\n Munich. Through the Car2Car research project, the BMW
\n Group and its consortium partners have demonstrated that high-quality
\n material loops are technically feasible in the automotive industry.
\n Under expanded processing and sorting conditions, it was possible to
\n increase the \u201cCar2Car rate\u201d from six to 51 percent. The \u201cCar2Car
\n rate\u201d, as defined by the project, is the percentage of materials from
\n an end-of-life vehicle that can, in principle, be recovered at high
\n enough quality for reuse in new industrial applications. Particularly
\n high recovery potentials were achieved for steel, aluminium and
\n copper, whereas significant technological challenges remain for
\n plastics and glass. At the same time, the project demonstrates which
\n conditions, investments and regulatory frameworks will be necessary to
\n further scale high-quality material loops in the future. The results
\n are based on a research and demonstration approach under optimal
\n processing and sorting conditions.<\/p>\n
\u00a0<\/p>\n
\n Sorting and processing unlock high-quality material loops\n<\/p>\n
Various recovery scenarios were explored as part of the research
\n project. The findings show that additional processing and sorting
\n steps can significantly increase the potential of high-quality
\n material loops. The steps include improved pre-sorting, modified
\n shredding processes, classification, sensor-based sorting of material
\n streams and more precise separation of aluminium alloys. Using methods
\n currently standard in the market, the project achieved a \u201cCar2Car
\n rate\u201d of six percent across all five focus material groups during a
\n vehicle recycling trial with minimal compulsory dismantling. With the
\n help of advanced process engineering and optimised processing routes,
\n the rate climbed to 51 percent. Under these conditions, the \u201cCar2Car
\n rate\u201d increased from one to 81 percent for steel, from 23 to 52
\n percent for aluminium and from 48 to 68 percent for copper.<\/p>\n
The findings confirm the considerable potential for high-quality
\n material loops, especially for metals. At the same time, the results
\n clearly demonstrate that this potential cannot be applied equally
\n across all material groups. Specifically, further development is
\n required for plastics and glass. To achieve large-scale industrial
\n implementation, additional investments will be needed in disassembly,
\n sorting and recycling infrastructure, as well as corresponding
\n regulatory frameworks.<\/p>\n
\u00a0<\/p>\n
\n Steel shows potential of high-quality material loops\n<\/p>\n
The project\u2019s key findings are illustrated by the example of steel.
\n Up until now, copper-bearing impurities from cables, connectors and
\n other components have hindered the recycling of end-of-life vehicle
\n scrap into high-quality automotive steels. The Car2Car project has now
\n demonstrated that an additional processing step can substantially
\n improve scrap quality. Copper contamination was reduced in a targeted
\n manner by sorting the steel scrap. This ensures high-quality steel
\n scrap as the starting material for new flat steel that meets the
\n requirements of modern automotive applications. A patent application
\n has been filed for this process.<\/p>\n
The so-called steel coils produced using this method were integrated
\n into industrial production following successful material and quality
\n testing. In a field test conducted at BMW Group Plant Leipzig, more
\n than 100,000 series parts were produced for use in vehicles. The
\n project thus demonstrates, along a real industrial value chain, that
\n new vehicle components can be manufactured from end-of-life vehicles.
