Annual report 2015 CARTIF Technology Center

INDEX WORDS FROM CARTIF CEO

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GENERAL INFORMATION

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What is CARTIF? Members of the Board CARTIF in figures CARTIF around the world Excellence Platforms and associations

PROJECTS INDUSTRIAL SOLUTIONS SARA SMART FACTORY WATCH ENERGY AND ENVIRONMENT ACUASYSTEM HUELLAS LACTISHOE VALPORC CONSTRUCTION AND INFRASTRUCTURE 3DCONS REPARA 2.0 AGROFOOD PRIMICIA PROGRESO HEALTH AND QUALITY OF LIFE MARCA SOLUCII

12 14 16 18 20 22

25 27 28 30 33 34 36 38 40 43 44 46 49 50 52 55 56 58

WORDS FROM CARTIF CEO

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To CARTIF, the exercise of 2015 has been one more year of technical, scientific and economic resistance, in spite of the adverse circumstances of Spain, of the R&D and, especially, of the technology centers in Castilla y León.

The research activity applied in the region, especially this which affects directly the efficiency of medium and small companies, received a very strong boost with the arrival of Regional Administration’s incentive actions from mid-nineties to the end of the first decade of current century. The fundamental tool of this innovative explosion was the creation of several Technology Centers. Without them and their raising awareness task, the results would have been very modest.

Own merit, the initial number of technology centers was reduced drastically in less than 20 years. These technology centers were created following the German Fraunhofer model.

However, in 2012, regional direct aids were eliminated, which put us at a disadvantage against competitors from the rest of Spain and Europe. Simultaneously, the incentive actions for companies at regional and national level practically disappeared or were reduced significantly. In conclusion, reducing costs and wages was the way to overcome the crisis and get competitiveness. The other alternative, which consisted on improving processes and products, was relegated, unlike in Europe or in other Spanish regions.

This long explanation justifies our financial difficulties and these, in turn, reduce our capacity of internal research and knowledge updating.

These both are essential in order to compete in European markets and to supply truly useful technologies to our companies. Naturally, technological and economic development of the region where we are also suffer.

Coming back to our immediate reality, European research and innovation system has achieved an important source of income. We have made a huge effort to present a significant number of proposals. In turn, we have run out all the possibilities of the national innovation system.

Similarly, we have worked hard to achieve direct contracts with companies and thus stimulate applied research and the innovation of our economic environment.

As result of all these efforts, we can present today a balance evaluation that allows us to continue one more year with this activity, which began in October 1994. This has been possible without taking harmful measures to our staff, without wage cuts or dismissals. I would like to point out that we have not had to go into debt or to take financial measures of any kind.

Once again, I have to show gratitude for the great effort of professors, researchers and staff.

Dr. José Ramón Perán CARTIF CEO

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GENERAL INFORMATION

WHAT IS CARTIF?

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CARTIF IS...

TURN OPPORTUNITIES INTO COMPETITIVE ADVANTAGES IDENTIFY AND DEVELOP BUSINESS CHALLENGES AN EFFICIENT AND PROACTIVE ATTITUDE COMMITTED TO DRIVING BUSINESS INNOVATION

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MEMBERS OF THE BOARD

TECHNOLOGY ADVISERS D. Fernando Aldana Ex-general Secretary of CYTED Programme Dr. José R. Perán CARTIF CEO

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BOARD

ASSOCIATED COMPANIES

SEADM

AYUNTAMIENTO DE BOECILLO

(PRESIDENCY)

CECALE (VICEPRESIDENCY)

ACITURRI

UNIVERSIDAD DE VALLADOLID (SECRETARY)

ESPAÑA-DUERO Grupo Unicaja

QUESERÍAS ENTREPINARES, S.A. ACCIONA GALLETAS GULLÓN, S.A. DRAGADOS

CARBUROS METÁLICOS, S.A. INDUSTRIAS RÍOS, S.L. MAXAM

IBERDROLA PROINGESA GRUPO SIRO PRODUCTOS SOLUBLES S.A. BODEGAS MATARROMERA

SEDET TALLERES PASAHI VALLADOLID, S.L.

