Susterra: circularity and innovation for a new range of solutions

In line with our commitment to sustainability and circularity, we have launched Susterra, a new range of products that groups and distinguishes solutions in the portfolio with the greatest contribution to decarbonization, the circular economy, or health and well-being in the workplace.

Published in International Cement Review. October 2024.

In the current context of climate change and the urgent need to decarbonize the global economy, the construction industry, particularly cement production, faces significant challenges. We have made a strong commitment to sustainability and the circular economy. This commitment is reflected in our “Sustainability Roadmap 2030,” which, among others, sets ambitious goals to reduce CO2 emissions and increase the use of renewable energy. 

The plan aims to be carbon neutral by 2050, with an interim goal of reducing emissions by 20% by 2030. To achieve this, our company promotes the circular economy, the addition of materials that reduce the clinker percentage in cement products, the consumption of renewable energy, and the adoption of advanced technologies such as artificial intelligence (AI) to increase production efficiency. 

Susterra: a new range of solutions with sustainable attributes 

In line with our commitment to sustainability and circularity, we have launched Susterra, a new range of products that groups and distinguishes solutions in the portfolio with the greatest contribution to decarbonization, the circular economy, or health and well-being in the workplace. This range includes cements, concretes, mortars, as well as solutions for construction and urban furniture. 

Specifically, Susterra groups our solutions that promote the circular economy by giving materials a second life, using alternative fuels, and incorporating recycled materials in manufacturing; reducing CO2 emissions by prioritizing energy efficiency, replacing fossil fuels, and using active additives and recycled aggregates; and ensuring safe working environments by promoting solutions that minimize emissions of volatile organic compounds (VOCs), thereby improving health and safety in the workplace.

Within the Susterra solutions that reduce carbon footprints, there are cements with more than 20% CO2 emission reductions compared to CEM I types produced in 2020 by the company in Spain. Concretes in this range also reduce emissions by more than 25% compared to conventional concretes. 

Susterra also includes mortars and pavements containing more than 2.5% recycled material, as well as over 80 products certified with the EMICODE PLUS seal, guaranteeing low VOC emissions. 

Circularity at Molins 

Susterra materializes our company’s commitment to the circular economy. We have developed a strategy focused on using alternative raw materials and fuels, reusing water, recovering heat, and recycling aggregates and concrete, among other materials. The goal is to reduce the consumption of natural raw materials and fossil fuels by leveraging by-products from other industries, allowing an energy substitution rate of 40% by 2030. 

Our company currently has up to 8 facilities dedicated to the material and energy recovery of materials. These plants transform waste into raw materials, giving them a second life. Examples include the GRP, Pronatur facilities, and the Alternative Raw Materials plant. The latter, located in Pallejà, valorized over 75,000 tons of non-hazardous construction and demolition waste as well as other industrial waste in 2023, incorporating 12.7% alternative raw materials in cement production last year. 

The Pronatur and GRP plants, on the other hand, valorize materials into alternative fuels, specifically recovered solid fuels (CSR) and tire derived fuel (TDF), used in the cement plant in Spain. These fuels have enabled 55% of the thermal energy used in this plant in 2023 to come from alternatives to fossil fuels, reducing the consumption of petroleum coke and CO2 emissions, as these fuels are entirely or partially biomass. 

Susterra cement range 

Susterra includes three types of cements differentiated by their applications and the levels of CO2 emission reductions achieved: 

• CEM II B-L 32.5 N: this portland cement is recommended for masonry mortars, special mortars, and medium-strength mass or reinforced concrete works. Available in 25 kg bags and bulk, CEM II B-L 32.5 N has over 30% lower carbon emissions compared to the 2020 reference CEM I 52.5 R. 
• CEM II B-M (P-L) 42.5 R: ideal to produce reinforced, sprayed, or mass concrete, non-prestressed precast elements, and road paving. Available in bulk, CEM II B-M (P-L) 42.5 R reduces carbon emissions by over 25% compared to the 2020 reference cement. 
• CEM IV/A(P) 42.5 R – SR: this sulfate-resistant cement is ideal for underwater structures or soils with high sulfate content. It reduces carbon emissions by over 25% compared to the 2020 reference cement. 

Some of these cements have enhanced active additives, such as pozzolans, which maintain performance while reducing the clinker/cement factor, contributing to the reduction of the carbon footprint of both cement and concrete. 

It is noteworthy that all our portland cements in Spain are produced with clinker aligned with European taxonomy, therefore, qualified as environmentally sustainable by this regulation. The increasing use of alternative fuels and decarbonated raw materials, modern facilities, and the implementation of advanced and innovative technologies like artificial intelligence (AI) in production processes have helped us reach this point. AI allows us to optimize energy and water consumption, improving industrial process efficiency.  

Susterra: a further step in Molins’ decarbonization 

The launch of Susterra marks a milestone on our company’s path to decarbonization. In May 2024, over 50% of the cement sold in Spain by Molins in tons was from the Susterra range, demonstrating the market’s acceptance and demand for more sustainable solutions. 

Susterra cements are already being used in major projects, such as the new construction of Spotify Camp Nou. In this project, Susterra concretes with a lower carbon footprint, formulated with Susterra cement and recycled aggregates, are being supplied. These products meet the most stringent standards and have advanced transparency with our clients, as the cement and concrete used come with externally verified Environmental Product Declarations (EPDs). 

This example highlights Susterra’s capacity to contribute to sustainability and the circular economy in large-scale infrastructure projects. 

In conclusion, through the Susterra range, we are leading the way towards a more sustainable and circular construction industry. The combination of more efficient processes, the use of advanced technologies, and a clear circular economy and decarbonization strategies allows us to offer solutions that not only meet the highest technical standards but also significantly contribute to reducing CO2 emissions and the sector’s sustainability. With Susterra, Molins is not only building the present but also driving a more sustainable future for all.