Automotive Plastics Recycling in a Circular Economy through Molecular Recycling Technologies: Technology Status, Material Advances and Challenges

The urgent need to address the global plastic waste crisis and its impact on climate change has created a demand for a materials revolution. Volkswagen Group of America Inc. (VWGoA) in collaboration with Eastman Chemical Company, is taking the lead in driving circular economy solutions for plastics through groundbreaking molecular recycling technologies. This innovative approach enables the conversion of difficult-to-recycle plastics from the automotive industry into raw materials for producing new specialty plastics and fibers, all while maintaining their quality and performance. Our primary focus lies in dealing with a wide range of plastic waste streams, including mixed plastics, colored plastic materials, post-consumer car carpets, and textiles. The collaboration between VWGoA and Eastman Chemical Company not only brings innovation but also addresses recycling challenges associated with these difficult materials, while providing environmental and sustainability metrics for the recycling process. The knowledge gained from this project contributes to global waste management efforts and fosters a cleaner and more sustainable future. With the molecular recycling process enabling the synthesis of various polymer types, it presents a direct alternative to virgin fossil-based plastics. This is particularly relevant as the automotive industry strives to reduce carbon footprints and divert plastic scrap and automotive shredder residue (ASR) from landfills, benefiting original equipment manufacturers (OEMs) and their suppliers. This molecular recycling process, developed by Eastman Chemical Company and successfully implemented by Volkswagen (VW), has proven to reduce greenhouse gas emissions by 25-50 percent compared to the conventional use of virgin-fossil-based raw materials in the automotive sector. Leveraging their expertise in automotive manufacturing, VW has successfully implemented initiatives to reduce CO₂ emissions through the use of lightweight body panels. This collaboration builds upon their past achievements of the VW's innovation hub in North America. Proof of concept is demonstrated through the Atlas Cross Sport Spoiler Assembly, Passat R-Line Diffuser, and Atlas Cup Holder Substrate, showcasing the successful recycling of mixed plastics. These components serve as examples of the effectiveness and viability of the mixed plastic recycling process to manage plastics from end-of-life vehicles in a sustainable way. In this study, by employing innovative molecular recycling technologies, these proof of concepts highlight the ability to transform challenging waste plastics into high-quality materials suitable for automotive applications. The successful recycling of mixed plastics not only demonstrates technical feasibility but also emphasizes the commitment to sustainability and circular economy principles within the automotive industry.