\n However, for large-scale industrial implementation, scalable process
\n chains, additional infrastructure and viable business models are still needed.<\/p>\n
\u00a0<\/p>\n
\n Huge potential for metals, further development needed for
\n plastics and glass\n<\/p>\n
At the same time, the project highlighted that progress towards a
\n circular economy varies, depending on the material and the technology
\n available. While recycling processes are already in place for metals
\n such as steel, aluminium and copper, there is still a lack of
\n solutions for plastics and glass that meet the automotive industry’s
\n high quality standards.<\/p>\n
The wide variety of materials, complex composite material structures
\n and stringent quality requirements make it difficult to produce
\n high-quality recyclates for high-end automotive applications. For
\n plastics, in particular, it has become evident that precisely tailored
\n process chains comprising various sorting and processing technologies
\n will be needed in the future to consistently achieve the material
\n quality necessary for automotive material loops.<\/p>\n
\u00a0<\/p>\n
\n Insights for next-generation circular vehicle concepts\n<\/p>\n
The findings from Car2Car will feed into further development of the
\n BMW Group’s circular economy, confirming its established Design for
\n Circularity approaches. They will also help design vehicles even more
\n systematically for high-quality material loops. Cooperation with
\n end-of-life vehicle recycling partners, such as PreZero, can also
\n benefit from the experience gained through this project.<\/p>\n
Beyond the BMW Group and the participating project partners, the
\n Car2Car findings also provide an important data basis for further
\n development of the entire automotive recycling landscape. In the
\n context of future regulatory requirements, such as the European ELV
\n Regulation, Car2Car illustrates which technological, economic and
\n structural conditions must be created to enable higher material
\n recovery rates and closed material loops. This includes innovation and
\n investment in disassembly, sorting and recycling technologies,
\n increased digitalisation and framework conditions that promote
\n transparency, quality and the return of materials to European material loops.<\/p>\n
Car2Car does not focus on what is already standard today but
\n highlights the potential that high-quality material loops could offer
\n in the future. Whether this potential will be realised depends not
\n only on technical feasibility, but also on factors such as access to
\n end-of-life vehicles, favourable market conditions, investment and
\n viable business models throughout the entire recycling value chain.<\/p>\n
\u00a0<\/p>\n
\n Quotes\n<\/p>\n
\u00a0<\/p>\n
\u201cThe circular economy is an integral part of the BMW Group\u2019s
\n corporate strategy. Car2Car shows that its full potential can be
\n realised when the entire value chain is optimised. Together with our
\n partners, we are using the project findings to develop new process and
\n business models that combine environmental and economic benefits, and
\n advance the transition towards a circular automotive industry.\u201d
Alexander Efthimiou, Senior Vice President Business
\n Development, BMW Group\n<\/p>\n
\u00a0<\/p>\n
\u201cWith Car2Car, we wanted to understand under which conditions
\n materials from end-of-life vehicles can be reused in new cars. The
\n project has shown the potential in current material streams from
\n end-of-life vehicles that have not yet been optimised for high-quality
\n material loops. The most significant progress was seen with steel: We
\n were able to demonstrate that high-quality flat steel for automotive
\n applications can be produced from end-of-life vehicle scrap. In the
\n field test at BMW Group Plant Leipzig, more than 100,000 series parts
\n were produced using this steel and installed in vehicles \u2013 making the
\n project\u2019s results tangible.\u201d
Hilke Schaer, Car2Car project manager, BMW Group\n<\/p>\n
\u00a0<\/p>\n
\n Broad consortium spanning the entire value chain\n<\/p>\n
The Car2Car research project brings together partners from the
\n automotive industry, materials manufacturing, the recycling industry
\n and academia. The aim was to investigate the recovery of materials
\n from end-of-life vehicles for use in new automotive applications along
\n the entire value chain. A further objective was to identify suitable
\n process routes for high-quality material loops.<\/p>\n
\u00a0<\/p>\n
The consortium included BMW AG, TU Bergakademie Freiberg (MVTAT, IEST
\n and IGT institutes), the Helmholtz Institute Freiberg for Resource
\n Technology (part of Helmholtz-Zentrum Dresden-Rossendorf (HZDR)),
\n Technical University of Munich (Professorship of Circular Economy,
\n Chair of Materials Handling, Material Flow and Logistics (fml) and the
\n Institute for Machine Tools and Industrial Management (iwb)), Scholz
\n Recycling, STEINERT UniSort, thyssenkrupp Steel Europe, Salzgitter
\n Mannesmann Forschung, Aurubis, Novelis Germany, OETINGER Aluminium and
\n Pilkington Automotive Germany.<\/p>\n
\u00a0<\/p>\n
The final report of the full Car2Car consortium is available for \u00a0<\/p>\n \n FAQ:\n<\/p>\n \n What is the Car2Car research project? \n What was the project’s key finding? \n What does the \u201cCar2Car rate\u201d mean? \n Which materials were the main focus? \n Why is steel particularly relevant? \n Have the results been tested on an industrial scale? \n How many end-of-life vehicles were examined in the field test?\n<\/p>\n The field test covered 433 vehicles from 60 different BMW Group \n Where is further development needed? \u00a0<\/p>\n \n Overview of key findings\n<\/p>\n \n Material stream\n <\/p>\n \n \u201cCar2Car rates\u201d under research conditions\n <\/p>\n \u00a0<\/p>\n Steel<\/p>\n \u201cCar2Car rate\u201d increases from Aluminium<\/p>\n \u201cCar2Car rate\u201d increases from Copper<\/p>\n \u201cCar2Car rate\u201d increases from Overall system<\/p>\n \u201cCar2Car rate\u201d increases from Industrial application Over 100,000 series parts \u00a0<\/p>\n If you have any questions, please contact:<\/p>\n \n \u00a0\n<\/p>\n \n BMW Group Isabel Richter<\/p>\n Press spokesperson<\/p>\n Head of Sustainability Communications BMW Group<\/p>\n Telephone: +49-151-601-53189<\/p>\n Email: Isabel.Richter@bmw.de\u00a0<\/p>\n \u00a0<\/p>\n \n \u00a0\n<\/p>\n \n The BMW Group\n<\/p>\n \u00a0<\/p>\n With its four brands, BMW, MINI, Rolls-Royce and BMW Motorrad, the In 2025, the BMW Group sold 2.46 million passenger vehicles and more \u00a0<\/p>\n The economic success of the BMW Group has always been based on \u00a0<\/p>\n \n www.bmwgroup.com <\/a><\/p>\n LinkedIn: http:\/\/www.linkedin.com\/company\/bmw-group\/<\/a><\/p>\n YouTube: https:\/\/www.youtube.com\/bmwgroup<\/a><\/p>\n Instagram: https:\/\/www.instagram.com\/bmwgroup<\/a><\/p>\n
\n download here<\/a>.