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CARTIF IN FIGURES

CLIENT COMPANIES

157

STAFF

156 47 PHDS

30,1%

MEN

53%

WOMEN

47%

AVERAGE AGE

36 YEARS OLD

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PROJECTS

MILLION EURO INCOME

116 7,71 M€

75 WITH COMPANIES

31 INTERNATIONAL

10 GENERIC RESEARCH

SPIN OFFS

65% 27% 8%

ORIGIN OF OPERATING INCOME COMPETITIVE PUBLIC FUNDING

58,8%

PRIVATE CONTRACTS

41,2%

11 SPIN OFFS 17

CARTIF AROUND THE WORLD CARTIF works to support the spanish companies involvement in international programmes, committed driving to business innovation.

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CARTIF INVOLVEMENT IN THE H2020 PROGRAMME (2015)

CARTIF INVOLVEMENT IN LATINAMERICAN PROJECTS (2007-2015)

NUMBER OF APPROVED PROJECTS: 8 NUMBER OF PROJECTS LED: 2 RETURN: 3,2 M€

NUMBER OF APPROVED PROJECTS: 20 NUMBER OF PROJECTS LED: 6 RETURN: 1,1 M€

CARTIF INVOLVEMENT IN THE EU 7FP (2007-2015)

CARTIF INVOLVEMENT IN OTHER EU PROGRAMMES (2007-2015)

NUMBER OF APPROVED PROJECTS: 23 NUMBER OF PROJECTS LED: 7 RETURN: 7 M€

NUMBER OF APPROVED PROJECTS: 27 NUMBER OF PROJECTS LED: 17 RETURN: 5,4 M€

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EXCELLENCE Our Laboratories have these accreditations: • Environmental Trials. Accreditation Nº 335/LE656 (accredited by AENOR) • Trials in compound materials, paints, varnishes, and pellets. Accreditation Nº 335/LE1276 (accredited by AENOR).

• Non metallic materials testing AS 7003 (accredited by Nadcap).

• The Centre has different certifications in quality, environmental management, research and development management and Ecodesign. The Department of Quality works with an Integrated Management System.

• In 2015, CARTIF was the first Spanish Laboratory to be accredited by the Spanish Entity of Accreditation, to make trials in wood pellets through the ENplus® accreditation.

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PLATFORMS AND ASSOCIATIONS ·· EUROPEAN CONSTRUCTION TECHNOLOGY PLATFORM (ECTP)

·· EIP Raw materials (Commitment Metal

·· EFFRA (European Factories of the Future Research Association).

·· EIP Smart Cities and Communities

·· EERA (European Energy Research Alliance): JPs: E3s, Smart Cities ·· BIC (Bio-based Industries Consortium) ·· EARMA: European Association of Research Managers and Administrators. ·· ISES: International Solar Energy Society. ·· IWA: International Water Association. ·· EIP Agriculture (Focus Group, Protein Crops) ·· EIP Water (Action group: Industrial Water reuse and recycling.)

Recovery from Low Grade Ores and Wastes)

·· euRobotics AISBL ·· JPI CH (National Consultation Panel for the JPI Cultural Heritage and Global Change) ·· COST Action FP1205: Innovative applications of regenerated wood cellulose fibres ·· COST ActionTD1203: Food Waste Valorisation for Sustainable Chemicals, Materials and Fuels (EUBis) ·· COST Action TD1406: Innovation in Intelligent Management of Heritage Buildings

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PROJECTS

INDUSTRIAL SOLUTIONS If there’s something that defines CARTIF’s activity is our ability to provide end customers ready-to-use industrial solutions. The efficient manufacturing and the transition towards the Factory of the Future are at the core of our fundamental objectives. To achieve them, we rely in our research lines, continuously updated, and according the market needs.

