Have you ever wondered what happened to all those vials that contained the COVID vaccines? Most of those small borosilicate glass containers have not been recycled. Instead, they have been incinerated or sent to landfill, where they will remain for centuries.
The problem lies in the material itself. Borosilicate glass, known for its strength, chemical stability, and heat resistance, is essential for pharmaceutical packaging and laboratory equipment. But these very qualities also make it difficult to recycle in standard glass furnaces, which are designed for soda-lime glass used in bottles and jars.
Why borosilicate matters
Borosilicate contains boron, a critical raw material identified by the European Union for its role in technologies such as batteries and nuclear energy. Europe imports all of its borate minerals, so every vial that ends up in landfill represents a lost resource.
At present, virtually no pharma-grade borosilicate glass is recycled — a striking contrast to soda-lime glass, where at least 70% is recovered in Europe.
The EVERGLASS solution
The EU-funded EVERGLASS project is developing a promising new route: glass laser morphing. Instead of relying on traditional furnaces, researchers use powerful lasers to recycle borosilicate and other “hard-to-recycle” glasses. The process begins by cleaning and crushing waste glass into a fine powder. This powder is then heated with a laser to temperatures of up to 2000ºC, hot enough to melt borosilicate.
Because the laser can precisely control the melting process, the molten glass can be shaped directly without moulds. Researchers have already created sturdy prototypes and are now working on increasingly complex shapes and porous structures.
Unlocking new possibilities
Although recycled borosilicate may not meet the strict standards required for pharmaceutical packaging, the potential applications are broad. From durable cookware to filters and supports for chemical processes, the technology opens new doors for circular use of glass materials.
Looking ahead, the EVERGLASS team envisions modular recycling systems that could one day be installed in hospitals or laboratories, allowing glass waste to be processed directly on-site.
Key takeaways
Borosilicate glass is vital for pharma and labs but nearly impossible to recycle in traditional furnaces.
Its disposal in landfills wastes valuable boron, a critical raw material for Europe.
EVERGLASS is developing glass laser morphing to efficiently recycle borosilicate glass.
The process avoids furnaces, saves energy, and enables direct shaping of new products.
Future applications range from cookware to filtration systems, with potential for local, on-site recycling.
To learn more about the project, read the full interview published in DirectIndustry e-Magazine below.