\n The BMW Group-specific final report can be found here<\/a>.<\/p>\n
\n
Car2Car is a research project focused on the recovery of
\n materials from end-of-life vehicles for use in new automotive
\n applications. It investigated under which conditions high-quality
\n material loops are possible along the automotive value chain.<\/p>\n
\n
The key finding was that it was possible to increase the \u201cCar2Car
\n rate\u201d from six to 51 percent under expanded processing and sorting
\n conditions. Particularly high recovery potentials were achieved for
\n steel, aluminium and copper. A key factor is that these results were
\n achieved without dismantling end-of-life vehicles beyond the
\n compulsory disassembly currently standard in the industry before recycling.<\/p>\n
\n
The \u201cCar2Car rate\u201d refers to the percentage of materials from an
\n end-of-life vehicle that can, in principle, be recovered at high
\n enough quality for reuse in new automotive applications. It is
\n therefore more than just a conventional recycling rate. The decisive
\n factor is not just whether a material can be recycled, but whether it
\n can be returned to the automotive material loop with a comparable
\n level of quality.<\/p>\n
\n
The main focus of the project was on steel, aluminium and copper.
\n Potential and limits for plastics and glass were also considered.<\/p>\n
\n
In the case of steel, it was possible to demonstrate that just
\n one additional processing step, in the form of sorting, can reduce
\n copper-bearing impurities, resulting in high-quality steel scrap. This
\n was then used to produce flat steel for modern automotive applications.<\/p>\n
\n
Yes. In the field test at BMW Group Plant Leipzig, more than
\n 100,000 series parts were produced from recovered steel and then
\n installed in vehicles. In this way, it was possible to demonstrate,
\n along a real-world industrial value chain, that new vehicle components
\n can be produced from end-of-life vehicles. However, this industrial
\n field test does not yet mean that the relevant recycling and
\n processing processes are widely available on the market.<\/p>\n
\n models, including test vehicles that were less than five years old.\u00a0<\/p>\n
\n
Comparable progress has not been achieved with plastics and glass
\n to the same extent as with steel, aluminium and copper. Further
\n innovation is required in areas such as vehicle design, disassembly,
\n sorting and recycling.<\/p>\n
\n 1 to 81 percent.<\/p>\n
\n 23 to 52 percent.<\/p>\n
\n 48 to 68 percent.<\/p>\n
\n 6 to 51 percent.<\/p>\n
field test<\/p>\n
\n from recovered Car2Car steel produced at
BMW Group Plant
\n Leipzig and installed in vehicles.<\/p>\n
Communications\n<\/p>\n
\n BMW Group is the world\u2019s leading premium manufacturer of automobiles
\n and motorcycles and also provides premium financial services. The BMW
\n Group production network comprises over 30 production sites worldwide;
\n the company has a global sales network in more than 140 countries.<\/p>\n
\n than 202,500 motorcycles worldwide. The profit before tax in the
\n financial year 2025 was \u20ac 10.2 billion on revenues amounting to \u20ac
\n 133.5 billion. As of 31 December 2025, the BMW Group had a workforce
\n of 154,540 employees.<\/p>\n
\n long-term thinking and responsible action. Sustainability is a key
\n element of the BMW Group\u2019s corporate strategy and covers all products
\n \u2013 from the supply chain through production to the end of their useful life.<\/p>\n