Production Process Analysis of Earth-Based Plasters

Amongst the strategies proposed by governments worldwide to achieve energy efficiency and low environmental impacts from anthropic activities, many address the construction sector, which has proven to be the most energy-demanding one in the modern era. Some approaches include adopting low-embodied energy construction materials and promoting the transition to Circular Economy as standard practice. The study presented is part of a broader research project, titled ITER, aimed at the development of entirely recyclable earth-based plasters, formulated with additives derived from waste materials of the agricultural and stone processing sectors (specifically, natural fibers and marble dust, respectively). This project aims to optimize both the material (enhancing its physical, mechanical, thermal, durability, and hygienic performance) and the production process (by minimizing environmental impacts and promoting industrial symbiosis, turning waste into resources). Specifically, this paper addresses one of the initial phases of the ITER project, in which the production and transformation processes of the individual components are examined in detail, along with the final manufacturing process of the premixed plaster formulation. The objective is to identify the most critical operations throughout the entire production cycle. In addition, a preliminary assessment of the carbon footprint is carried out to identify the most impactful phases, which will need to be improved in the subsequent stages of the project. The outcome of this assessment is the identification of existing limits and critical manufacturing activities of the current production process, which will be the baseline for the development of the implemented process in the future research steps.