Covestro Develops PCR Polycarbonates from End-of-Life Headlamps

17 Apr 2025 CW Team

Materials manufacturer Covestro has launched post-consumer recycled (PCR) polycarbonates made from end-of-life automotive headlamps, in a move aimed at strengthening circularity in the auto industry. These TÜV Rheinland-certified grades, containing 50 per cent recycled content, are now commercially available for new automotive applications.

Developed under a joint programme led by GIZ, with Volkswagen and NIO as key partners, the recycled material is currently being validated for use in future vehicle models.

""This new line of polycarbonate represents a significant step in supporting the automotive industry's transformation towards a circular future,"" said Lily Wang, Global Head of the Engineering Plastics Business Entity at Covestro. ""By offering high-quality PCR materials derived from end-of-life headlamps, we're enabling our customers to meet increasingly stringent regulatory requirements while contributing to closed-loop recycling of automotive plastics.""

The initiative involves collaboration with Chinese recycler Ausell, and focuses on building a closed-loop recycling model for high-value plastics from end-of-life vehicles (ELVs). It also aims to establish reliable supply chains for quality recycled materials, particularly in China and Europe.

""This partnership underscores the importance of cross-sector collaboration in driving the circular economy forward,"" added Martin Hansen, Regional Director, GIZ East Asia.

The launch comes at a time when automakers are under growing pressure to meet recycling mandates such as the EU’s End-of-Life Vehicle Directive and China’s EPR programme. Covestro’s new PCR polycarbonates meet Vehicle Interior Air Quality (VIAQ) standards, offering superior surface finish and high performance for demanding applications.

As part of its broader sustainability agenda, Covestro has also introduced PCR polycarbonates with up to 90 per cent recycled content and has set up a dedicated mechanical recycling line in Shanghai.

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