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Controlled Closed Loop Recycling
The automotive industry currently
achieves recycling ratios demanded
by legislation but this will become more
difficult in the future due to an overall
reduction of vehicle weight by increased
use of polymers.
Ferrous and other metals are currently
shredded and recycled. The residual
material, termed Auto Shredder Residue
(ASR) consists of plastics, rubbers, foams,
etc. and makes up to 30 percent of
the weight of the vehicle. Usually ASR
is incinerated or disposed on landfills,
segregation and recycling is economically
impossible due to its multi-material
nature.
The European project CONCLORE will
develop a sustainable system for manufacturing
a 100 percent-recyclable car
interior product, recovering it at the end
of the useful life of the vehicle and recycling
it either for reuse within the automotive
industry or for other applications.
Developing a single-component thermoplastic
sandwich-structure and utilising
Product Embedded Identification (PEID)
CONCLORE will guarantee continuous
quality of recovered material and define
a new state of the art by establishing an
advanced recycling model called Controlled
Closed Loop Recycling (CCLR),
integrating Reverse and Forward Supply
Chain Management (SCM) geared towards
100 percent material recovery.
The EU End-of-Life Vehicle (ELV) directive
(2000/53EC) issued by the European
Commission aims to reduce more than 9
million tons of waste generated by over
12 million cars each year, defining the
following recycling quotas:
85 percent by 2006 by an average
• weight per vehicle and year (80 percent
of reuse and recycling)
95 percent by 2015 by an average
• weight per vehicle and year (85 percent
of reuse and recycling)
The initial recycling ratio of 85 percent
for 2006 can currently be fulfilled by
most manufactures. Keeping up with the
quota, will become difficult though, due
to the increased application of polymers.
A higher polymer ratio helps save fuel by
lowering the overall vehicle weight.
The Project CONCLORE, coordinated
by BIBA, is working on a solution to this
problem. Funded with 2 Mio. Euros the
Project will, together with major players
from the automotive value chain, like
Fiat Research and Faurecia, one of the
largest automotive suppliers in Europe,
define a new state of the art by establishing
an advanced recycling model
called the Controlled Closed Loop
Recycling (CCLR), geared towards 100
percent material recovery.
By substituting multi-component structures
through single-component thermoplastic
sandwich-structures a prerequisite
for fully recyclable automotive parts will
be achieved. Utilising PEID for identification,
CONCLORE will realise the reintegration
of used polymer materials into the
production process and integrate Reverse
and Forward Supply Chain Management
(SCM) into a Sustainable Supply Management
(SSM) loop.
Rita Burkert, Christian Dörsch
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