Projects we are working on.

2024 - 2026

System for Reducing the Environmental Impact of Rubber Waste Processing

Technology Agency of the Czech Republic – 7th Public Competition "Environment for Life 7" (2023 - 2026)

Partners: Brno University of Technology, Faculty of Electrical Engineering and Communication, Institute of Automation and Measurement
 

The project aims to implement a comprehensive system for a rubber waste recycling line, along with its digital twin, to optimize the parameters of the final recycled material while minimizing environmental impact. The physical recycling line will be equipped with industrial tools and a control system, which will adapt the recycling process in real time based on sensor data to ensure that the recycled material meets the required parameters. Data from all actuators and sensors will be transmitted to a cloud-based or on-premise database, where they will be processed according to specific customer needs. The digital twin of the recycling line will be designed to provide optimization and monitoring capabilities throughout its entire lifecycle.

"This project, 'System for Reducing the Environmental Impact of Rubber Waste Processing,' is co-financed with state support from the Technology Agency of the Czech Republic under the 'Environment for Life 7' program. This project is funded under the National Recovery Plan from the European Recovery and Resilience Facility."

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2024 - 2026

New Grinding and Wet Output Filtration Technology for Recycling High-Moisture Mineral Materials

Technology Agency of the Czech Republic – 10th Public Competition TREND 2024 – 2026

Partners: Czech Technical University in Prague – Faculty of Mechanical Engineering, KyberTec

This project focuses on the recycling of mineral waste, such as slag, clinker, and fly ash, and its application in the construction industry to reduce the environmental impact of industrial processes. The introduction of innovative recycling technologies, including grinding lines, has enabled efficient processing of these materials to obtain valuable raw materials for construction applications. The project, led by Lavaris and its partners, aims to develop a new high-speed mill and filtration system that minimizes energy consumption and enhances recycling efficiency. The focus is on adaptive control and innovations in transportation technologies to achieve the best possible recycling outcomes.

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"This project, 'New Grinding and Wet Output Filtration Technology for Recycling High-Moisture Mineral Materials,' is funded with state support from the Technology Agency of the Czech Republic and the Ministry of Industry and Trade of the Czech Republic under the TREND program."

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2023 - 2026

Development of Large-Format 3D Printing from Recycled Plastics and Its Commercial Application in Innovative Eco-Design – PlastIT

Technology Agency of the Czech Republic – 11th Public Competition TREND 2023 – 2026
Partners: Plastenco Design s.r.o., Czech Technical University in Prague – Faculty of Architecture

The project aims to develop a prototype print head for large-format 3D printing using recycled plastic, with a particular focus on printing from regranulated polymer materials, especially polyethylene terephthalate (PET) and polyethylene terephthalate glycol (PETG). Additionally, the project explores the feasibility of printing with other polymer materials, a technology that is not yet available on the market. As part of the project, we will optimize printing software to process model data for use with a robotic arm. To ensure a comprehensive solution, a web platform will be created, allowing designers to upload 3D models for printing with recycled materials. The platform will also feature an eco-catalog, showcasing products to potential customers. 

"This project, 'Development of Large-Format 3D Printing from Recycled Plastics and Its Commercial Application in Innovative Eco-Design – PlastIT,' is funded with state support from the Technology Agency of the Czech Republic and the Ministry of Industry and Trade of the Czech Republic under the TREND program."

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2023 - 2026

Collaboration Between Schools and Companies – Practical Education at LAVARIS s.r.o.

Ministry of Industry and Trade, 2023 – 2026

Partners: Charles University – Institute for Environmental Studies, Czech University of Life Sciences, Prosek Secondary Technical School of Mechanical Engineering, Bethlehem Square Secondary Technical School of Mechanical Engineering, Czech Technical University in Prague – Faculty of Architecture, Faculty of Mechanical Engineering

​This program focuses on supporting practical training for students from partner secondary schools, vocational colleges, and universities. Lavaris offers a unique opportunity for students in fields such as mechatronics, automation, environmental protection, mechanical engineering, technology, informatics, and control systems. We provide specialized internships, allowing students to gain valuable hands-on experience under the guidance of our qualified professional mentors. This practical training enables students to apply theoretical knowledge in a real-world industrial environment, preparing them for future careers.