These research lines include, the flexible manufacturing, intelligent and efficient manufacturing processes and collaborative robotics and advanced automation, among others. In addition to this research work, we also keep track of the needed profitability four our customers so they maintain their market position.

SARA INTELLIGENT SYSTEM OF VIRTUAL REALITY FOR LEARNING OPERATIONS AND INDUSTRIAL ASSEMBLY

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The car industry is working with a highly optimized manufacturing processes. Many of these processes such as painting, solder and some assembly elements (for example, windscreen), are made with robots. However, there are several processes carried out by operators and it is not possible to automate due to the complexity of the operations, its high cadence (short cycles) and especially, the high cost of the inclusion of automatic systems.

SARA project aims to develop a new concept of assistance for manual assembly positions in the industry.

CARTIF and PROINGESA work in order to make a system in which the operator is assisted by visual monitoring of its operations and instructed by spatial virtual reality over the job. The goal is to eliminate every possible mistake in the assembly process (philosophy ‘poka-yoke’) and it allows the training of inexperienced workers completely autonomously.

In addition, the proposed system allows to integrate manual assembled systems in the traceability system and prepare reports and statistics on cycle times and productivity. The systems could be applicable in assembly operations in industrial environments, and particularly in the car industry, specifically in the assembly of inserts on panels in which is necessary carry out assembly operations.

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SMART FACTORY WATCH PREDICTIVE MAINTENANCE AND SUPERVISION SYSTEM

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This system, developed by CARTIF, allow the factories a smooth transition from preventive to predictive maintenance. Knowing the critical points of the machines respect power consumption and performance, SFW helps to take the best decisions in the factory, based on the actual data and information of what is happening in the machines.

This system is very useful if there exist processes and machines that need to be continuously supervised in

relation to their condition or power consumption; or in the case of failure of some elements or machines stops the whole or a significant part of the process generating substantial associated costs; or if the replacement or repair of faulty machines requires a medium term scheduling and a long stop time; or if the preventive maintenance requires the replacement of elements that are far from the end of their useful life.

of critical variables, the automatic generation of malfunction alarms, the remaining useful life prediction of the machine components, the predictive maintenance based on vibration and process measurements and the automatic configuration of alarm thresholds.

Smart Factory Watch offers the online web supervision

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ENERGY AND ENVIRONMENT We have 17 years’ experience in technologies, R&D projects and developments for the companies that concern to all the stakeholders in the Energy and Environment sector. We were pioneer in renewable energies and biofuels research in Spain and now, we have one of the most prepared research group in Energy all over Europe.

ACUASYSTEM SENSORS TO MEASURE WATER POLLUTION ACUASYSTEM is an experimental development project that combines scientific knowledge and scientific and business techniques, thanks to the participation of

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different companies that create a balanced consortium.

It is an innovative project that will lead on to a comprehensive platform with enhanced functionality and properties compared to other markets.

The application of optical solutions and ICT will increase control over current treatment processes in water-treatment plant, improving water management and advancing in the development of technology applications which contribute to improving safety.

It will be possible analyzing the real-time input of

bacteriological contaminants to the water treatment and also in a significant number of control points along the chain of treatment or distribution network.

On the other hand, energy consumption monitoring throughout the treatment plant will allow to analyze the energy efficiency of different processes, as well as the identification of potential points of energy savings that allow to propose optimum energy saving measures.

The final goal is to develop an integrated platform

water /energy that allows to manage water systems in an efficient and sustainable way. To get it, it will be designed and built an innovative optical sensor prototype that allows the fast detection of pathogens in water that will be integrated into this single platform ensuring access to water in accordance with current regulations.

The CARTIF researcher team is responsible for the design, construction and calibration of microbiological prototype.

