Pioneering
an innovative
and circular
economy

With an estimated 900 aircraft that will leave service every year, the market volume to grasp equals more than 9000 aircraft worldwide in the next 10 years. Knowing that the aviation sector since 1970 shows a doubling of activity every 15 years, with over 30000 aircraft on projected order, it is that an urgent societal challenge exists in the treatment of end-of-life aircraft. In addition, global regulations on retired aircraft processing and important incentives by the EU in the field of the circular economy are expected. By introducing the circular economy business model, Eco Fly has developed a unique selling proposition for aircraft owners, increasing the value of end-of-life aircraft materials by a factor of 8 compared to the competition. With an ambitious but realistic market share target of 22% of the worldwide aircraft fleet dismantled being by Eco Fly within 5 years, the value of that market share exceeds EUR 400 million.

By using a service model which is more favourable to aircraft owners than buying these aircraft, as well as value creation via re-manufacturing airframe parts in to new products, the income expected is more stable, the generated value on the airframe is 8 times higher than with competition and there is no need to pay for aircraft procurement; thus there is a better cash flow position. In our service model, 100% of our generated aircraft value is given back to the aircraft owner, so working with Eco Fly has both a strong financial and environmental advantage. Stable income and a performance incentive for Eco Fly is guaranteed via a service fee paid per aircraft. With established sites in Switzerland and planned sites in the USA, Abu Dhabi, Northern Africa and Asia, Eco Fly will employ more than 300 FTEs over the next 5 years, with annual employment growth of 74% on average. Through partnerships with knowledge institutes, innovation knowledge is anchored in Europe. With the backing of the largest metal recycling group in Switzerland, with sites all over Europe and covering risk-including technology development, Eco Fly is on course for market valorisation and scale-up.

With a highly experienced team, ranging from aircraft design through maintenance and flight operations to European policy-making on the circular economy and finance, it is believed that the Eco Fly team is well placed to achieve the ambitious objectives outlined in this business plan. Doing so, Eco Fly solves an important environmental problem with healthy business, favourable market conditions and strong growth prospects.

The company specialises in the field of automotive shredder residue (ASR) and waste electrical and electronic equipment (WEEE) recycling. Low-temperature continuous pyrolysis lies at the heart of ASR and WEEE treatment processes. Utilisation takes place in a specially designed TDP-type pyrolysis unit. Pyrolysis is a highly environmentally friendly technology, which was adapted to comply with the environmental standards of European legislation. Pyrolysis is the thermo-chemical decomposition of organic compounds. The oils and gasses resulting from the pyrolysis process can be used without restriction and are even lower in pollutants than coal. They replace around 15,000 tonnes of coal a year that would otherwise have to be imported from South Africa. This is around half the amount currently imported.

Pyrolysis products reduce the share of coal in total consumption (currently 25 per cent) by present to around half. Alternative fuels include tyres, plastic chips, waste oil, sterilised meat meal, sewage sludge and solvents.

The waste product from the pyrolysis process is coke. This contains heavy metals in quantities that exceed the specifications of the Cement Directive and may not be used in Switzerland‘s cement kilns. The coke is therefore collected in containers and transported away for further processing.

The environmental impact assessment has shown that the overall environmental impact is low. Overall, CO2 is even saved because the Resh pellets would have to be incinerated anyway. Instead of being incinerated in a waste incinerator, they are burned in a cement kiln, thus eliminating the need to burn coal. Further CO2 is saved by not having to transport them from South Africa.

Eco Carbon recycles in-house resources by recovering valuable materials. The decomposition of natural and synthetic organic materials produces a carbon decomposition product called biochar. Eco Carbon has its own production and testing facilities. The unique know-how and experience of the employees in the field of waste recycling and green technology determine the success of the company. The operation of our departments is adapted to the needs of our customers: if necessary, ongoing tests can be carried out at the production site. We are always ready to organise test runs to demonstrate the positive effect of waste processing to our customers. A respectful and caring approach to the environment is the guiding principle of Eco Carbon‘s activity.The company‘s environmental management system is certified according to the international standard ISO 14001. Thanks to the high independence of our facilities, it is possible to treat materials with minimal costs and low energy consumption. Our values are reflected in our company name. We are aware of our responsibility towards future generations and therefore carry out all activities in accordance with the highest environmental, health and safety standards.

A shredder plant, like a combined heat and power plant (CHP), is an important part of our national recycling economy and fulfils important functions. The goal of CO2-neutral recycling of inhouse residual fractions from decentralised and autonomous use of energy is ecologically and economically sustainable.