Prysmian and Versalis Launch Chemical Recycling Push for Cable Plastics

Prysmian Group and Versalis, the chemicals arm of Italy’s Eni, have agreed to develop a dedicated supply chain to chemically recycle plastic waste from power and energy cables, a move aimed at tackling one of the cable industry’s most persistent recycling challenges, according to company statements and industry reporting.

Plastic insulation used in modern energy cables, particularly cross-linked polyethylene, has long resisted conventional mechanical recycling because of its complex, multi-layered structure. As grid upgrades accelerate across Europe and other regions, the volume of end-of-life cables is rising, increasing pressure on manufacturers to find scalable circular solutions.

Under the partnership, Prysmian will collect plastic scrap from its manufacturing operations as well as from decommissioned cables returned by large customers. Versalis will process the material at its Mantua site in northern Italy using its proprietary Hoop® chemical recycling technology, converting the waste into pyrolysis oil and then into feedstock for new polymers. Prysmian plans to reuse those polymers in the production of new high-performance cables.

Industry data show that XLPE accounts for a significant share of cable insulation in power and renewable energy infrastructure, yet most of it currently ends up in landfill or energy recovery. Analysts say chemical recycling is increasingly viewed as one of the few viable pathways for recovering value from such cross-linked plastics, though questions remain over cost, energy intensity and scalability.

The companies estimate that the process could recover roughly 60% of XLPE scrap into reusable material, a rate that would mark a step change for cable recycling if achieved consistently at an industrial scale. Observers note that the initiative also reflects a broader trend among European manufacturers to secure recycled feedstock internally as regulatory pressure mounts to cut emissions and reduce virgin plastic use.

Prysmian said the first pilot phase is scheduled to begin in Italy in the second half of 2026. Versalis described the project as an example of how advanced chemical technologies can address end-of-life issues for complex industrial products. Industry groups argue that partnerships of this kind will be critical if Europe is to meet circular economy targets without disrupting supply chains for critical energy infrastructure.

Analysts say the success of the pilot will likely determine whether similar closed-loop models are rolled out more widely across Prysmian’s global operations and potentially adopted by other cable makers facing similar waste challenges.

Source: Eni

SUNSHINE Spotlight: The Prysmian–Versalis partnership signals growing momentum behind chemical recycling as a practical route to close the loop on hard-to-recycle cable plastics.