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HUELLAS REDUCE THE ENVIRONMENTAL FOOTPRINT IN RAILWAY CONSTRUCTION The aim of LIFE HUELLAS project, led by CARTIF, is to develop tools and methodologies in order to optimize the taking decisions in railway construction projects with the goal of reduce the carbon footprint and water foot-

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print. To this end, the project will review and analyze the environmental impact of each stage of the construction process. The results of this audit will allow to develop some indicators of the life cycle, to create a best practices publication.

The first step in this analysis is the comprehensive collection of information. Later, it will focus on the study of the transformation of the environmental impact on carbon and water footprints through the development of methodology recognized evaluation. After this

collection, a tool will be developed to establish different planning alternatives of works, showing specific values footprint and environmental indicators. The tool will be tested in two pilot works with different characteristics.

The project has begun to evaluate specific conditions of railway projects, which will give rise to a database allow the understanding of all the languages, both builders and environmental projects.

Spanish Association for Standardization and Certification (AENOR) and the Association of Construction Companies of Spain National Level (SEOPAN) CARTIF intends to show that it is possible to reduce the carbon footprint of rail infrastructure projects by 10% and its water footprint by 5%. This project will contribute to mitigating the effects of climate change.

In addition, it counts with the collaboration of the Agriculture, Food and Environment Ministry (MAGRAMA), the

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LACTISHOE PRODUCTS FOR FOOTWEAR FROM LACTIC ACID The main goal of LACTISHOE projects is obtaining a new range of products for footwear (templates and inner lining) with beneficial properties for the foot by incorporating lactic acid microencapsulated.

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In order to achieve it, it is going to carry out a hybrid process of fermentation and separation of distillation membranes of lactic whey to obtain lactic acid with high yield and purity. Then, microencapsulation lactic will be carried out, for its following incorporation in the templates and in the inner lining of the shoe. In addition, Ecodesign strategies will be incorporated into the process of lactic acid getting.

Thus, it is possible to add value to the waste, the lactic whey, which has never been used in the footwear industry,

providing beneficial health properties: achieve a stronger, softer and more resilient skin, thanks to the power regenerating, moisturizing and softening lactic acid.

The expected results of the project will get three objectives:

The partners who are going to carry out the research are CARTIF and CTCR, while the companies Arneplant and Garmaryga will apply the results to templates and inner lining in manufacturing shoes.

• An innovative industrial system that improves the current ratios of lactic acid obtaining. • An integrated and sustainable development of the footwear industry. • An environmental benefit.

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VALPORC SUSTAINABLE MANAGEMENT OF PIG CARCASSES AND MANURE The current management of the by-products of primary production in pig sector, especially dead pigs and manure, supposes a serious environmental problem, because of the volume and its little or no recovery

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of them, because normally they are disposed of by incineration or landfill delivery.

In this situation, the main goal of LIFE VALPORC project is to demonstrate a sustainable alternative to the management of the pig carcasses and pig manure, addressing the environmental problems associated with its current management and valorizing these waste by turning it into biofuels (biogas and biodiesel) and organic fertilizers, with the corresponding environmental and socio-economic added value.

The results obtained at this moment by the CARTIF

team research show that co-digestion of meat byproducts (flour and fats) with the effluents generated in the process of rendering and pig manure is a viable alternative to cost-effectively manage these currents waste.

The study demonstrates that by-products from animals are substrates which could be important in biogas production process, but their high fat and protein contained can cause inhibition problems by fatty and ammonia in industrial digesters. The co-digestion of these products with waste streams such as pig manure and rendering process water favors the process of

anaerobic digestion, with the limitation of the amount of flour in the mixture to codigest, which should not exceed 10% of total mixture.

The proportion of other substrates tested is less critical, because with different mixtures of thereof is possible to get similar values of methane generation. The valuation system of pig carcasses and pig slurry, proposed in VALPORC project, is materialized in a plant of 1t/day processing capacity, designed to optimize energetically the production of flour and fat and promote safe recovery of these elements.

