastic cable waste
A Closed-Loop Vision for Cable Plastics
At the core of the partnership is a closed-loop approach to plastic cable waste. Prysmian will collect plastic scrap generated during its manufacturing processes, as well as material recovered from decommissioned cables supplied by major customers. These waste streams include polymers that have historically been difficult to recycle, especially cross-linked polyethylene, commonly known as XLPE.
XLPE is widely used as insulation in high-performance energy cables because of its durability and electrical properties. However, those same characteristics make it resistant to conventional mechanical recycling. As a result, much of this material has traditionally been downcycled, incinerated, or sent to landfill. chemical recycling chain for plastic cable waste
Hoop Technology and Chemical Recycling at Scale
Versalis will process the collected cable plastics at its Mantua facility using its proprietary Hoop chemical recycling technology. This process converts mixed and cross-linked plastic waste into pyrolysis oil, which can then be refined into feedstock for new polymer production. The resulting materials are suitable for reuse in demanding industrial applications, including new energy cables.
Chemical recycling differs from mechanical recycling by breaking plastics down to their chemical building blocks rather than reshaping them. This allows the recovery of value from complex, multi-layer materials that cannot be easily separated. For the cable industry, where products often contain bonded polymer layers, this approach opens new pathways to circularity.
Recovering Value From XLPE Waste
According to the partners, up to 60 percent of XLPE insulation processed through the Hoop system can be recovered and reused in new cable production. This represents a significant improvement for a sector where recycling rates for cross-linked plastics have remained low. chemical recycling chain for plastic cable waste
For the first time, the companies indicate that a cross-linked cable containing all polymeric layers combined can be chemically recycled at industrial scale. This capability is particularly relevant as Europe faces rising volumes of cable waste linked to aging infrastructure, offshore wind development, electric vehicle charging networks, and grid reinforcement projects.
Pilot Phase and Timeline
The pilot phase of the chemical recycling chain is scheduled to begin in Italy in the second half of 2026. During this phase, the partners will assess technical performance, material quality, and supply chain economics. If successful, the model could be expanded to additional facilities and potentially replicated in other European markets. chemical recycling chain for plastic cable waste
Starting in Italy allows the project to leverage existing industrial assets while aligning with national and EU-level sustainability strategies. Italy’s role as both a manufacturing hub and a testing ground could prove critical in demonstrating scalability.
Supporting Circular Economy and Decarbonization Goals
The partnership directly supports the European Union’s Circular Economy Action Plan, which aims to reduce waste, increase recycling rates, and promote sustainable product design. Industrial-scale solutions for hard-to-recycle plastics are expected to play a growing role as landfill restrictions tighten and compliance costs rise. chemical recycling chain for plastic cable waste
For Prysmian, the initiative contributes to reducing material intensity and Scope 3 emissions across its value chain. As customers increasingly evaluate suppliers based on lifecycle impacts, access to recycled polymers that meet performance standards becomes a competitive advantage.
Versalis, Eni’s chemicals arm, is using the project to advance its broader transformation toward circularity, advanced recycling technologies, and lower-carbon industrial processes. Chemical recycling is a central pillar of that strategy, offering a way to manage complex waste while maintaining material quality. chemical recycling chain for plastic cable waste
Implications for the Cable Industry
The cable industry has long struggled with recycling complex plastic insulation. Mechanical recycling methods often fail to deliver consistent quality, limiting the reuse of recovered materials in high-performance applications. Chemical recycling offers an alternative that aligns technical requirements with sustainability goals.
If the Prysmian and Versalis model proves successful, it could reduce dependence on virgin raw materials, lower lifecycle emissions, and create new value streams from waste previously treated as a cost. This shift may also help stabilize supply chains at a time when polymer markets are exposed to price volatility and geopolitical risk. chemical recycling chain for plastic cable waste
Beyond Italy: A European Model
While the initial focus remains on Italy, the strategic implications extend beyond national borders. Grid investment is accelerating across Europe as countries pursue electrification, renewable energy integration, and energy security. These developments will inevitably generate large volumes of cable waste in the coming decades. chemical recycling chain for plastic cable waste
The ability to recover and reuse materials from retired infrastructure may become a defining factor in the sustainability performance of energy supply chains. A scalable chemical recycling chain could therefore influence procurement decisions, regulatory compliance strategies, and long-term investment planning across the sector.
A Turning Point for Industrial Recycling
The Prysmian and Versalis partnership highlights how chemical recycling is moving from experimental concepts to embedded industrial applications. By linking waste collection, advanced processing, and reintegration into manufacturing, the project demonstrates a practical route toward circularity for complex products. chemical recycling chain for plastic cable waste
As Europe tightens environmental regulations and companies face increasing accountability for material choices, initiatives like this may set new benchmarks. If replicated at scale, chemical recycling chains for plastic cable waste could become a cornerstone of sustainable energy infrastructure in the years ahead. chemical recycling chain for plastic cable waste
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