Background Zinc mines are rapidly depleting throughout the world. In the EU, the situation is even more problematic, as almost all Member States (with the exception of Ireland) rely on imports. At the same time, zinc waste represents a real environmental problem due to its progressive loss in the hot zinc-coating process, where molten zinc alloys are used to galvanise steel wire in order to improve its resistance to corrosion. In this galvanising process, up to 60% of the applied zinc turns to ashes and solid residues. As a result, large amounts of zinc are required. Overall, it has been estimated that 30 million tonnes of galvanised steel wire are produced in Europe, of which 4.5 million tonnes are produced in Italy, consuming more than 1 070 000 tonnes and 160 000 tonnes respectively. The recycling or reuse of zinc chips has economic as well as environmental benefits. However, recycling is rather difficult to pursue because the hot zinc reacts with the underlying steel, forming intermetallic compounds that are difficult to recover. As a result, the most feasible process to address the problem is the reuse of the metal. Objectives The main objective of the LIFE M&M Man and Metal project is to develop an innovative business model for obtaining an eco-compatible metal wire in which the traditional hot-dip galvanising treatment is replaced by a controlled application of lighter and thinner protective metals (containing a high percentage of aluminium, better known as quasi-alloys). The end result will be durable and fully recyclable products with maximum corrosion resistance. The aim is to find alternatives to zinc, thereby increasing the useful life of the product and reducing the amount of protective coating. It will have a positive environmental impact. Expected results: Reduction in the use of zinc by up to 90%; Reduction in the thickness of the protective coating by more than 40%; Development of a process to produce protective alloys and quasi-alloys using recovered materials containing aluminium; 20% reduction in the embodied energy and in the CO2 generated compared to traditionally galvanised wire; Increase in the useful life of the wire treated with the new process in comparison to the traditional process (by 250% in rural appliances and 800% in industrial appliances); Elimination of the formation of intermetallic compounds, maximising the recovery of useful alloys; Improvement of some physical properties (e.g. ductility) of the coated wire; and Improved surface finish and appearance of the protected surface.