Italian startup launches ‘fully recyclable’ production boat

Italian startup Northern Light Composites (Nlcomp) has launched its new EcoRacer30 sailing boat, which the firm claims can be fully recycled thanks to new composite technology.

Nlcomp, which is based in Monfalcone, specialises in rComposite technology, which the firm says allows for easier recycling of composite material at the end of the boat life.

Currently, it is estimated that approximately 95 per cent of fibreglass boats end up abandoned at the end of their lifecycle.

The Ecoracer30 is a 9-metre sailing boat designed by Matteo Polli that utilises rComposite. It launched during the recent Ocean Race Grand Finale in Genova, which concluded on 2 July 2023.

rComposite ‘replaces thermosetting resins with a thermoplastic matrix’, according to the firm. This change allows for easy chemical processing and recovery of the raw materials, enabling the boat to be recycled.

Nlcomp says it has made its technology available for use by other shipyards, thanks to ‘a commitment to driving positive change in the industry.’

“To test and validate rComposite, we initially built our own boats, which not only achieved success in regattas but also earned numerous awards,” says Fabio Bignolini, CEO of Nlcomp. “Now, we are thrilled to extend the accessibility of rComposite and share our expertise with all participants in the market. We are offering licensing opportunities to shipyards interested in utilising our innovative materials and techniques.”

The second Ecoracer30 is currently under construction and has already been sold. Two more boats will be built by the end of this year, followed by four more next year. Nlcomp also has plans to launch the Ecoracer Sailing Series, a series of regattas featuring recyclable sailing vessels, in the summer of 2025, as soon as a fleet of eight boats is built.

To achieve this goal, Nlcomp says it is going to launch a new company, open to investors, that will manage the fleet of boats.

“This solution is the most efficient way to achieve our production goals and launch the inaugural Ecoracer Sailing Series within two years. We are already in discussions with several well-known Mediterranean locations,” says Bignolini.

Nlcomp recently joined with the French firm Thomas Tison Yacht Design & Engineering to develop the EcoFoiler, a 3.8-metre foiling dinghy made with recyclable materials.

In 2022, Nlcomp’s EcoOptimist went into production. The boatbuilder says the EcoOptimist is not only built from sustainable materials but is also recyclable – more than 90 per cent of the hull is already recyclable, and it’s expected to rise to 100 per cent.

The EcoRacer30, which has a starting price of €130,000, was developed on experience gained from the EcoRacer25, Nlcomp’s previous project. The EcoRacer25 is billed as the world’s first recyclable sportboat. In 2022, the vessel won the Italian Sportboat championship held in Lake Garda against a fleet of forty fibreglass competitors.

The EcoRacer30’s sails are filmless 4T Forte from One Sails, which Nlcomp says are currently the only recyclable sails on the market. They can be easily recycled and repurposed for the production of accessories, such as sail headboards, markers, or sunglasses.

“From an engineering perspective, the EcoRacer30 posed a fascinating challenge,” says yacht designer Polli. “The project had two primary requirements: firstly, to repurpose existing moulds and minimise environmental impact, and secondly, to design a versatile boat capable of delivering excellent performance in various wind and sea conditions. Moreover, these objectives had to be achieved using sustainable materials.

“The mechanical properties, including weight, density, and structural rigidity, were taken into consideration from the early stages of the design process.”

The Ecoracer30 was engineered and manufactured in three locations in Italy: Monfalcone, Fano, and Genova. Magnani Yachts, the first shipyard in Italy to hold the rComposite building license, was responsible for manufacturing the composite using thermoplastic resins, a combination of virgin and recycled carbon fibres, and Amplitex flax fibres by Bcomp. This was done through an infusion process known for its cleaner production method.