Research into new chemical formulations for the two-component and multi-component doming resin sector, monomer-free and with a natural polymeric catalyst – construction of a pilot plant for the injection of the new green multi-component resins

The project is carried out thanks to the Tuscany ERDF Regional Programme 2021 – 2027, ACTION 1.1.4 Research and development for enterprises, including in partnership with research organisations.
CALL No. 2: R&D projects for MSMEs and Mid-caps.

Acronym: ecoDOMES
CUP: 27717.29122023.043000657_1225

ecoDOMES is the project through which COLOR-DEC ITALY s.r.l. has embarked on a concrete transition towards materials and processes with a lower environmental impact, with the aim of bringing to market a new family of green resins and a new generation of systems for applying them. The purpose is twofold: to innovate polyurethane formulations along bio-based lines that are safe for operators and the environment, reducing the carbon footprint across the entire supply chain, and to redesign mixing and dispensing machines so that they deliver high industrial performance even with “slower”, more sustainable catalysts. The project focused on replacing the most critical components, with particular attention to reducing and progressively eliminating free monomer in the isocyanate component, on exploring polymers derived from natural sources, and on validating alternative raw materials obtained from CO₂ and vegetable oils and fats. In parallel, a prototype two-component and multi-component system was developed that can handle the new resins consistently, thanks to thermal control at the mixing head, static-dynamic systems and solutions that accelerate curing without resorting to energy-intensive ovens.
The results achieved confirm the soundness of the approach. Demonstration formulations were developed with monomer content reduced to levels that are not significant for use, while maintaining or improving the transparency, adhesion and resistance to external agents typical of CDI’s decorative and functional applications. Real-world tests on emblem and LED-strip samples showed a pot life suited to processing times and reliable final curing, supported by high-frequency fields, microwaves and radiant panels that cut energy consumption and cycle times. The new prototype system passed reliability and repeatability tests and is ready for industrialisation, paving the way for a generation of machines designed from the outset for green resins. A pilot line was also built to recover and recycle the LED-strip substrate, reducing waste and the use of virgin raw materials, to the benefit of the circular economy. The picture is completed by updated safety data sheets, full compliance with current regulations and a training plan that protects operators’ health.
Thanks to ecoDOMES, COLOR-DEC ITALY s.r.l. strengthens its role as a pioneer, combining materials chemistry and process engineering in a single industrial vision. The new formulations and state-of-the-art systems give customers in the fashion and construction sectors access to high-performance, sustainable solutions, with measurable benefits in terms of energy consumed, emissions avoided and workplace safety. Consistent with smart specialisation trajectories and the principles of Transition 5.0, the project is a concrete step towards a more responsible and competitive supply chain, ready to scale up on international markets.