 

"This project, 'Practical Education at LAVARIS s.r.o.,' is co-financed by the European Union and the Ministry of Industry and Trade."

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2021 - 2023

Recycling and Transformation of Construction Drywall Waste into New Building Products and High-Value Applications

Technology Agency of the Czech Republic – 3rd Public Competition TREND 3 (2021 – 2023)

Partners: Czech Technical University in Prague – Faculty of Civil Engineering, KNAUF Praha, spol. s.r.o., MORAVOSTAV Brno, a.s. – Construction Company

The goal of this project is to design a comprehensive solution for collecting, separating, recycling, processing, and reusing drywall waste in the construction industry. Currently, this type of waste is disposed of in landfills without recovery. As part of the project, we will develop a smart container for construction waste, a simplified separation and recycling line, and a mill adapted for gypsum calcination. Additionally, we will focus on the design and development of new dry mixtures and products with a high content of recycled drywall waste. The recycled products will undergo experimental testing, including the development of a passive-standard perimeter wall made from blocks of recycled material.

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"This project, Recycling and Transformation of Construction Drywall Waste into New Building Products and High-Value Applications, is funded with state support from the Technology Agency of the Czech Republic and the Ministry of Industry and Trade of the Czech Republic under the TREND Program."

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2021 - 2023

Development of effective tools for minimizing construction and demolition waste generation, its monitoring, and reuse

Technology Agency of the Czech Republic – 3rd Public Competition ENVIRONMENT FOR LIFE 3, 2021 – 2023
Partners: CTU in Prague – Faculty of Civil Engineering, Moravostav Brno, a.s., construction company

In the project, we developed expert documentation for legislative amendments aimed at minimizing and reusing construction and demolition waste, potentially in combination with secondary raw materials. A detailed analysis was conducted, describing and evaluating the feasibility of building deconstruction, recycling of demolition waste, and preparing methodological guidelines, including calculations of the ecological footprint and economic costs. It was necessary to stabilize and expand the knowledge base related to the processing of construction and demolition waste. This covered the entire cycle (demolition, deconstruction) and the recycling process itself, up to reintegration into construction systems and materials. A conceptual approach was also developed, which we regularly consulted with representatives of the Industrial Ecology Department of the Ministry of Industry and Trade of the Czech Republic.

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This project, "Development of Effective Tools for Minimizing Construction and Demolition Waste Generation, Its Monitoring, and Reuse," is funded with state support from the Technology Agency of the Czech Republic and the Ministry of the Environment of the Czech Republic under the Environment for Life Program.

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2018 - 2020

Recycling of drywall panels and new material uses with added value

Technology Agency of the Czech Republic – 3rd Public Competition TRIO 3 2018 – 2020

Partners: CTU – Faculty of Civil Engineering, Knauf Prague, Ltd.

The main objectives of the submitted project are the development of technical and technological solutions for the efficient recycling of drywall (SDK) boards of different production types or waste generated from the installation of drywall boards (partitions). The first objective was the modification and adjustment of high-speed milling for the purpose of disintegration of SDK in terms of milling fineness, potential mechano-chemical activation, and possible conversion of gypsum rock into gypsum with wide possibilities for further applications. The second objective was the development of a pilot-scale recycling line for SDK, utilizing a high-speed mill and a new type of crusher that enables the production of granulate with a defined particle size. The third objective is the verification of optimized use of the milled filler as a simple or active filler recycled back into SDK production. Another objective is the development of lightweight aggregate based on gypsum for floor bedding, obtained by crushing or milling and pressing, and the verification of its suitability for lightweight masonry elements based on cement-free binders.

