Dainese Group unveils an innovative and unique project to transform the life cycle of motorcycle helmets, ensuring maximum safety whilst championing sustainability

At EICMA 2024, Dainese unveils LIFE IMPACTO for the very first time – a cutting-edge solution designed to change the linear life cycle of motorcycle helmets, addressing the challenges of how to dispose of these sustainably and creating a circular process based on selective dissolution recycling.

To date, no viable industrial-scale solutions for recycling motorcycle helmets have existed: these were previously disposed of in landfills or incinerated.

The goal of this ambitious and innovative project – co-funded by the European Community as a result of winning the LIFE23 subprogramme Circular Economy and Quality of Life call to tender – is to implement a proactive approach to managing end-of-life products, preventing them from becoming waste and developing a sustainable, efficient process to separate and recycle the polymeric materials of which helmet are composed, as well as using the materials obtained through recycling in the manufacture of new helmets or other “green” products. Without ever losing sight of ultimate goal: to ensure maximum safety of riders in all conditions and at all times.

The project is being rolled out by a consortium of five Italian companies: Dainese Group in the role of coordinator; Innovando, an innovative SME specializing in reverse logistics; Re-sport, a start-up spin-off from the University of Bologna which is focused on innovative technologies for recycling composite sports equipment; Misitano&Stracuzzi, suppliers of bio-based solvents extracted from citrus fruit waste; and the University of Bologna for the research and development component of the project.

LIFE IMPACTO is based on an innovative plant which enables the separation of the different plastic materials of which the helmet is composed, through the action of bio-based solvents (limonene and ethyl acetate) obtained from food industry waste. In this way, the key plastic materials (ABS, EPS and PC) can be recovered and reused within the same value chain.

To give an idea of the scope of this revolution, with 5,000 recycled helmets, 3,700 kilograms of ABS, 1056 kilograms of EPS and more than 600 kilograms of PC can be obtained. This process leads to a real, tangible benefit for the environment, with a 60% reduction in CO2 emissions, a 60% reduction in electricity consumption and a 50% reduction in water consumption.

Life Impacto is also opening up new job opportunities in two of the consortium bodies, Dainese Group and Innovando, creating a positive knock-on effect on employment.

The ultimate goal of this ambitious project is to introduce a homologated, environmentally-sustainable helmet model to the market, conceived and designed according to the design for recycling approach, without the use of glues and with a reduction in the variety of materials used, as well as greater ease of breaking down the various materials when these are recycled.

LIFE IMPACTO is a virtuous example of the transition from a linear economy – which takes, produces, and disposes – to a circular economy, which reduces, reuses, and recycles. This model poses a challenge for the majority of companies, given that society is increasingly aware of the negative effects of the linear model on the environment and the need to safeguard it for current and future generations.

In a world first, Dainese Group is pioneering a revolution that combines safety and sustainability, creating a replicable model that can be applied in other areas.

Dainese is already in the future.