BMW Group Information 2004 Recycling of end-of-life vehicles Each year, several million cars in the European Union reach the end of their service life. Legislation within the EU member countries requires that all participants – including manufacturers of new cars – recycle end-of-life vehicles in an environmentally sound manner. For the BMW Group, this is not merely a question of fulfilling legal requirements. The real aim is to make sensible ecological and commercial use of one of the world’s biggest sources of raw materials, while closing materials cycles and thereby contributing to the conservation of resources.

BMW Group Legislation governing car recycling in Europe Certificate of destruction: In 2000, the European Union issued legislation applicable to the customer’s final official record all member nations entitled the directive on end-of-life vehi- The take-back of end-of-life vehicles is carried out at take- cle recycling. This initiative specifies that any new vehicle back points designated by the manufacturer. While accept- registered on or after 1 July 2002 must be taken back from ing an ELV the car’s condition is verified as well as its com- the last owner free of charge. As of 1 January 2007, this rule pliance with regulatory criteria for free return of the vehicle, applies to all vehicles taken off the road. Car manufacturers then its residual value is determined. To be eligible for free are obligated thereby to carry all, or a significant part, of the product return, the vehicle must still have all major compo- costs associated with the ELV recycling. nents and cannot contain any extraneous waste. The collec- tion facility then issues a certificate of destruction, which is The text of the directive details the recycling of particular required for final vehicle deregistration, which releases the components and materials, and also stipulates recycling final owner from tax and insurance obligations. For the cus- quotas that will be go in effect EU-wide in 2006. tomer, this is the final step in the vehicle disposal process; for the dismantling facility, the work has just begun. A further goal of the directive is to provide a foundation for making future generations of automobiles more recyclable. The legislation aims to achieve this through various mea- sures, including a requirement that materials be labelled and precluding the use of lead, mercury, cadmium and hexava- lent chromium. Additionally, vehicle recyclability will now be integrated into type approval, for which all car makers must apply through approved testing institutes for each new model. Type approval will verify a car’s future recyclability on the basis of its material composition.

BMW Group: Leading the way in ELV recycling By the early 1990s, the BMW Group had already begun establishing nationwide structures in several European countries for take-back and recycling of end-of-life vehicles, making it the first car manufacturer in the world to imple- ment such a programme. In Germany, this network now comprises around 100 authorised dismantling facilities and a further 100 ELV take-back points. With the implementa- tion of the EU Directive on ELVs, car manufacturers are required to establish adequate availability of take-back points in all EU member states. This will also be in effect for the ten new members joining the EU in 2004 as part of its expansion towards Eastern Europe.

Key points in the EU Directive on ELVs

• Article 5.3: End-of-life vehicles may only be deregistered when they have received a “certificate of destruction”.

• Article 5.4: Beginning in 2007, the return of any ELV to a take-back point designated by the manufacturer will be free of charge to the last holder or owner, in effect since 2002 for new vehicles.

• Article 6.3.c: Dismantling and storage shall be carried out in such a way as to ensure the suitability of vehicle components for reuse and recovery, and in particular for recycling.

• Article 7.2.a: Effective 1 January 2006, a reuse and recycling quota for end-of-life vehicles equivalent to 85% (95% from 2015) of average vehicle weight is required.

• Article 8.1: Coding standards for components and materials should facilitate the identification of components and materials that are suitable for reuse or recycling.

Further informations on the EU Directive Pretreatment High-end recycling: reuse of components and parts In a preliminary step, all pyrotechnic components such as In the next stage, the recycling specialists determine which airbags, battery safety terminals (BST) or safety belt preten- of the vehicle’s parts are suitable for assignment to “high- sioners are triggered for safety reasons. Special devices are end recycling”, or re-utilising a part or component for its then used to remove all operating fluids. This stage includes original function. Overhauling a component and placing it siphoning off air-conditioning system refrigerant and brake back into service thus represents the ideal case in terms of fluid, draining radiator coolant, motor oil and transmission recycling. Replacement engine production at the BMW oil, and extracting any remaining fuel using a special drilling Landshut plant provides the most obvious example of high- machine with a draining device. The various fluids are kept end recycling. The wide variety of existing reconditioned separate and placed into containers according to type for engines includes 30-year-old four-cylinders used in the old processing or recycling by specialised facilities. Removing BMW 02 Series, various high-performance engines from operating fluids ensures that potentially environmentally- the M models, 12-cylinder engines and powerplants from harmful fluids and substances cannot cause ground, water contemporary series. The 15,000 engines reconditioned or air contamination in subsequent stages of recycling. each year by the facility represent an important constituent of the BMW Group replacement parts programme, which not only encompasses additional mechanical components such as gearboxes, clutches and differentials, but also elec- tro-mechanical and electronic components, including gen- erators, starters, control units and instrumentation. A total of around 2000 different parts are available from 150 product groups.

These parts, which are available through dealerships, offer customers the same guarantees and quality as new parts for as little as half the price. Reconditioning is also of signifi- cant benefit to the environment, since up to 60 per cent of certain disused parts is recovered in the process of return- ing them to their original function.

