D4.1. Planning the Validation of ANALYST Solutions in Real Industrial Environments

The ANALYST project has published Deliverable 4.1 – “Report on validation activities planning”, a key milestone that defines how the project’s solutions will be tested, refined, and validated in real industrial settings.

This deliverable sets the foundation for Work Package 4 (WP4), which focuses on demonstrating and validating the ANALYST innovations — namely the ANALYST-BOX (methodological framework) and ANALYST-DIGI (digital decision-support platform) — within practical use-case environments.

A structured validation strategy for real-world impact

Given the complexity of Safe and Sustainable by Design (SSbD) assessments and the diversity of industrial needs, the deliverable introduces a structured and coordinated validation strategy.

The approach is designed to:

• Ensure consistent testing of ANALYST solutions

• Align expectations across partners

• Enable meaningful feedback from industrial stakeholders

• Support continuous improvement and final deployment

At its core, the validation programme follows a stepwise and iterative methodology, ensuring that the tools evolve based on real-world application and user experience.

Three industrial use cases at the core of validation

Validation activities are anchored in three representative PVC use cases, covering key stages of the plastics value chain:

1. Flexible pipes (construction sector) – based on suspension PVC

2. PVC-coated fabrics (automotive sector) – based on emulsion PVC

3. Foamed rigid profiles (construction sector) – based on suspension PVC

These use cases allow the project to:

• Assess both conventional and bio-circular attributed PVC

• Evaluate hazardous additives and safer alternatives

• Analyse trade-offs between safety, sustainability, performance, and cost

By working closely with industrial partners across the value chain, the validation ensures that results reflect real operational conditions and decision-making needs.

Four complementary validation phases

To ensure a comprehensive evaluation, the methodology is structured around four validation phases:

1. Functional validation

Verifies that the ANALYST tools operate correctly from a technical perspective (data flows, calculations, system integration).

2. Usability validation

Assesses user experience, accessibility, and clarity for industrial partners applying the tools in real scenarios.

3. SSbD logic validation

Evaluates the scientific robustness and consistency of the methodology across the four SSbD dimensions:

• Safety

• Environmental

• Economic

• Social

  
  

4. Decision-support relevance

Determines whether the solutions provide actionable insights that support real industrial decision-making. Together, these phases ensure that ANALYST is not only technically sound, but also usable, reliable, and valuable for industry.

Iterative validation cycles (M30–M40)

Validation will be carried out through three iterative cycles between Month 30 and Month 40:

• Cycle 1 – Preliminary validation

  Focus on functionality and early usability; identification of critical issues

• Cycle 2 – Intermediate validation

  Improved usability and full SSbD assessments across use cases

• Cycle 3 – Final validation

  Assessment of decision-support relevance and readiness for deployment

Each cycle follows a structured process:

1. Validation

2. Feedback collection

3. Implementation of improvements

This iterative approach ensures continuous refinement, enabling the tools to evolve based on real feedback and practical challenges.

Key performance indicators (KPIs) and monitoring

The performance of ANALYST solutions will be systematically assessed through quantitative and qualitative KPIs, including:

• Tool functionality and system reliability

• Ease of use and user satisfaction

• Methodological consistency and scientific robustness

• Usefulness for decision-making and perceived added value

These indicators are monitored throughout the validation cycles and used to guide improvements and final optimisation of the tools.

Addressing data gaps and uncertainties

A critical component of the deliverable is the identification of data gaps across the four SSbD dimensions:

• Safety: incomplete hazard profiles for novel substances

• Environmental: limited life cycle data for new materials and additives

• Economic: lack of reliable price data for emerging alternatives

• Social: challenges in accessing consistent and standardised social indicators

To address these gaps, the project proposes mitigation strategies such as:

• Use of proxy datasets and scientific literature

• Integration of multiple databases

• Scenario analysis and sensitivity checks

• Continuous collaboration with industrial partners

This ensures that the validation results remain robust, transparent, and scientifically credible.

Roadmap, risks and continuous improvement

The deliverable also defines a clear roadmap (M30–M40), aligning validation activities across partners and use cases.

In parallel, a risk management strategy is introduced to address potential challenges such as:

• Missing or incomplete data

• Technical issues in the digital platform

• Misalignment between methodology and industry needs

• Low engagement from industrial partners

Mitigation measures - including early workshops, iterative feedback loops, and prioritisation of improvements - ensure that validation activities remain on track.

Enabling deployment and replication

By combining:

• A structured validation methodology

• Real industrial use cases

• Continuous feedback and improvement

• Robust monitoring and risk management

Deliverable 4.1 lays the groundwork for the final deployment of ANALYST solutions.

Importantly, it also supports:

• Replication of the methodology across other sectors and materials

• Scalability of SSbD approaches in industry

• Contribution to the ongoing development of EU SSbD frameworks and policies

  
  

Conclusion

Deliverable 4.1 represents a crucial step in transforming ANALYST from a research concept into a practical, industry-ready solution.

By embedding validation in real industrial environments and structuring it through iterative cycles, the project ensures that its tools are not only scientifically sound, but also usable, reliable, and impactful for decision-making in the plastics value chain.