● PCR Polycarbonate crafted from recycled automotive headlights paves the way for a circular automotive future

● Market-ready product offering

● TÜV Rheinland-certified, balancing compliance and superior performance

● Volkswagen and NIO validate material properties

Covestro, a leading material manufacturer, unveils a new series of post-consumer recycled (PCR) polycarbonate derived from recycled automotive headlights, marking a significant advancement in the closed-loop recycling of automotive materials. This product line is the culmination of a collaborative project initiated by the German International Cooperation Agency (GIZ), with key partners Volkswagen and NIO. The PCR polycarbonate contains 50% recycled content, is TÜV Rheinland-certified, and can be repurposed for automotive component production. Volkswagen and NIO are currently verifying material properties, with plans for potential integration into future car models.

Wang Li, Global President of Covestro's Engineering Plastics Business Unit, stated, "The introduction of this new PCR polycarbonate product line signifies another stride forward in our mission to support the automotive industry's transition to a circular economy. By transforming end-of-life headlights into high-quality PCR materials, we not only assist customers in meeting increasingly stringent regulations but also contribute positively to the promotion of closed-loop recycling for automotive plastics."

The collaborative project brings together leading automakers and recycling partners like AUSELL to explore closed-loop recycling pathways for high-value plastics from end-of-life vehicles. The project emphasizes enhancing the recycling system and establishing a stable, reliable supply chain for recycled materials. Through collaboration, Covestro and its partners have devised practical solutions to convert end-of-life headlights into high-performance PCR materials suitable for various automotive applications via physical recycling processes.

Martin Hansen, Chief Representative of GIZ East Asia, remarked, "This collaboration underscores the pivotal role of cross-industry partnership in driving circular economy development. By uniting key industry stakeholders, we provide practical solutions for recycling high-value plastics from end-of-life vehicles while fostering sustainable material loops in the automotive industry through innovation."

The launch of the new PCR material is timely. The automotive industry, inherently resource-intensive, faces escalating environmental challenges and regulatory pressures. For instance, the European Union aims to regulate the proportion of recycled materials in new vehicles through the End-of-Life Vehicles Directive, while China promotes an extended producer responsibility system for automotive products. Other major markets have also introduced sustainable development requirements, collectively pushing global automakers to seek innovative, sustainable material solutions that address evolving regulatory demands.

Covestro's new PCR product series meets the stringent performance requirements of automotive applications, offering excellent surface quality to ensure superior aesthetic outcomes for final products while adhering to stringent vehicle interior air quality (VIAQ) standards. This material blends sustainability with high performance, enabling automakers to meet regulatory requirements and environmental goals without compromising product quality.

Committed to sustainable development and the circular economy, Covestro continuously expands its product line of recycled-content materials. In recent years, Covestro has introduced PCR polycarbonate with up to 90% recycled content and established its first global dedicated production line for physically recycled polycarbonate in Shanghai. Last year, Covestro unveiled its first polycarbonate product series based on mass balance production and incorporating post-consumer chemically recycled raw materials.

About Covestro:

Covestro is a global leader in the production of high-quality polymers and their components. Through innovative products, processes, and methods, the company contributes to sustainable development and enhances quality of life across multiple sectors. Covestro serves customers worldwide in key industries such as mobility, building and living, electronics, and electrical. Additionally, Covestro polymers are utilized in sports and leisure, telecommunications, healthcare, and the chemical industry itself.

The company is fully committed to transitioning to a circular economy, aiming to achieve net-zero emissions for scopes 1 and 2 by 2035 and for scope 3 by 2050, ultimately achieving climate neutrality. In fiscal year 2024, Covestro recorded sales of €14.2 billion. As of the end of 2024, Covestro operated 46 production sites globally and employed approximately 17,500 individuals (calculated on a full-time equivalent basis).