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CONSTRUCTION AND INFRASTRUCTURE To answer the needs of this competitive market, we have developed one specific research line based in Smart and Sustainable Construction with the aim to help our clients to get the transformation and sustainability of the construction industry through building integration of renewable energy systems, the implementation of digital home and new technologies for the building rehabilitation with one special mention for the cultural heritage. All of this is inside the global concept regeneration of the urban environments (Smart City) We also develop other research lines in infrastructure, logistic and transport through the application of Computer Intelligence techniques to the domain of transport infrastructures preservation, both roads and railways: knowledge extraction and intelligent modeling.

3DCONS NEW CONSTRUCTION PROCESSES USING 3D PRINTING This project will work to introduce 3D printing technologies in the construction industry, and to automate a number of jobs in the construction and rehabilitation of buildings and in the heritage restoration.

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The development project is a compendium covering the development of robotics, the search of new ranges of construction materials and the technological momentum of design and construction.

The new 3D printing systems planned will serve for the rehabilitation of faรงades by direct printing and manufacture of prefabricated elements without molds or formwork. These printing systems work with new range of interior and exterior materials based on cement, lime, gypsum and mixed blends, especially developed for application by extrusion.

The project includes the development of new robotic systems to print full-scale construction elements or rehabilitate facades through the printed on vertical elements, without problems for users of the building.

It is looking for new ranges of materials that allow to control their thermal and aesthetic properties at each point of application and new design tools that convert plans and buildings models into production orders for full-scale printing systems.

areas of economic activities. By eliminating molds or formwork systems, 3D printing technology enables the manufacture of geometric forms unthinkable until now in a practical level, opening up the creative freedom to architects.

CARTIF collaborates in several technical work related to robotics and artificial vision, one of its more established lines of research.

The falling of technology prices causes that, in less than a decade, is common to use 3D printing in many

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REPARA 2.0 NEW TECHNIQUES AND INFORMATION SYSTEMS FOR SUSTAINABLE REHABILITATION OF ROAD PAVEMENTS

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Repara 2.0 project aims to develop new technologies and methodologies to support infrastructure management and allow rehabilitate and preserve any road with less economic and environmental costs, improving their adaptation to climate change. It is a critical moment at the national level due to bad state of the Spanish road.

Repara 2.0 will be developed around three axes: the production of new recycled bituminous mixtures; the

manufacture of new pavements by using mixtures of recycled manufactured at less than 100째C, and the creation of a new dynamic weighing systems capable of detecting with the required precision the load of heavy vehicles, and will serve to control in an effective way any violation that impaired the firm.

New technologies and materials related to this project will be analyzed and characterized from the point of view of its environmental performance, making the

corresponding life-cycle assessment LCA for all of them. As a result of this work, it will be developed a methodological guide for the study of environmental performance in road rehabilitation projects.

In order to ensure that new technologies developed in the project arrive to the market as soon as possible, it will be developed a specific software to design new pavements of the future with this type of technologies.

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AGROFOOD The concern of modern society about controlling their health through their diet, makes essential a thorough control of the manufacturing process of food, which guarantees maximum quality and safety. We work on offering solutions to the industry and the consumers, paying attention to their needs. To accomplish this, we optimize the manufacturing processes, develop new products, and do agrofood waste recovery, besides of undertaking physicochemical, microbiological and sensory analysis.

PRIMICIA PERSONALIZED NUTRITION FOR THE PREVENTION AND CONTROL OF CHRONIC DISEASES

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The aim of PRIMICIA project is to bring to the market food of highly effective controlling chronic inflammation, with effects in preventing related diseases (obesity, cardiovascular system disorders, central nervous system disorders, rheumatoid arthritis, cancer, etc.) from customizing diet for the population stratified according to generic profiles and assessing their effect through nutrigenetic clinical trials. In this project, it will be addressed the analysis and the elimination of potential barriers to bring to the food market some oriented food, called ‘personalized nutrition’.

