What if boats in the future were made of recycled carbon?

What if the boats of the future were made of recycled carbon? From today it is possible! Hera Group inaugurated yesterday in Imola FIB3R, the first European plant capable of regenerating carbon fiber on an industrial scale. This material, increasingly popular in the nautical field since the 1990s for the construction of hulls, rigging and sails, is currently imported mainly from Japan and China. That is why this new state-of-the-art facility, with a production capacity of 160 tons per year of recycled fiber, is therefore a step forward not only in terms of environmental sustainability, but also strategic independence in a global context marked by tariffs and trade tensions.

The carbon fiber regeneration process

The new FIB3R plant is a concrete response to the growing need for sustainability in the marine industry. The regeneration process adopted by FIB3R, is based on an innovative pyrolysis and gasification technology, which allows the fiber to be separated from the resin and the energy generated to be reused, thus reducing environmental impact.

The fiber is treated with a pyrogasification technology. During the pyrolysis stage, the fiber is separated from the resin due to its high thermal resistance. Subsequently, the resin, transformed into gas, is reused to feed the system, optimizing energy recovery.

The end result is a regenerated, pure carbon fiber with intact mechanical properties, ready to be reused in a variety of industries, from automotive to aerospace to fashion and, of course, even marine.

The application of carbon fiber in boating

In recent decades, carbon fiber has revolutionized boat design and construction, introducing unprecedented innovation and performance. Thanks to its extraordinary structural strength combined with low weight, this material has emerged as the ideal choice for hulls, masts, sails and rigging. Its ability to resist corrosion and versatility in processing make it indispensable in the construction of modern, high-performance yachts.

In Italy, two major players have marked the development and adoption of carbon fiber in the nautical sector-Raul Gardini with Il Moro di Venezia and Luca Bassani with Wally.

The Moor of Venice and the technology hub of Montedison

The use of carbon fiber in racing boats had a turning point with Il Moro di Venezia, Raul Gardini’s America’s Cup boat. Gardini, a visionary and pioneer, turned the Tencara Shipyard into a research and development hub for advanced materials, taking advantage of Montedison’s know-how.

The result was a state-of-the-art boat: hull, deck and internal structures weighed a total of only 2,000 kg, an achievement unthinkable with previous technologies. The sails were also studied extensively, combining carbon fiber and polyester to ensure maximum efficiency and lightness.

Wally and the revolution in the world of recreational boating

If Il Moro di Venezia marked a turning point in racing yachting, Wally and Luca Bassani did the same for pleasure boating. When Bassani launched his Wallygator in 1991, the carbon sandwich hull and carbon fiber mast were a first in the industry. Inspiration came from New Zealand challenger KZ-1, the first to compete in the 1988 America’s Cup with a sandwich construction of carbon, Kevlar and Nomex, as well as an all-carbon fiber mast.

The next step was then to make a boat built entirely of carbon fiber. Here in 1994 came the ketch Nariida. In addition to an innovative design and tremendous weight reduction, Nariida adopted carbon laminate sails long before 3DL and 3Di membranes were available. Since then, Wally has continued to push the limits of carbon technology, culminating in Better Place, a 50.50-meter long sloop-the largest carbon fiber sloop ever built!

James Barbaro