Munich. Through the Car2Car research project, the BMW
Group and its consortium partners have demonstrated that high-quality
material loops are technically feasible in the automotive industry.
Under expanded processing and sorting conditions, it was possible to
increase the “Car2Car rate” from six to 51 percent. The “Car2Car
rate”, as defined by the project, is the percentage of materials from
an end-of-life vehicle that can, in principle, be recovered at high
enough quality for reuse in new industrial applications. Particularly
high recovery potentials were achieved for steel, aluminium and
copper, whereas significant technological challenges remain for
plastics and glass. At the same time, the project demonstrates which
conditions, investments and regulatory frameworks will be necessary to
further scale high-quality material loops in the future. The results
are based on a research and demonstration approach under optimal
processing and sorting conditions.
Sorting and processing unlock high-quality material loops
Various recovery scenarios were explored as part of the research
project. The findings show that additional processing and sorting
steps can significantly increase the potential of high-quality
material loops. The steps include improved pre-sorting, modified
shredding processes, classification, sensor-based sorting of material
streams and more precise separation of aluminium alloys. Using methods
currently standard in the market, the project achieved a “Car2Car
rate” of six percent across all five focus material groups during a
vehicle recycling trial with minimal compulsory dismantling. With the
help of advanced process engineering and optimised processing routes,
the rate climbed to 51 percent. Under these conditions, the “Car2Car
rate” increased from one to 81 percent for steel, from 23 to 52
percent for aluminium and from 48 to 68 percent for copper.
The findings confirm the considerable potential for high-quality
material loops, especially for metals. At the same time, the results
clearly demonstrate that this potential cannot be applied equally
across all material groups. Specifically, further development is
required for plastics and glass. To achieve large-scale industrial
implementation, additional investments will be needed in disassembly,
sorting and recycling infrastructure, as well as corresponding
regulatory frameworks.
Steel shows potential of high-quality material loops
The project’s key findings are illustrated by the example of steel.
Up until now, copper-bearing impurities from cables, connectors and
other components have hindered the recycling of end-of-life vehicle
scrap into high-quality automotive steels. The Car2Car project has now
demonstrated that an additional processing step can substantially
improve scrap quality. Copper contamination was reduced in a targeted
manner by sorting the steel scrap. This ensures high-quality steel
scrap as the starting material for new flat steel that meets the
requirements of modern automotive applications. A patent application
has been filed for this process.
The so-called steel coils produced using this method were integrated
into industrial production following successful material and quality
testing. In a field test conducted at BMW Group Plant Leipzig, more
than 100,000 series parts were produced for use in vehicles. The
project thus demonstrates, along a real industrial value chain, that
new vehicle components can be manufactured from end-of-life vehicles.
However, for large-scale industrial implementation, scalable process
chains, additional infrastructure and viable business models are still needed.
Huge potential for metals, further development needed for
plastics and glass
At the same time, the project highlighted that progress towards a
circular economy varies, depending on the material and the technology
available. While recycling processes are already in place for metals
such as steel, aluminium and copper, there is still a lack of
solutions for plastics and glass that meet the automotive industry’s
high quality standards.
The wide variety of materials, complex composite material structures
and stringent quality requirements make it difficult to produce
high-quality recyclates for high-end automotive applications. For
plastics, in particular, it has become evident that precisely tailored
process chains comprising various sorting and processing technologies
will be needed in the future to consistently achieve the material
quality necessary for automotive material loops.
Insights for next-generation circular vehicle concepts
The findings from Car2Car will feed into further development of the
BMW Group’s circular economy, confirming its established Design for
Circularity approaches. They will also help design vehicles even more
systematically for high-quality material loops. Cooperation with
end-of-life vehicle recycling partners, such as PreZero, can also
benefit from the experience gained through this project.
Beyond the BMW Group and the participating project partners, the
Car2Car findings also provide an important data basis for further
development of the entire automotive recycling landscape. In the
context of future regulatory requirements, such as the European ELV
Regulation, Car2Car illustrates which technological, economic and
structural conditions must be created to enable higher material
recovery rates and closed material loops. This includes innovation and
investment in disassembly, sorting and recycling technologies,
increased digitalisation and framework conditions that promote
transparency, quality and the return of materials to European material loops.
Car2Car does not focus on what is already standard today but
highlights the potential that high-quality material loops could offer
in the future. Whether this potential will be realised depends not
only on technical feasibility, but also on factors such as access to
end-of-life vehicles, favourable market conditions, investment and
viable business models throughout the entire recycling value chain.
Quotes
“The circular economy is an integral part of the BMW Group’s
corporate strategy. Car2Car shows that its full potential can be
realised when the entire value chain is optimised. Together with our
partners, we are using the project findings to develop new process and
business models that combine environmental and economic benefits, and
advance the transition towards a circular automotive industry.”
