POLYECO SA

Within the framework of strategic plan — and specifically the focus of its Research and Development Department on the continuous exploration of new technologies and trends in the management of emerging waste streams and categories — Polyeco developed this initiative. Its main objective is the creation of an innovative process for the management of maritime pyrotechnic waste, integrating the principles of safety and environmental compliance, circular economy, and sustainable development.

Maritime pyrotechnic devices — such as flares, smoke signals, and rockets — are mandatory safety equipment on vessels, serving as distress signals in accordance with the International Convention for the Safety of Life at Sea (SOLAS). However, the complete absence of mature management technologies, combined with the lack of a regulatory framework governing their lifecycle and preventing improper or illegal practices, poses significant risks to both human safety and the environment. Frequently, these materials end up in the sea, degrading marine ecosystems, while there are also documented cases of illegal disposal in municipal waste streams — leading to uncontrolled fires — or even illegal use during demonstrations and sporting events, creating serious public safety threats.

Responding to this technological and regulatory gap, Polyeco has developed an innovative deactivation and material recovery technology, which has already been successfully tested in pilot applications and proven its effectiveness.

The new and innovative Flare De-Activation and Recovery Unit (FDRU) technology addresses a critical gap in the maritime industry. It provides a safe and efficient solution for the management of expired flares, smoke signals, and other distress devices, combining environmental responsibility with operational efficiency.

Shipping companies and port authorities gain a reliable tool for compliance with international regulations, while vessel crews can easily dispose of hazardous waste for further management. At the same time, this technology enables the recovery of materials and energy, reducing the ecological footprint and strengthening the circular economy.

It is a “green” initiative that brings together safety, innovation, and sustainability, creating new prospects for the future of the shipping industry, guided by scientific research in the highly demanding field of explosives and pyrotechnics. 

 

The initiative began in 2023, following defined phases and control mechanisms (laboratory-scale investigation, design, and construction of specialized equipment). It is currently in the siting, permitting, and pre-operational phase.

Polyeco, recognizing the importance of proper and safe management of maritime pyrotechnic waste, undertook this research and development project focused on the integrated management of such waste. Specifically, the developed process applies to handheld flares, parachute flares, and smoke signals — mandatory safety devices onboard vessels that expire three years after production.

The R&D team designed a process for the deactivation of collected, declassified pyrotechnics, aiming first to neutralize them and convert them into non-explosive materials, and subsequently to utilize them as alternative raw materials or fuels for the cement industry, following processing in Polyeco’s licensed production lines at its facilities in Aspropyrgos, Attica.

This is a physico-chemical process that involves mechanical fragmentation, chemical neutralization of the ignition compound through a patented reaction, and further stabilization aimed at material recovery.

This initiative serves as tangible evidence of the company’s continuous development and technical competence in delivering new, reliable, and innovative solutions. Guided by a commitment to transparency and technical integrity, Polyeco has voluntarily initiated an independent verification process of the developed methodology by an international recognized certification body, which is expected to be completed soon.

The installation of the unit within the Attica Region is a strategic choice based on the principle of proximity, as this region hosts the country’s largest maritime and shipping activity, reducing transportation costs and environmental footprint.

 

Prompt results
The implementation of the innovative FDRU process ensures the safe neutralization of expired or hazardous pyrotechnics, significantly reducing the risk of accidents. In Greek waters, approximately 178,000 registered vessels each carry at least four pyrotechnic devices, which expire every three years and become waste. Through the FDRU process, these materials are managed in full compliance with international (IMO, SOLAS) and national regulations, while reducing management costs through organized collection and treatment. Additionally, the process offers the possibility of recovering valuable materials, promoting the circular economy and preventing pollution of marine and terrestrial environments. It is estimated that around 60 tons of materials per year — which currently end up in the sea, landfills, or illegal use — can now be safely and legally recovered.

Long-term results

The application of the FDRU process generates substantial long-term benefits for the maritime sector, the waste management industry, and society as a whole. It enhances the corporate image of shipping and port organizations as responsible and “green” entities, potentially reducing insurance costs through lower risk exposure. At the same time, it paves the way for new markets and business models around recycling and material recovery, while advancing scientific research in the field of pyrotechnic waste management and contributing to technological progress.

Environmental and social benefits

This initiative significantly contributes to sustainable shipping and public safety, minimizing the risk of illegal disposal or uncontrolled circulation of pyrotechnics in urban waste streams or unsafe use by individuals during demonstrations or sporting events. In doing so, it reduces the likelihood of fires and serious accidents, protecting both human safety and the environment.

The investment has significantly strengthened the company’s strategic position in the field of environmentally responsible waste management. It has also demonstrated Polyeco’s ability to implement complex technical projects with a high degree of scientific, technological, and organizational maturity and accountability.

- It has enhanced corporate reputation and stakeholder trust through the adoption of responsible practices and transparent performance monitoring.
- It has created new jobs and fostered expertise in critical areas such as the management of explosive/pyrotechnic waste and environmental compliance.
- It has been integrated into the company’s broader sustainability strategy, with potential for expansion into new geographic regions or partnerships with public and private entities.
- It has improved operational efficiency and internal governance through standardized procedures, staff training, and performance metrics.