TechnoCarbon to produce high-performance ultra-low-carbon materials in Vitrolles

A light, durable, and environmentally friendly composite material capable of replacing traditional building components

After several years of research and development, the industrial startup TechnoCarbon is ready to produce the first Pierre-Carbone supermaterial prototypes in Vitrolles near Marseille. Founded in 2018 in Paris by Stephan Savarese, TechnoCarbon moved to the Aix-Marseille-Provence metro area in 2022. The company has since benefited from Provence Promotion’s support and the agency’s network of contacts. Following the installation of a first demonstrator facility at thecamp in Aix-en-Provence, which was recognized by the Capenergies energy sector cluster, and an initial site in L’Estaque in Marseille, TechnoCarbon chose Vitrolles for its innovation center, which includes a design office and a pilot workshop for pre-series production.

The Pierre-Carbone low-carbon and hyper-resilient building material is continuing to turn heads in the construction world! The idea for the product came about in a kitchen as a solution to the design challenges associated with a cooktop area and the innovation is proving to be as promising as it is solid. Pierre-Carbone, which means “Rock-Carbon” in French, has established itself as an ideal low-carbon alternative to steel, aluminum, and concrete for sectors such as construction, public works, and energy. There are also applications for the Blue Economy as carbon stone can replace metal alloys on ships and reinforced concrete in ports.

Its technology, which is protected by a dozen patents, is based on a novel composite structure: two pieces of granite stone that surround a central layer of carbon fiber, which is identical to the material used in the aeronautics and space industries, as well as in racing yachts (Vendée Globe, America’s Cup, etc.). This design has already won 28 awards for its exceptional strength and durability, most recently receiving the prestigious JEC Startup Booster award in the Process, Manufacturing & Equipment category at the 2024 edition of JEC World, the world’s leading composite materials trade show.

“Pierre-Carbon is five times stronger than steel or concrete and far more durable. We are currently carrying out certification tests on thicker sections to confirm the remarkable results we had on a 16-mm thick piece in 2021 at the CSTB science center for building materials. The mechanical resistance of the material is so great, you need extremely powerful machines to do the testing,” explains Stephan Savarese, the founder of TechnoCarbon.

Key local support for development and industrial expansion

The company plans to start with custom projects, then produce small batches. This will serve as preparation for mass production and the plan is to open a factory nearby. The site in Vitrolles would then be used for innovation and R&D purposes while also incorporating a training center so future production partners and users of TechnoCarbon technologies can learn how to integrate Pierre-Carbone into their projects.

“The confidence of our partners, the welcome we have received from local stakeholders, the contacts we have made, and the encouragement we have received from Provence Promotion have been essential to the success of our business and to our development. Despite the delays we encountered during the post-COVID period, we have been able to carry out productive experiments in the territory and are now eager to launch the pre-industrial phase,” says Stephan Savarese, who recruited a business development manager in September 2024 to support this new development stage. Starting in March 2025, production will be launched with a target of 1000 tonnes per year. This will rise to 7000 tonnes per year when the factory is operating.

The first contact between Provence Promotion and TechnoCarbon was made in May 2020 at the Innovate online trade fair. Following this, the agency provided the company support by identifying property solutions, partnerships, and financing, which was done in collaboration with a network of local actors in Aix-Marseille, including the Pays d’Aix Développement agency, thecamp innovation center, the Aix-Marseille-Provence Metropolis, the Chamber of Commerce and Industry Aix-Marseille-Provence, and the Novachim chemistry and materials network. The company has received R&D funding from the Bpifrance public investment bank and subsidies from the Région Sud and the Ademe environmental transition agency as part of the green fund for territories in transition. This has complemented the initial support TechnoCarbon received from business angels, family offices, and private investment funds.

Boosting the energy transition with an innovative new material

TechnoCarbon is dedicated to designing innovative industrial materials to reduce the carbon footprint of cities and industries. Using a deeptech approach and advanced scientific research, the company created their breakthrough material for the energy transition.

The raw material for Pierre-Carbone is granite extracted from the Sidobre massif in the Tarn region of France, a natural resource with a low environmental impact. Although the production of carbon fibers is still very carbon-intensive and energy-consuming, its optimized use for the assembly of this new material means that the carbon footprint is lower than for traditional products. Greenhouse gas emissions for the production of Pierre-Carbone are already significantly lower than those for concrete and steel (with a carbon footprint at least 10 times lower steel), and emissions will be further reduced by the use of organically sourced fibers, which are currently being tested.

Lightweight and extremely resistant, Pierre-Carbone also optimizes the quantity of material required per project, reduces the energy needed for the transport of the materials, and, thanks to its durability, limits maintenance and the need to replace original materials. The manufacturing process also minimizes emissions thanks to the recycling of grey water, and the company has an ambitious zero waste target at the end of the production chain based on the recyclability of the material.

Supported by Stéphane Astic, the managing director who is in charge of organization, financing, and fund-raising for TechnoCarbon, the operational team works on the design, production, certification, and marketing. There is a wide range of construction applications for Pierre-Carbone, including support pylons, angle irons, industrial and urban infrastructure elements, and interior architecture.

Currently made up of eight people, including two engineers specialized in design and modeling, the team will be expanded in March 2025 to include two new technical experts to support the launch and optimization of the pilot production line. Ultimately, TechnoCarbon aims to create 30 jobs within three years with the support of the Sud Provence-Alpes-Côte d’Azur Region.