Background The European Union produces on average six million tons of wire products every year. Most specialised companies in this sector are medium in size, but the market is dominated by a few large producers responsible for about 70% of production. Some 32% of the total production in Europe comes from Germany, followed by Italy which is credited with approximately 22%. Italy produces about 1 250 000 tonnes of wire mesh, 300 000 tonnes of wire mesh products, and has about 74 production facilities. Wire production consumes large quantities of resources, in particular, energy, water, oils, acids, zinc, and various other products. At the same time, manufacturing activities produce emissions (e.g. particulates, NOx, carbon monoxide and CO2), wastewater (with suspended solids, dissolved iron, traces of other metals, soaps), liquid waste, sludge and solid waste. Objectives The LIFE-Inno.Pro.Wire project aims to develop and demonstrate an innovative process for the production of extruded steel wires, with lower environmental impact compared to the conventional process. The innovation is based on the use of a new polyamide coating for steel wires called PA6, which is used instead of PVC, to improve environmental and technical performance. The new process will be demonstrated on an extrusion line, in which softened metal is forced through a shape to produce a continuous ribbon of wire product. Energy savings can be made, because the process of galvanization can be eliminated. The specific objectives are to: Develop a replicable methodology for the production of eco-sustainable non-galvanized steel wires, including new materials and new processes; Implement a pilot system demonstrating the benefits related to energy and resource savings, and to assess wire performance; Contribute to the implementation and consolidation of the PEF (Product Environmental Footprint) experimental methodology for an environmental assessment of processes and products; Contribute to the diffusion of technology in public procurement for construction and maintenance of roads (Green Public Procurement, GPP); and Raise awareness of the benefits of adopting environmental measures in industrial production among companies in the sector, national and international public institutions, and non-experts. Expected results: The main result of the project will be the adaptation of the extrusion line for the new process, along with a demonstration of feasibility and the specifications for a replicable process with low resource and energy impacts. The PEF study will highlight the environmental advantages of the new production process compared to conventional ones, in terms of reductions in energy and resource use, waste production, and through 14 environmental indicators, such as climate change, ozone depletion and human toxicity. The project will consolidate the PEF experimental methodology, which will result in the production of high-quality data for future implementations. In particular, quantifiable results include: Average savings of 20% of the weight of polymer with reference to the tonnes of coated wire, achieved by a lower specific weight of the compound and by the innovative extrusion process that provides lower material thicknesses; Energy savings of approximately 47% (from 164 to 90 kW) and elimination of logistical costs for moving galvanized wire with trucks; Elimination of the waste typically generated with hot galvanizing and the use of chemical baths; and Elimination of zinc dust and the related filters used during the life cycle of the process.