Jaguar Land Rover Automotive plc, the UK’s largest vehicle manufacturer, is expanding the use of recycled aluminium in its car bodies to cut waste and reduce carbon emissions.
The £2 million project, called REALITY, has found a way to enable the closed-loop recycling of aluminium from end-of-life vehicles back into high-performance product forms for new vehicle body manufacture in the UK by Jaguar Land Rover.
REALITY builds on the REALCAR project allowing tens of thousands of tonnes of aluminium generated in the manufacturing process to be recycled and reused as a closed-loop. Aluminium from other sources, including end-of-life vehicles, can now be graded and ‘born again’ in the manufacture of new cars.
This unique ‘closed-loop’ automotive recycling system helps to further develop the circular economy model to deliver both financial and environmental benefits.
REALCAR began as a partnership between Jaguar Land Rover, Innovate UK, Novelis, Norton Aluminium, Stadco, Brunel University London, Zyomax and Innoval Technology. The original project and subsequent work with suppliers enabled Jaguar Land Rover to reclaim more than 75,000 tonnes of aluminium scrap and re-use it in the aluminium production process in 2016/17.
Implementing closed-loop aluminium recycling has involved cutting-edge chemistry, new infrastructure and investment of more than £13 million. It is driving a new culture that treats waste material as a high-value commodity. Quality will remain paramount, and the project has evaluated aluminium grades at chemistry and microstructure level to increase tolerance to recycling.
The project, part-funded by Innovate UK, has involved more than 10 press shops (Jaguar Land Rover and external suppliers) with aluminium being remelted by Novelis.
Simon Edmonds, Director of Manufacturing and Materials at Innovate UK, said: “Innovate UK is proud of our support for the REALCAR programme, and this exciting latest stage of the project, REALITY, is another excellent example of collaboration between large and small businesses in the supply chain, supporting them to scale up and become more productive. These projects have been a model in terms of professional delivery of complex research and development.”
Work continues to will refine the process of turning aluminium from ‘end-of-life’ cars into new vehicles. The REALITY project will continue to deliver significant sustainability benefits, with aluminium recycling requiring up to 95 per cent less energy than primary aluminium production. Innovate UK awarded a grant of £1.3 million to the project in 2016 as part of its Manufacturing and Materials Round One funding competition.
The new project will consider advanced sorting technologies and evaluate the next generation aluminium alloys for greater recyclability. Innovations in the sorting and separating technologies applied to automotive end-of-life waste streams will also help other sectors, including packaging and construction. Resource recovery specialist Axion has joined the project to develop the sorting technologies for recovery of a high grade recycled aluminium. The project partners are Jaguar Land Rover, Axion Recycling, Innovate UK, Novelis, Norton Aluminium, Brunel University London, WMG University of Warwick and Innoval Technology.
REALITY supports material stewardship as part of the Aluminium Stewardship Initiative (ASI) Performance Standard, to actively encourage the most effective recycling approaches for aluminium. Jaguar Land Rover is an ASI member (https://aluminium-stewardship.org/).
For more information on how the REALITY project is an evolution from the REALCAR project, visit: https://youtu.be/2493lsmnCHM
Notes to editors
- Jaguar Land Rover will invest £4 billion annually to extend its model range and manufacturing footprint
- The World Car of The Year, the Jaguar F-Pace, contributed to the resurgence of the Jaguar brand which saw an 83% increase in sales year on year
- Over the past six years, Jaguar Land Rover has doubled sales and employment, more than tripled turnover, and invested more than £15 billion in new product creation and capital expenditure
- Jaguar Land Rover is one of the UK’s largest exporters and generates around 80% of its revenue from exports
Jaguar Land Rover
Jaguar Land Rover is the UK’s largest automotive manufacturer, built around two iconic British car brands: Land Rover, the world’s leading manufacturer of premium all-wheel- drive vehicles; and Jaguar, one of the world’s premier luxury sports saloon and sports car marques.
We employ almost 42,000 people globally and support around 240,000 more through our dealerships, suppliers and local businesses. Manufacturing is centred in the UK, with additional plants in China, Brazil, India and Slovakia.
At Jaguar Land Rover we are driven by a desire to create class-leading products that deliver great customer experiences. The largest investor in R&D in the UK manufacturing sector, we have invested £16 billion in the last seven years and in the current year alone will spend over £4 billion on new product creation and capital expenditure. In 2016 Jaguar Land Rover sold more than 583,000 vehicles in 136 countries, with more than 80 per cent of our vehicles produced in the UK being sold abroad.
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