Cigarette butts recycling: a customized dust control system for Re-Cig

How was the idea that could change the way we recycle born?

Some ideas arise almost by chance. Others, like in the case of Re-Cig, stem from a precise combination of observation, environmental awareness, and entrepreneurial vision. The story is told by Marco Fimognari, CEO and founder of the company, which today remains the only one in Europe capable of recovering and transforming cigarette butts into reusable plastic granules. A truly unique project, one that found in Tama Aernova  the ideal partner to face key challenges related to emission treatment, custom industrial extraction, and the real sustainability of production processes.

It all began in 2016. Marco, a smoker at the time, stubbed out a cigarette in his home ashtray and asked himself a simple yet powerful question:

“What could I recycle that no one else is recycling yet?”

From that everyday moment, an idea took shape, an idea that would grow into an enterprise dedicated to collecting and recovering cigarette butts, a highly polluting waste still lacking a true disposal and recycling chain. After three years of research, prototypes, and testing in collaboration with the University of Trento, Re-Cig filed a European patent for a method that allows cigarette butts to be transformed into a secondary raw material, ready to become everyday products.

Today, with over 5,500 active installations and a network of more than 500 companies and public administrations served, Re-Cig stands as a solid and continuously growing reality, proving how innovation and sustainability can turn even the most complex waste into a valuable resource.

Is the circular economy applicable today?

From the beginning, the core of the project was clear: to give a second life to a type of waste once considered unrecoverable. Over time, this vision has continued to grow and evolve. “We realized that sustainability is not only environmental — it is also social, economic, and cultural. And it must be put into practice day after day.”

Today, the company collects and reuses rainwater for its industrial processes and is planning the installation of a photovoltaic system to cover more than 70% of its energy needs. It also collaborates with local social enterprises for the production of Re-Cig ashtrays. There are also social initiatives, such as supporting corrective tattoo projects for medical purposes and organizing eco-walks to raise awareness about cigarette butts pollution.

What challenges does a plant that has never been built before present?

In this recycling field, there are very strict regulations. When Re-Cig launched its own plant, it immediately became clear that the company would have to comply with stringent emission standards. “Our process is both mechanical and thermal. It generates emissions; therefore, it’s essential to keep them under control — not only to meet regulatory requirements but also to protect the health of our workers.”

What makes it unique? A system that had never been built before no standard models, no off-the-shelf solutions. It required a technical partner capable of developing a tailor-made design, carefully analyzing every stage of the process, the composition of the fumes, and the key challenges related to the treatment of special waste and emissions from thermal processes.

How to choose the right filtration partner for this situation?

Following thorough market research, Re-Cig chose TAMA AERNOVA for both the system and the technical and advisory assistance that would be available to the business during every step of the procedure, from securing permits to post-installation maintenance.

“Someone who would truly support us was what we needed. We wanted a partner with whom we could establish a solid and long-lasting partnership, not just a supplier. That is precisely what we discovered with Tama Aernova.”

The system's ability to modify the airflow capacity in accordance with production demands is among its most crucial features. Because of this adaptability, Re-Cig can maintain the plant's effectiveness over time—even during expansion phases—by avoiding intrusive changes or temporary replacements. An adaptability that results in stable operations and maximized investment.

After more than two years of operation, the system was carefully sized to allow for flexibility, allowing Re-Cig to expand without having to make short-term changes to the filtration infrastructure. A clear advantage that is enhanced by another crucial component: the assurance that comes from knowing that your system is stable, compliant, and operating at a high level.

How does industrial extraction improve the process every day?

Although it began as a regulatory requirement, the decision to start with an adequate dust control system proved to be crucial for Re-Cig.

“Emissions are the first thing that get checked. Thanks to the support we received, we now know we can rely on an effective system — one that meets current needs and is ready for future developments.”

Extraction plays a key role throughout the various stages of the process, from screening to washing, drying, and plastic pellet production. It ensures safe working conditions, keeps the work environment clean, and protects both employees and the surrounding area. The partnership with Tama Aernova did not end with the installation. It continues today through routine maintenance and new upcoming challenges.

In the near future, Re-Cig will replace part of its plant with an automated line, and once again, Tama Aernova will play a key role in adapting the treatment system to meet new operational requirements. Each recovered cigarette butt is treated to remove harmful substances and transformed into certified plastic granules, ready for new applications, from fashion accessories and eyewear components to reusable everyday objects. A perfect example is the portable ashtray, made from 90 recycled cigarette butts, which Marco proudly shows: small, practical, and meaningful.

What happens when technology and sustainability meet?

The Re-Cig story deeply resonates with us: it speaks of true sustainability and of how technology, when applied correctly, can support and strengthen a bold idea. We are genuinely proud to be part of this journey. Day after day, we continue to develop solutions for industrial extraction and filtration systems designed to endure over time and adapt to future needs.

Do you have a non-standard plant and need a custom filtration solution? Contact us. We’ll be happy to design it together.

FAQ

How are fumes from a thermal recycling process filtered?
Through custom-designed systems equipped with baghouse or cartridge filters, which capture particulate matter and harmful gases before they are released into the atmosphere.

What are the advantages of a customized extraction system?
It ensures optimal efficiency, compliance with regulations, greater operator safety, and the possibility of future expansion.

Which regulations must an industrial extraction system comply with?
The system must guarantee compliance with regional and national emission limits, be subject to regular inspections, and be equipped with effective monitoring systems.