Background The presence of moisture in polymers and technopolymers has negative effects on their recycling. The dimension of the environmental problem is huge, as the use of plastics is constantly increasing. Technopolymers, in particular, had the largest growth (+8% in one year) compared to other plastics. It is becoming increasing important to recycle this type of plastic, which has led industry to develop means of reducing polymer water content through de-moisturising systems such as hot air, electromagnetic fields and vacuum. Unfortunately, these methods are characterised by extremely low energy efficiency and by the generation of over treated products, which can amount to 10-15% of the recycled material. The overtreatment is due to the fact that an effective removal of the excess water requires prolonged or multiple treatments at high temperature, which can negatively impact the material. The inefficiency cannot be avoided with current practices, because the level of moisture is not monitored in real time and only approximate parameters are used during de-moisturising, which is consequently neither reproducible nor controllable. Objectives The LIFE long WASTE-FREE project aims to introduce an innovative method of measuring real time moisture content of polymers to be recycled, and to adjust the de-moisturising treatment according to the data acquired in order to avoid the formation of over treated materials. This novel method of dehumidification during PVC production is expected to reduce energy consumption, the use of raw materials and chemical additives, the production of waste, and to generally optimise the production cycle. The project’s objectives include: To demonstrate an innovative de-moisturising process that varies according to the moisture level of the input material, with load properties constantly measured and the equipment regulated accordingly so that only the required amount of energy is used and no more; To avoid thermally damaging the polymer material during the recycling process by using an improved temperature control system; To design, develop and apply real time microwave-based sensing of moisture, to measure water content directly in the material to be processed and not in the air; and To construct a new system with a de-moisturising tunnel tilted at 45°, to maximise the exchange surface and avoid the use of hot air systems that are commonly responsible for thermal damage to the recycled plastics. Expected results: Up to 50% reduction in CO2 emissions as a result of the new equipment using less thermal energy for dehumidification; A drastic reduction in production-related waste, by avoiding the thermal degradation and inefficient dehumidification of plastics that can cause irreversible damage both to raw materials and final products; Savings in the use of raw material due to a more precise moisture control upstream of the granulation process, which avoids the risk of unsuitable chemical transformation; Reductions in additives added (plasticisers, flame retardant, catalysts in general), which are the first to be volatilised due to drying problems in the event of over dehumidification and are therefore used in excess. The new process will use only the amount of additives strictly necessary, with average reductions expected of around 30%; and Constant control and optimal management of the quality of the products.