Verretex SA, an EPFL spin-off specializing in regenerated glass-fiber textiles, together with Ryse Energy, a global manufacturer of small wind turbines and hybrid off-grid systems, announced the successful completion of a pilot study proving that 100% recycled glass-fiber textiles can serve as a direct replacement for virgin fabrics in wind turbine blades.
The pilot was carried out at Ryse Energy’s manufacturing facility in Spain, led by Neil Baxter, Technical Composite Specialist at Ryse Energy. The trial demonstrated that Verretex’s recycled textile could be integrated into Ryse’s existing blade lay-up and curing processes without any tooling changes or cycle time adjustments.
Neil Baxter emphasized the importance of maintaining performance while reducing environmental impact: “We are constantly evaluating ways to reduce our carbon footprint without sacrificing performance. Our team was able to integrate Verretex’s recycled textile seamlessly, and the resulting test blades met the strength and durability requirements essential for wind turbine performance. This shows the real-world potential of recycled composites in renewable energy manufacturing.”
Mitchell Anderson, CEO & Co-founder of Verretex, called the pilot “a clear path to low-carbon blades”, stating: “This pilot validates Verretex as a true drop-in solution for blade makers. We regenerate textiles from end-of-life and production scrap glass fibers to create virgin-like, low-carbon materials that fit existing production — no retraining, no retooling.”
A Life-Cycle Assessment (LCA) by TECH-FAB Europe (via PwC) highlighted that 89% of the carbon footprint of glass-fiber fabrics comes from the glass fiber production stage. By avoiding new fiber production through its regeneration process, Verretex significantly reduces emissions while ensuring circularity.
The pilot confirmed:
- Drop-in compatibility: No production or equipment changes were required.
- Strength targets achieved: The test blades met Ryse’s rigorous standards for small wind turbines.
- Compliance with IEC standards: Designed in line with IEC 61400-2 for safety and durability.
Verretex’s process reuses end-of-life and scrap glass fibers into high-quality textiles, advancing the circular composites economy without the need for energy-intensive remelting. Ryse Energy plans to expand the use of these materials across its facilities in Spain, Europe, and the US.
Looking ahead, Verretex will scale production to meet demand and reduce costs, while Ryse Energy aims to integrate recycled textiles in commercial turbine models for large-scale carbon footprint reduction.