Find out how Ossicolor turns mud into value.
At Ossicolor, we don’t see anodizing sludge as ‘waste’ but as a real opportunity for innovation. We don’t just talk about our commitment to sustainability — we prove it through targeted investments, cutting-edge technologies, and strategic collaborations.
1. The initial context
Until a few years ago, the sludge generated by washing the anodic oxidation cycle represented a significant cost for the company, both in terms of disposal and environmental impact. With a moisture content of between 75% and 80%, it was disposed of as undifferentiated waste, entailing high economic and logistical burdens. Ossicolor decided to change its approach: the aim was to transform this residual material into secondary raw material with tangible value.
2. Collaboration with the University of Trento
Three years ago, thanks to a discussion with Professor Straffelini of the University of Trento’s Department of Engineering, an expert in tribology, the possibility of using dried sludge as an abrasive for brake pads opened up. The basic requirements to make this solution viable were:
- Substantial reduction of moisture content: lowering the residual water from 75–80% to a maximum of 10%;
- Controlled particle size: obtain a particle size suitable for the production specifications of the brake.
The Engineering Department thus conducted initial laboratory tests on the dried sludge, validating its compatibility with the friction materials used in the brake industry. Initial results confirmed the technical feasibility, paving the way for a more advanced development project.
3. Design and creation of the drying plant
Identifying a reliable industrial partner was essential. After a thorough analysis, an Italian company chosen for the project built a drying system tailored to our needs. The main features of the system include:
- Air-circulation drying at 75°C: ensures uniform treatment and reduces energy consumption;
- Preliminary sludge extrusion: increases the heat exchange surface area, accelerating the evaporation process;
- Continuous parameter control: monitoring of temperature, air flow and residual humidity to maintain the desired values.
In June 2024, the system was installed in our factory. In the following months, we conducted a series of tests to optimise the operating parameters: drying times, air flow rate, cleaning cycles and quality control. The Engineering Department validated these tests by simulating a complete working cycle of a car brake system in the laboratory. The result was positive: as of 2025, the plant fully meets our production requirements, guaranteeing sludge with a residual moisture content of 10% and controlled granulometry, ready to be used as an abrasive in brake pads.
4. Results and validation
The research and development project, financed by the Autonomous Province of Trento and developed over 2 years, produced
- Scientific publications in industry journals, documenting the engineering solutions adopted;
- Confirmation of tribological compatibility: the dried sludge, used in laboratory tests, met the required performance standards for friction and wear testing;
- Start of industrial tests at a major brake system manufacturer, scheduled for 2025, to obtain final validation.
From the beginning of 2025, the drying plant is fully operational: the treated sludge no longer represents a disposal cost, but has become an opportunity as a secondary raw material for the brake pad industry.
Other initiatives for a more sustainable industry
The recovery of oxidation sludge is only the last part of our overall approach to sustainability. At Ossicolor we fulfill daily actions such as:
- Water-based painting: we eliminate the use of harmful solvents, reducing emissions of volatile organic compounds (VOCs);
- Recovery and recycling of aluminum scrap: production offcuts are collected, cleaned, and sent to authorized recycling centers, minimizing raw material waste;
- Made-to-measure and sustainable packaging: thanks to the latest technology, we make all packaging to measure, using paper tape and recovering all packaging, including plastic.
Next step: circular economy
The introduction of an industrial symbiosis model can generate measurable benefits:
- Reduction of disposal costs: by transforming waste into secondary raw material, operational expenses related to sludge management are reduced;
- Reduced extraction of virgin resources: the use of dried sludge decreases the demand for traditional abrasives, lowering the overall environmental footprint;
- Increased competitiveness: offering a ‘green’ product under cost-effective conditions, thereby opening up new market segments interested in sustainable solutions;
- Logistical optimisation: instead of transporting high-water content sludge at high costs, deliver a lightweight, low-water content raw material.
Dissemination as wealth
Our commitment is not limited to the installation of technologies: we aim to disseminate a corporate culture in which sustainability is an integral part of strategic decisions.
To learn more about the technical details of the project, stay up-to-date on the next validation stages and find out about all Ossicolor’s initiatives, please contact us or subscribe to our newsletter and follow our social channels to keep up with the latest news on our sustainability and innovation projects.
Choosing Ossicolor means making a difference: together we transform today’s waste into tomorrow’s opportunities.