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Our primary task was to maximize the proportion of materials obtained in this way, which included developing a solution based on the maximum substitution of natural gypsum with recycled gypsum as a filler in construction materials and products, as an alternative to conventional sources. An important aspect was to improve or maintain the functional (mechanical, thermal) properties of the optimized gypsum-based materials and products through appropriate modifications using nanotechnology for material hydrophobization.

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This project, "Recycling of Gypsum Board and New Material Uses with Added Value," was co-financed with state support from the Technology Agency of the Czech Republic under the TRIO 3 Program 2018–2020. The project was also funded within the National Recovery Plan from the European Recovery and Resilience Facility.

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2020 - 2022

Mobile recycling line for processing construction waste from mineral thermal insulation materials and utilization of the recyclate, including the possibility of direct application on construction sites

Technology Agency of the Czech Republic – 4th Public Competition ZÉTA 2020 – 2022

Partners: CTU – Faculty of Civil Engineering, Knauf Insulation

The main goal of the project was to design, develop, and optimize a mobile line for recycling mineral thermal insulation materials from new constructions, renovations, and demolitions. The solution covers all types of construction applications and meets current technical and environmental requirements. The line now efficiently separates insulation materials from other construction waste such as plaster residues, construction adhesives, mortars, polyurethane foams, and more. The project also included the design of new construction mixtures using the processed recycled insulation materials. Some of these solutions are now applicable directly on construction sites. We also established a set of material properties for the proposed mixtures, which depend on the quantity and method of recycled material processing.
 

This project, "Mobile recycling line for processing construction waste from mineral thermal-insulation materials and the utilization of recyclate including the possibility of direct application on construction sites," was co-financed with state support from the Technology Agency of the Czech Republic under the ZÉTA Program 2020 – 2022. This project was funded within the framework of the National Recovery Plan from the European Recovery and Resilience Facility.

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2017 - 2019

Lightweight Masonry Materials Based on Micronized Mineral By-products with Controlled Performance Properties

Technology Agency of the Czech Republic – 2nd Public Competition TRIO 2 2017 – 2019

Partners: CTU – Faculty of Civil Engineering, Knauf Insulation

The main objectives of the project developing a new type of lightweight masonry units utilizing mineral by-products or mineral construction waste were:

• A solution based on the maximum substitution of cement or other binders by mechanochemical activation of particles from concrete recyclates.

• Utilization of the mentioned alternative binder as a partial intelligent filler together with finely ground limestone dust or sludge, which in some regions represent an environmental problem.

• Substitution of quarried aggregate with fine fractions of concrete recyclate and creation of masonry units applying 100% recycling.

• Identification and use of the simplest possible foaming systems for the concrete mix while maintaining a stable foam system for producing lightweight masonry units, aiming to eliminate the need for autoclaving in later production stages.

• Setting, optimizing, and verifying semi-industrial production of lightweight masonry units, including the realization of a suitable prototype for a simplified production line.

• Improvement of the functional properties of the foamed concrete mix through suitable nanotechnological solutions to ensure 2D or 3D hydrophobization of the lightweight masonry units.

• Identification and verification of at least one suitable type of fibers to be added to the lightweight masonry product, preferably originating from waste processing or by-products, to enhance strength and deformation characteristics.

• Technical specification and validation of the final products to ensure their applicability not only in the Czech Republic and European Union countries (Western countries such as Belgium or Italy, especially in relation to post-earthquake reconstructions, as well as Eastern countries like Romania or Ukraine, in connection with conflicts and post-war reconstruction), but also to possess export potential to less developed regions such as North Africa (Egypt) and Middle Eastern countries (Jordan, Palestine, Saudi Arabia, Kuwait, etc.).
   

• This project, "Lightweight masonry materials based on micronized mineral by-products with controlled performance properties," was co-financed with state support from the Technology Agency of the Czech Republic under the TRIO 2 Program 2017 – 2019. This project was funded within the framework of the National Recovery Plan from the European Recovery and Resilience Facility.