Alexander Efthimiou, Senior Vice President Business
Development, BMW Group
“With Car2Car, we wanted to understand under which conditions
materials from end-of-life vehicles can be reused in new cars. The
project has shown the potential in current material streams from
end-of-life vehicles that have not yet been optimised for high-quality
material loops. The most significant progress was seen with steel: We
were able to demonstrate that high-quality flat steel for automotive
applications can be produced from end-of-life vehicle scrap. In the
field test at BMW Group Plant Leipzig, more than 100,000 series parts
were produced using this steel and installed in vehicles – making the
project’s results tangible.”
Hilke Schaer, Car2Car project manager, BMW Group
Broad consortium spanning the entire value chain
The Car2Car research project brings together partners from the
automotive industry, materials manufacturing, the recycling industry
and academia. The aim was to investigate the recovery of materials
from end-of-life vehicles for use in new automotive applications along
the entire value chain. A further objective was to identify suitable
process routes for high-quality material loops.
The consortium included BMW AG, TU Bergakademie Freiberg (MVTAT, IEST
and IGT institutes), the Helmholtz Institute Freiberg for Resource
Technology (part of Helmholtz-Zentrum Dresden-Rossendorf (HZDR)),
Technical University of Munich (Professorship of Circular Economy,
Chair of Materials Handling, Material Flow and Logistics (fml) and the
Institute for Machine Tools and Industrial Management (iwb)), Scholz
Recycling, STEINERT UniSort, thyssenkrupp Steel Europe, Salzgitter
Mannesmann Forschung, Aurubis, Novelis Germany, OETINGER Aluminium and
Pilkington Automotive Germany.
The final report of the full Car2Car consortium is available for
download here.
The BMW Group-specific final report can be found here.
FAQ:
What is the Car2Car research project?
Car2Car is a research project focused on the recovery of
materials from end-of-life vehicles for use in new automotive
applications. It investigated under which conditions high-quality
material loops are possible along the automotive value chain.
What was the project’s key finding?
The key finding was that it was possible to increase the “Car2Car
rate” from six to 51 percent under expanded processing and sorting
conditions. Particularly high recovery potentials were achieved for
steel, aluminium and copper. A key factor is that these results were
achieved without dismantling end-of-life vehicles beyond the
compulsory disassembly currently standard in the industry before recycling.
What does the “Car2Car rate” mean?
The “Car2Car rate” refers to the percentage of materials from an
end-of-life vehicle that can, in principle, be recovered at high
enough quality for reuse in new automotive applications. It is
therefore more than just a conventional recycling rate. The decisive
factor is not just whether a material can be recycled, but whether it
can be returned to the automotive material loop with a comparable
level of quality.
Which materials were the main focus?
The main focus of the project was on steel, aluminium and copper.
Potential and limits for plastics and glass were also considered.
Why is steel particularly relevant?
In the case of steel, it was possible to demonstrate that just
one additional processing step, in the form of sorting, can reduce
copper-bearing impurities, resulting in high-quality steel scrap. This
was then used to produce flat steel for modern automotive applications.
Have the results been tested on an industrial scale?
Yes. In the field test at BMW Group Plant Leipzig, more than
100,000 series parts were produced from recovered steel and then
installed in vehicles. In this way, it was possible to demonstrate,
along a real-world industrial value chain, that new vehicle components
can be produced from end-of-life vehicles. However, this industrial
field test does not yet mean that the relevant recycling and
processing processes are widely available on the market.
How many end-of-life vehicles were examined in the field test?
The field test covered 433 vehicles from 60 different BMW Group
models, including test vehicles that were less than five years old.
Where is further development needed?
Comparable progress has not been achieved with plastics and glass
to the same extent as with steel, aluminium and copper. Further
innovation is required in areas such as vehicle design, disassembly,
sorting and recycling.
Overview of key findings
Material stream
“Car2Car rates” under research conditions
Steel
“Car2Car rate” increases from
1 to 81 percent.
Aluminium
“Car2Car rate” increases from
23 to 52 percent.
Copper
“Car2Car rate” increases from
48 to 68 percent.
Overall system
“Car2Car rate” increases from
6 to 51 percent.
Industrial application
field test
Over 100,000 series parts
from recovered Car2Car steel produced at
BMW Group Plant
Leipzig and installed in vehicles.
If you have any questions, please contact:
BMW Group
Communications
Isabel Richter
Press spokesperson
Head of Sustainability Communications BMW Group
Telephone: +49-151-601-53189
Email: Isabel.Richter@bmw.de
The BMW Group
With its four brands, BMW, MINI, Rolls-Royce and BMW Motorrad, the
BMW Group is the world’s leading premium manufacturer of automobiles
and motorcycles and also provides premium financial services. The BMW
Group production network comprises over 30 production sites worldwide;
the company has a global sales network in more than 140 countries.
In 2025, the BMW Group sold 2.46 million passenger vehicles and more
than 202,500 motorcycles worldwide. The profit before tax in the
financial year 2025 was € 10.2 billion on revenues amounting to €
133.5 billion. As of 31 December 2025, the BMW Group had a workforce
of 154,540 employees.
The economic success of the BMW Group has always been based on
long-term thinking and responsible action. Sustainability is a key
element of the BMW Group’s corporate strategy and covers all products
– from the supply chain through production to the end of their useful life.
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