A new plastic recycling process developed in Europe is helping old car plastics return to new vehicles instead of being burned as waste.
Researchers from the Technical University of Munich found that the plastic recycling method can cut greenhouse gas emissions by up to 29% while supporting new EU recycling targets.
The project focuses on recovering plastic from scrapped vehicles and keeping it in a closed recycling loop for future car production.
Every year, between four and six million vehicles reach the end of their life across Europe. Most of these vehicles are dismantled, shredded, and separated into different materials before disposal or recycling. Metals are commonly recovered, but plastics are often lost or burned.
The European Union is now increasing pressure on the automotive industry to improve recycling rates. A proposed End-of-Life Vehicles Regulation aims to increase the use of recycled materials in new cars. The regulation also pushes manufacturers to reuse plastics from old vehicles in future vehicle production.
Researchers studied a new recycling method created through the Car2Car research project. Their findings were published in the scientific journal Waste Management. The study explored how plastics from shredded vehicles can remain inside the automotive recycling system.
How Car Plastic Recycling Process Works
Before shredding begins, several parts are removed from a vehicle. Batteries, airbags, wheels, catalytic converters, and fluids are taken out first. The remaining vehicle shell is then shredded into mixed fragments of metal, foam, textiles, rubber, and plastic.
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This mixed material is difficult to recycle because different substances are tightly combined. Many plastic pieces are small, dirty, or attached to other materials after shredding. As a result, much of the leftover waste is currently burned in industrial plants.
The Car2Car research team developed a sorting method to recover more usable plastics from this waste stream. The process uses additional shredding and screening steps before advanced sensors separate different materials. Mid-infrared sensors can identify specific plastic types by how they reflect light.
Researchers tested the process using materials from more than 400 end-of-life vehicles. The vehicles included different engines and powertrain types. The recovered plastic material can be reused to make new products after further treatment and cleaning.
Professor Magnus Fröhling explained that plastic recycling in the automotive sector is still in its early stages. He said future vehicles may contain around 200 kilograms of plastic each. That makes plastic recovery increasingly important for both manufacturers and regulators.
The proposed EU regulation requires new vehicles to contain increasing amounts of recycled plastics over time. Under the plan, 25% of plastics used in new cars must come from post-consumer recycled material. Part of this recycled content must also come directly from old vehicles through closed-loop recycling.
Closed-loop recycling means that materials from an old product return to the same industry rather than being used elsewhere. In this case, plastics from old vehicles would be recycled into future vehicles. The EU wants at least 20% of recycled automotive plastics to come from this closed-loop system.
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To examine whether those targets are realistic, the TUM research team created a material flow model. The model studied how vehicle design, dismantling levels, and sorting technology affect recycling performance. Researchers also examined the climate impact of replacing incineration with recycling.
The study found that some recycling scenarios already meet the EU’s proposed 2035 closed-loop target of 3%. Researchers also found that the new sorting process significantly reduces greenhouse gas emissions. Emissions fell by up to 29% compared with current waste incineration methods.
Why Vehicle Recycling Matters
The automotive industry faces increasing pressure to reduce emissions across the full life cycle of vehicles. Attention is no longer focused only on fuel efficiency or electric powertrains. Governments and manufacturers are also examining how vehicles are built, recycled, and reused.
Plastic production relies heavily on fossil fuels and energy-intensive manufacturing processes. Recycling existing plastics reduces the need for new raw materials. It also lowers the amount of waste sent to landfills or incinerators.
Researchers said the current study still has limitations because all tested vehicles came from a single manufacturer and shared a similar production period. Different vehicle brands and newer car designs may produce different recycling results. Even so, the team believes the findings show a practical starting point for improving automotive recycling systems.
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Fröhling said future progress will depend on better vehicle design and improved material choices. Carmakers may need to use components that are easier to separate and recycle at the end of a vehicle’s life. He added that combining practical solutions with long-term goals will be essential for building a more sustainable automotive industry.
The research highlights how recycling technology is becoming an important part of the future car market. As Europe tightens environmental rules, automakers are expected to invest more in circular manufacturing systems. The shift could help reduce waste, lower emissions, and reshape how vehicles are designed in the years ahead.