In the early years of the century, the sequencing of the human genome and the development of biology systems, in addition of the use of new tools, have a definitive research on nutrition, food and health boost.

PRIMICIA borns in the context of what has been called ‘new nutrition’, as a discipline that firstly was focused on the needs of the human body and now it has turned into a science that studies at the molecular level, the action of nutrients and their impact on the origin and evolution of many chronic diseases.

The project will contribute to the new wave of R&D that is emerging around functionality, nutrigenetic and stratified nutrition.

This is the first CIEN project focused on this topic, in which leading industry players, companies of functional ingredients, innovative food companies and important research centers. The cooperative work of all of them will help to revitalize the industry in the regions where it is developed, maintaining and increasing industrial and technological activity in these areas and thus contributing to an improvement in living standards.

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PROGRESO PROTEINS OF THE FUTURE

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This project studies how to establish mechanism and technologies necessary to obtain, from alternative protein sources, new ingredients rich in proteins for the three large population groups: children, adults and elderly. The ultimate goal is to ensure the supply of protein from existing sources from agro-food products or new sources.

CARTIF collaborates in the project contributing their experience in extrusion technology application in order to improve the properties of protein ingredients which later will be used in the project, as well as in the formulation and development of extruded snacks, rich in proteins and adapted nutritionally to the elderly necessities.

Moreover, the project will study and evaluate two technologies that allow research new sources of raw materials, compatible with the production of compound feed ingredients, applying the bioconversion of raw materials with microalgae in heterotrophic regime and cooking oil at low temperature.

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HEALTH AND QUALITY OF LIFE We are committed with the future’s greatest challenge: to improve people’s quality of life, particularly for the ageing phenomenon from different health perspectives, by developing and marketing high-impact life-transforming products and services.

MARCA REMOTE MAINTENANCE OF WATER MANAGEMENT FACILITIES

The MARCA project will provide tools to make easier the access to contents, communications and technologies needed to guidance, support and registration of maintenance of machines, equipment, infrastructures and the rest of facilities related to integrated water cycle: debugging, water supply, sanitation, etc.

It is an innovative project of experimental development that will allow to launch a new product focused on the

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maintenance of supply facilities, water collection and treatment that will combine scientific and business knowledge.

The maintenance personnel of companies has extensive experience, but their physical limitations or age complicate to move to perform maintenance in certain locations. The aim is to enable they can remotely assist and advise younger workers on how to perform

maintenance operations required.

In order to get it, the system developed in this project is based on augmented reality technologies, mobility and communication, and on generating a knowledge base to incident management. The system will be integrated into the Personal Protective Equipment (PPE) that, for safety, the operator must carry on direct interventions.

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SOLUCII IMPROVING DATA MANAGEMENT IN ICUS

Monitoring equipment and life support (vital signs monitors, ventilators, infusion pumps, etc.) connected to a patient in ICU, generate a large volume of information about his vitals evolution. This information is very useful when it is properly recorded and processed for the development of indicators, which allow a better monitoring of the evolution and diagnosis.

This equipment has a limited storage capacity (24 to 48 hours). For this period, the caregiver displays

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data and uses it to calculate different indicators (with significant variability between different organizations).

Subsequently, this information is written down in a paper in the stretchers. This process is a tedious task, and the information could be lost if it is not done in the period of time.

SOLUCII project proposes an advance over the current technique that will allow to develop an innovative solution of a system of support for comprehensive

analysis of patients in intensive care units (ICUs) to support the medical decision, based on Technology Information and Communications.

SOLUCCI is aligned with the objective of the European Programme Horizon 2020, within the Social Challenge (R1) Health, demographic change and well-being, because it will develop a medical solution adapted to the needs of the National Health System.

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published CARTIF Research Centre Boecillo Technology Park.

Valladolid 路 Spain www.cartif.com

staff CARTIF Communication Department

design www.typopotamo.com

photography Inside pictures: CARTIF.