 

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2014 - 2016

Development of Mechanically Activated Materials Based on Recycled Concrete for Advanced Stabilized and Cold-Recycled Structural Layers

Technology Agency of the Czech Republic – 4th Public Competition ALFA 4 (2014–2016)
Partners: Czech Technical University in Prague – Faculty of Civil Engineering, SAT s.r.o., TPA ČR, s.r.o.
 

The project focused on four main objectives:
 

1. Process optimization and development of mechano-chemical activation technology using high-speed grinding of mineral materials derived from concrete recyclates. The modifications primarily involved technical adjustments and adaptation of existing equipment to produce material with a maximum particle size of 0.2 mm, while also optimizing simultaneous grinding and dosing of chemical additives. The goal was to obtain a homogeneous, additive-enhanced alternative binder or fine-grained filler with an activated and modified surface.
 

2. Application and adaptation of high-speed grinding technology—alongside existing methods (e.g., fly ash, mineral fillers)—for fine-grained and waste materials typically found in transport infrastructure (fine fractions of concrete recyclates and quarry dust). The objective was to create intelligent microfillers or alternative binders by modifying the structure and particle size and by activating/modifying their surfaces, including in combination with chemical additives for broader use in durable constructions.
 

3. Use of nanochemical additives in combination with various types of microfillers and additional chemical admixtures (e.g., to enhance hydrophobic properties) in mixtures for transport construction, utilizing local materials (soils) or asphalt and concrete recyclates in cold recycling technologies. The goal was to design a cost-competitive alternative that would allow the use of less suitable types of aggregates, soils, and various granular construction recyclates. As a result, these materials could be used as fine fillers and binders for more load-bearing and durable structural layers. The applied additives were compared with traditional binders.
 

4. Defining the potential for using selected types of microfillers (from concrete recyclate or quarry dust) as intelligent fine-grained components in asphalt mixtures. The aim was to develop a more economically efficient alternative while maintaining the required quality standards of the mixtures.

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2012 - 2014

Durable Acoustic Asphalt Layers Utilizing High-Performance Asphalt Binders Modified with Rubber Microgranulate, Including Innovative Grinding Technology

Technology Agency of the Czech Republic – 2nd Public Call ALFA 2 (2012–2014)

Partners: Czech Technical University in Prague – Faculty of Civil Engineering, M – SILNICE a.s., SWIETELSKY stavební s.r.o.,
Brno University of Technology – Faculty of Civil Engineering

The project focused on the development of new asphalt mix technologies for acoustic pavement layers, with an emphasis on achieving a balanced benefit of noise reduction and durability. For this purpose, alternative types of asphalt binders modified with rubber microgranulate were further developed, along with the application of other suitable additives.

To achieve these binders, a new production technology for rubber microgranulate was also developed, utilizing specialized and further modified high-energy milling equipment.
 

2023
WhiteCycle

The WhiteCycle project, in which we collaborate with Michelin, is an innovative European initiative focused on the processing and recycling of PET plastic waste. The project involves a revolutionary enzymatic sorting and recycling process that enables the production of plastics with properties comparable to those of virgin materials. Its goal is to establish a circular economy for complex plastics. At Lavaris, we have developed technologies for processing hard-to-recycle textile-based plastics, such as polyester cord fabrics from tires and hoses. WhiteCycle aims to support the annual recycling of over 2 million tons of PET plastics by 2030 and reduce CO₂ emissions by approximately 2 million tons per year.

2021
Minagris

The EU-funded MINAGRIS project investigates the impacts of plastic waste on agricultural soil, biodiversity, and crop productivity. Research is being conducted at 11 different locations across Europe through case studies involving more than 20 universities and research institutions. The aim of the project is to provide tools and recommendations for the sustainable use of plastics in agriculture, ensuring safe and economically viable food systems in Europe. Lavaris contributes to the project by providing technical support and preparing microplastic samples for further research.

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