Securing Sources of Recycled Material

“To effectively harness the full resource potential of the end-of-life automotive sector, there is an urgent need for investment in efficient take-back systems, modern collection and sorting technologies, and the expansion of innovative recycling processes,” emphasized Dr. Aliaksandra Shuliakevich of Plastics Europe Germany.

Securing sources of raw materials is increasingly becoming a matter of strategic survival for automakers and suppliers, as meeting future recycling targets requires setting a course early on. For companies, this means massive pressure to adapt and invest in order to secure access to limited material streams today.Consequently, the industry is increasingly focusing on strategic partnerships across the entire value chain as well as the establishment of its own recycling centers of excellence, such as the center planned by Volkswagen in Zwickau for the automated dismantling of electric vehicles.

Is the Perception of Quality a Limitation of the Circular Economy?

A key topic in Baden-Baden was the discrepancy between the sustainable use of materials and the perceived value among customers. A survey conducted by automotive journalist Alexander Bloch among 3,000 participants revealed a sobering picture: 74% of respondents perceive interior quality today as being worse than in the past, with hard plastics (53%) and high-gloss surfaces (31%) in particular being perceived as “cheap.”

This is where the concept of “Design for Recycling” comes into play. Thomas Drescher emphasized: “Design for Recycling must not be viewed as a post-production review, but must be integrated into the development process at an early stage.” According to Drescher, design for recycling and a premium appearance are not mutually exclusive, but must be considered together in order to achieve the ELVR goals without any loss of value. Alexander Bloch aptly added: “Plastic doesn’t have to be bad—it just depends on what you make of it.”

PP Recyclates Put to the Test

Material science studies conducted by Borealis demonstrated just how technologically challenging the integration of post-consumer recycled (PCR) materials is. In painted bumper applications made from PP compounds containing 25% PCR and 15% talc, properties such as defect density and impact strength vary significantly depending on the quality of the recycled material.

PCR grades derived from household waste can cause defects in the paint surface, which is why Borealis relies on optimized compound design and specialized cleaning steps. Nevertheless, practical experience shows that high-quality mechanically recycled PP grades such as Borcycle M are already capable of meeting the strict requirements for Class A surfaces and paint adhesion.

Integrating Value Chains

“The inspiring technical presentations and exhibits at PIAE provide the ideal setting for strengthening and developing networks across the entire value chain, thereby promoting the development of recycling solutions for mass production in the automotive industry,” explained Tobias Epple, M.Eng., Automotive Application Marketing Manager at Borealis.

Epple emphasized that a functioning circular economy—that is, achieving high recycled content rates in new cars—is only possible if all partners along the value chain (raw material manufacturers, suppliers, OEMs, and recyclers) work closely together. Epple highlighted that new plastic solutions are necessary to use PCR recycled materials even in technically and aesthetically demanding applications without compromising perceived quality.

AI and Sensor Technology: Stability Despite Material Variations

Since recycled materials naturally exhibit greater fluctuations in viscosity and flow behavior than virgin materials, digital tools are becoming increasingly important. Dr.-Ing. Frank Thurner of Contech Software & Engineering presented an engineering AI system that identifies robust process windows based on process data. In a case study involving a hybrid interior component, this approach reduced scrap rates from 18% to 2% without having to modify the mold.

AI also offers new approaches to odor characterization, a critical issue for PCR in vehicle interiors. Representatives from Robert Bosch presented an AI-based gas sensor system (“electronic nose”) that achieves a classification accuracy of over 90% in distinguishing between virgin material and rPP. The goal is to replace the previously subjective testing procedure based on the VDA 270 standard with an automated and objective measurement method in order to facilitate the series production use of post-consumer recycled materials (PCR) in vehicle interiors.

In the field of lightweight structures, thermoplastic composites that enable true “closed-loop” recycling are coming into focus. A consortium led by Sabic, Audi, and OP-Mobility demonstrated the successful production of a tailgate made from 100% recycled Stamax PP-LGF (long-glass-fiber-reinforced polypropylene). Through a multi-step process that included pyrolysis, both the polymer and the glass fibers were recovered and reprocessed to the same quality.

Single-material products and separability

At the same time, there is a shift in thinking toward systemic reduction. Dennis Wessels (Volkswagen) warned against a “complexity trap”: “Sustainability doesn’t start with complex tools, but with conscious, simple design decisions.” VW is increasingly focusing on separability and single-material designs.

One example is the mirror triangle in a door panel. Previously, acoustic insulation foam was glued into place. Thanks to a geometric modification, this foam is now clamped in place. As a result, the component consists of a single material, can be separated without tools, and retains its acoustic function.

Škoda’s approach is to manufacture components from a single family of materials. The strategy aims to maximize mechanical recyclability at the end of the vehicle’s life and enable high-quality closed-loop material cycles. This strategy is already being applied to interior components, trunk solutions, and exterior parts. To achieve this, Škoda uses advanced polymer compounding and the targeted use of additives to ensure the required performance (such as stiffness and impact resistance) even without multi-material structures.

PU Coatings: Innovation or Hazardous Waste?

The role of PU coatings has been the subject of controversy. While processes such as PU in-mold coating (e.g., Color Form) shorten production chains and enable CO₂ reductions of up to 60% compared to conventional painting, the recycling problem associated with thermosetting PU systems remains unresolved. Volkswagen experts warned against producing a new generation of hazardous waste that is difficult to recycle if no functioning material cycles—such as through glycolysis—are established.

In his remarks at the press conference, Tobias Epple summed up: “The circular economy is only possible through close collaboration among all process partners involved in the life cycle.” This insight was also reflected in the keynote address by Prof. Dr. Stefan Bratzel (Center of Automotive Management). He called on the industry to adopt a “culture of resilience” and emphasized that “in this transformation process, it is not the supposedly strongest who will survive, but those who are most adaptable in responding to rapid change.”

Conclusion for Fabricators

The plastics industry is facing a major transformation. PIAE 2026 has made it clear that the technical feasibility of high-quality recycled materials exists in many areas—from stabilized AI-driven process control to fiber recycling in structural components.

Nevertheless, the availability of high-quality PCR, particularly PP, remains the industry’s bottleneck. Processors must adapt to fluctuating material qualities and invest early in simulation and data-driven optimization in order to meet upcoming regulatory quotas in a cost-effective manner.

The next PIAE will take place again in Baden-Baden on March 17 and 18, 2027. It remains to be seen to what extent the industry will have closed the gap between regulatory requirements and the reality of industrial recycling by then.