Country: Romania
Focus area:Green, Digital
Thematic area:
Digitalization and Connectivity, Data Analytics and Artificial Intelligence, Cyber Security and Digital Trust, Waste reduction and Recycling Technology , Energy-Efficient Technologies, Green & Sustainable materials
TRL phase: TRL 7 - system prototype demonstration in operational environment (System development)
Addressed business processes: INBOUND LOGISTICS process , MANUFACTURING OPERATIONS process , CUSTOMER CUSTOMER SERVICE process , PROCUREMENT process , TECHNOLOGY DEVELOPMENT process , HUMAN RESOURCE MANAGEMENT process , INFRASTRUCTURE process , OUTBOUND LOGISTICS process , MARKETING & SALES process
Solution overview
DTDA lab developed by IRCEM to assess, model, and optimize circularity, resource efficiency, and sustainability performance in manufacturing systems. It integrates LCA/LCI/LCC, Material Flow Analysis (MFA), digital twin modelling, CE indicators, climate impact modelling, and circularity KPIs.
The solution addresses challenges such as high material waste, inefficient resource use, limited data for sustainability decisions, carbon footprint reduction, and compliance with EU CE policies.
Targeted users: manufacturing companies, SMEs, clusters, regional authorities, and industrial value chains seeking to improve sustainability, reduce operational impacts, and transition to circular business models.
Key features
"Integrated CE modelling combining LCA, MFA, KPIs and digital twin concepts.
Alignment with EU Circular Economy monitoring frameworks (CEI/CEII) and Green Deal targets.
Rapid scenario simulation for resource efficiency and waste reduction.
Modular design adaptable to various industrial sectors (metal, plastics, machinery, construction).
Policy-testing features for EU/local authorities.
Provides both operational and strategic insights."
Integration and adaptability in manufacturing environments
"DTDA is fully compatible with existing manufacturing data systems (ERP, MES, IoT dashboards).
It can be customized for specific production lines, materials, processes, or energy systems.
Integration requires only operational data, BoM, process flows, and energy/material profiles—no hardware installation.
Compatible with most digital manufacturing tools and sustainability reporting systems."
Implementation support and training for manufacturers
"IRCEM offers full methodological support:
– needs assessment, data mapping
– process modelling, LCA/MFA setup
– testing & scenario simulation
– interpretation of results
– post-implementation monitoring and optimization
Training programs include CE modelling workshops, LCA certification modules, and digital circularity tools training.
Follow-up support includes KPI dashboards and sustainability reporting guidance."
Sustainability, compliance and certifications in the EU
"The solution aligns with:
– EU Circular Economy Monitoring Framework
– EU Taxonomy sustainability criteria
– ISO 14040/44 (LCA)
– ISO 14064 (GHG emissions)
– ISO 50001 (energy management)
– Standards relevant to digitalization and CE in manufacturing
Validation through EU-funded projects (Horizon Europe, Interreg, URBACT) ensures credibility."
Example of successful implementation of solution in manufacturing company.
"A manufacturing company in the metal-processing sector collaborated with IRCEM’s to evaluate material efficiency and identify circular economy opportunities along its production line. Using LCA, MFA and scenario modelling, IRCEM mapped resource flows, quantified waste streams, and simulated alternative process configurations.
The solution revealed high-impact inefficiencies in material cutting operations and energy consumption. The company implemented an optimized material flow strategy and introduced recycled material loops validated by IRCEM simulations.
Results included a 12% reduction in raw material use, a 9% decrease in energy consumption and improved process predictability. The findings supported the company’s sustainability reporting and alignment with EU Circular Economy and Green Deal requirements."
Case studies or testimonials showcasing the impact of the solution on real-world operations.
"Case Study 1 – Machinery manufacturing company (Digital Twin & Predictive Modelling)
IRCEM applied one protocols in order to model production sequences, maintenance cycles and energy use for a machinery producer. A digital twin simulation was developed to evaluate predictive maintenance strategies.
The model exposed inefficiencies in equipment downtime and identified optimal intervention windows. Recommendations were integrated into the company’s planning system, reducing unplanned downtime by 18%."
Link to the solution video or pdf technical documentation.
N/A
Expected return on investment (ROI)
"The IRCEM generates ROI primarily by reducing resource consumption, optimizing energy use, improving process efficiency, and minimizing waste.
Typical results observed across industrial users include:
-10–15% reduction in material waste through circularity simulations
-5–12% energy savings via optimized process modelling
-8–20% reduction in operational inefficiencies using digital twin and predictive analytics
-Faster compliance with EU Green Deal, Taxonomy and CE regulations, reducing future regulatory costs
-Improved competitiveness in green procurement and sustainable supply chains
Manufacturers typically recover their investment within 6–12 months, depending on data availability, production scale, and improvement measures implemented."
Cost overview: implementation and ongoing expenses
Since DTDA lab is a digital and methodological solution, not an equipment-based technology, initial costs are significantly lower than industrial hardware investments.
Initial costs include:
-Needs assessment and data mapping
-Setup of LCA/MFA models and digital simulation environment
-Tailored scenario development and CE KPI dashboard
-One-time training for company staff
-Depending on complexity, initial implementation costs typically range between €3,000–€15,000 for SMEs -and medium manufacturers.
Ongoing expenses include:
-Periodic updates of simulation models
-Extended scenario analysis on request
-Optional annual sustainability reporting support
-Access to training modules and expert consultations
-Annual maintenance and support are optional and typically range between €500–€2,000.
No hardware, factory downtime, or installation costs are required, making integration fast, low-risk, and highly cost-effective.
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