Covestro have introduced a new range of PCR (post-consumer recycled) polycarbonates made from end-of-life automotive headlamps, marking another milestone in closing the loop for automotive materials. Developed through a joint program initiated by the German federal enterprise GIZ (Deutsche Gesellschaft für Internationale Zusammenarbeit), with Volkswagen and Nio as key partners, these TÜV Rheinland-certified grades contain 50 per cent recycled content, and are now commercially available for new automotive applications. Volkswagen and Nio are already validating the material for potential use in future vehicle designs.
Under this initiative, Covestro have been collaborating with partners, including Chinese recycler Ausell and leading automakers, to establish closed-loop pathways for high-value plastics from end-of-life vehicles. This program focuses on strengthening recycling processes and establishing reliable supply chains for high-quality recycled materials from automotive waste streams. Through this partnership, Covestro and their partners have developed practical solutions for collecting and mechanically processing end-of-life headlamps into high-quality PCR grades suitable for a range of automotive applications.
The introduction of these new PCR grades comes at a critical time as the automotive industry, one of the most resource-intensive sectors, faces increasing environmental challenges and regulatory pressures. The EU’s End-of-Life Vehicle Directive, which sets recycling targets, along with China’s Extended Producer Responsibility (EPR) program and growing sustainability requirements in key global markets, are pushing automotive manufacturers worldwide to seek innovative and sustainable material solutions that comply with evolving regulations.
Covestro’s new PCR grades meet the high-performance standards required for demanding automotive applications, offering excellent surface quality for superior aesthetics and adhering to strict vehicle interior air quality requirements. This combination of sustainable content and premium performance empowers automotive manufacturers to meet both regulatory demands and environmental goals without compromising on product quality.
As part of its broader commitment to sustainability and the circular economy, Covestro continue to expand their portfolio of recycled-content materials. In recent years, the company have introduced PCR polycarbonates with up to 90 per cent recycled content, and opened their first dedicated mechanical recycling compounding line for polycarbonates in Shanghai. Last year, they introduced a new range of polycarbonates based for the first time on chemically recycled, attributed material from post-consumer waste via mass balance.
