BASF rPA6 – “BASF Reveals Powerful Polyamide Recycling Breakthrough at K 2025 — A Positive Step Toward Smarter, Sustainable End-of-Life Vehicle Solutions” – 06-10-2025

BASF rPA6

BASF Unveils Advanced Polyamide Recycling Methods for End-of-Life Vehicles at K 2025

At K 2025, BASF will present two breakthrough methods for recycling polyamides from end-of-life vehicles (ELVs). While the recovery of metals from retired cars has long been standard, plastics—often up to 200 kilograms per vehicle—are typically incinerated or landfilled. These new methods are designed to transform that trend, aligning with upcoming End-of-Life Vehicle Regulation (ELVR) requirements and pushing the automotive industry toward circularity. BASF rPA6

Chemical Recycling via Depolymerization

The first method introduced by BASF is an innovative chemical recycling process targeting heavily used and contaminated polyamide parts, such as oil pans collected from end-of-life vehicles through ZF Group. The process breaks down long polymer chains into their base monomers via depolymerization.

The key recovered monomer—caprolactam from PA6—is purified to remove contaminants that traditional mechanical recycling cannot handle. The purified monomers are then repolymerized into high-grade polyamide suitable for demanding automotive uses, closing the loop by transforming discarded parts into new premium components.

BASF rPA6

“Materials once seen as non-recyclable now serve as the foundation for premium new products.” — Martin Scheuble, Team Leader Circularity Engineering Plastics, BASF

Solvent-Based Recycling of Automotive Shredder Residue BASF polyamide recycling

The second pilot addresses the recovery of polyamides from automotive shredder residue (ASR)—a difficult-to-recycle mixture left after metals and glass are extracted. Partnering with a specialized recycling firm, BASF has developed sorting and processing technologies to isolate polyamide fractions with high purity.

Using a solvent-based process, BASF dissolves the polymer chains without breaking them. After purification, the material is reformed into PA6 compounds, ready for new applications. BASF rPA6

This approach was validated through trials on chain guide rails for Mercedes-Benz, with testing and near-production validation by Pöppelmann.

“This solvent-based recycling presents a practical solution for plastics that mechanical recycling can’t fully recover, strengthening the circular economy from car to car.” — Steffen Meyer, Team Leader Production Technology, Pöppelmann

Real-World Applications and Industry Validation

One of the most compelling aspects of BASF’s approach is its proven real-world viability. ZF Group has already utilized recycled material produced via BASF’s chemical recycling in a chassis part for Mercedes-Benz. Rigorous performance tests confirmed that the recycled polyamide met all chemical and physical performance requirements, demonstrating that recycled plastics can serve in demanding, safety-critical automotive applications. BASF rPA6

Similarly, the solvent-based process was validated through production-like testing of chain guide rails. These validations highlight that recycled polyamides are not just theoretical solutions but already practical for automotive engineering.

Sustainability and Life Cycle Benefits

Independent life cycle assessments (LCAs) reveal that both of BASF’s recycling methods drastically reduce CO₂ emissions compared to producing polyamides from fossil resources or incinerating automotive plastic waste. This environmental advantage makes the processes highly relevant in meeting corporate and regulatory sustainability goals. BASF rPA6

BASF’s approach—branded as #OurPlasticsJourney—addresses the entire lifecycle of plastic materials: make, use, recycle. By combining chemical, solvent-based, and mechanical recycling, BASF envisions a future where automotive plastics continuously circulate instead of becoming waste.

“To increase secondary raw material availability, expanding and diversifying recycling methods through pilot projects is crucial. This technological variety strengthens our efforts in resource conservation.” — Jana Krägenbring-Noor, Head of Sustainability, Mercedes-Benz BASF rPA6

Industry Perspectives and Future Outlook

Industry leaders emphasize that no single recycling technology can meet all needs. Instead, a portfolio of complementary recycling solutions is required to address diverse waste streams and performance demands. BASF’s parallel development of depolymerization, solvent recycling, and mechanical recycling reflects this strategic direction.

Dr. Martin Jung, President of BASF Performance Materials, underlines the importance of supporting all recycling technologies with appropriate regulation: “Improving mechanical and solvent recycling efficiency is important, but chemical recycling—including depolymerization and pyrolysis—is necessary to keep plastics in circulation and reduce waste.” BASF rPA6

Conclusion

With these two advanced recycling techniques, BASF is redefining how the automotive industry handles end-of-life plastics. From oil pans to shredder residues, materials once destined for incineration are now being reintroduced into high-value automotive applications. By demonstrating proven performance, real-world adoption, and significant sustainability benefits, BASF sets a new benchmark for circularity in engineering plastics.

As K 2025 highlights innovation and sustainability, BASF’s polyamide recycling breakthroughs represent a pivotal step toward a more resource-efficient, low-carbon automotive future. BASF rPA6

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