Material recycling for metal, glass and plastics But these complex components are not the only automobile parts that go through a careful dismantling process. Those parts of the car that are made of recyclable materials are also selectively dismantled, sorted and collected according to type, a practice that is now even more important in view of EU guidelines. These specify that, beginning in 2006, 85 per cent of an ELV by weight must be reused as parts or material. This requirement has long been fulfilled for metallic materials, which pertains not only to body steel and wiring harness copper, but also to materials such as the aluminium used in the undercarriage and magnesium employed in the instrument panel. Processing aluminium and magnesium from primary raw materials requires a significant amount of energy. However, since both of these lightweight metals can be recycled using a fraction of the energy needed to pro- duce them in the first place, they are among the most sought-after secondary raw materials. Glass and a number of large plastic components can now also be recovered and placed back into the production cycle. IDIS database facilitates economical dismantling These figures reflect a tenfold increase in recyclable plastic Today’s cars contain several thousand parts; their material parts. The IDIS program suite includes a comprehensive composition is highly diverse. A system called IDIS was database with dismantling diagrams for individual vehicle created to assist in dismantling these parts in the quickest components, specifications for average dismantling time and least complicated – and therefore most economical – and the weights of the components used. manner possible. An international database employed by (http://www.idis2.com/) over 20 automobile manufacturers, IDIS (International Dismantling Information System) stores component and Closed-loop recycling: material information on over 20,000 parts. Thus over 360 BMW as a pioneer in material flow management models can be recycled specifically. Type purity, and the ability to produce quality-assured sec- ondary raw materials from the recovered material, are essential to the recycling of any material. The BMW Group has made an important pioneering contribution in the area of material flow management by creating established recy- cling loops for composite materials, “PUR” foams and vari- ous thermoplastics. Today’s BMW and models can thus make use of up to 15 per cent recycled materials by weight.

Five per cent or less to landfills Once replacement parts and recoverable materials have been removed from an ELV, what remains of the car body is crushed to minimise the cost of transport to further pro- cessing at the shredding facility. At this next step, a hammer mill is used to reduce the pre-compacted auto bodies to palm-sized pieces. Magnetic and inductive separators then sort out ferrous and non-ferrous metals for recycling. The remaining non-metallic shredder “fluff” is recycled as raw material or used to generate energy. EU guidelines specify One of the key features of IDIS is identification of economi- that form 2015 only five per cent in weight can be deposit- cally recyclable plastic parts. BMW has since 1990 given a ed into landfills – roughly the content of an 80-litre waste- code to any plastic part weighing in excess of 100 grams, in collection bin. order to provide systematic recycling of plastics.

Through the years, the amount of recoverable plastics has increased with each successive BMW model. The com- bined weight of recyclable plastics in the various 3 Series generations, for example, progresses as follows:

BMW 3 Series parts optimised for recycling Basic recycling methods

Recycling quality: There are three different levels 43 kg applicable to the recycling of ELVs:

• Reuse represents the highest form of recycling: the complete and useful parts and assemblies are removed and reconditioned, or directly employed 26 kg again to fulfill their original function.

• Material recycling is dependent upon the removal 9 kg and collection of plastics, metals, glass and other materials, separated by type to the highest degree 4 kg possible. These are crushed and reused as starting materials in the manufacture of new components.

first second third fourth • Thermal recycling makes use of materials with a generation generation generation generation high energy content as a source of fuel to produce (1975–1982) (1982–1990) (1990–1998) (1998–) heat in the generation of electric power, for example. End-of-life vehicle recycling process

Vehicle acceptance • Vehicle assessment • Issue of certificate of destruction

Car Identification: • Drawing up documents to accompany vehicle • Determining extent of dismantling work • Recording into Software

Approval of initial processing stage

Neutralizing pyrotechnic devices • Airbags, seat belt tensioners, battery post clamp

Initial vehicle processing Operating fluids • Removing all operating fluids • e.g. treatment of oil by • Sealing all drain apertures securely specialist companies to obtain base oils

Removal of hazardous substances • Removal of battery, latent-heat store, halogen bulbs, etc. • Substances in accordance with Annex II of end-of-life vehicle legislation

Approval for dismantling Merchandising of used spare parts

Dismantling • Used spare parts Recycling of • Materials (minimum extent materials acc. to end-of-life vehicle legislation)

Approval for compacting

Core scrap Removal of core scrap • Engine and transmission, possibly axles

Ferrous metals Compacting

Transfer to shredder Non-ferrous metals • Separation into aluminium, magnesium and copper

Shredding process Shredder resiude • Grinding • Energy generation • Sorting Research lab and recycling facility: the BMW Group Recycling and Dismantling Centre (RDC) Further examples of innovative tools developed In order not only to ensure continual improvement of the at RDC include: vehicle recycling process in terms of thoroughness, econo- my, and environmental compatibility, but also to achieve the 1. Single apparatus for discharging pyrotechnic highest degree of new vehicle recyclability by incorporating components (airbags, belt pretensioners, etc.) on environmental considerations in the development process, all European-made vehicles the BMW Group established one of the world’s leading facilities in this field: the Recycling and Dismantling Centre 2. Optimised hydraulic shears for quicker dismantling (RDC). The RDC is both a certified waste treatment facility of catalytic converters, wiring harnesses and other components

3. Glass removal devices for recovering windshield, rear and side window glass

Recycling: BMW Group sets the standards Recycling has long been normal practice in the BMW Group. Environmentally-oriented thinking and practices geared towards closed-loop recycling are today as much a part of the company’s corporate culture as “Sheer Driving Pleasure.” Integrating the Recycling and Dismantling Centre (RDC) into the automobile development process has pro- duced cars that take into consideration all product life cycle requirements – all the way to recycling.

and a laboratory for basic research, development work and specialised basic and advanced training. The integration of a recycling centre like RDC in the new vehicle development process sets a standard for the automotive industry world- wide. New material combinations or components for new BMW Group models are evaluated here for recyclability before series development even begins. If the new designs pass muster, the specialists at the RDC might develop cor- responding new recycling technologies, and they have to Further information on the think at least 15 years ahead. They are already working on BMW Group is available on procedures that will not see practical implementation for the Internet: years, such as technologies for the optimal dismantling and recycling of hydrogen vehicles and their specialised compo- BMW Group www.bmwgroup.com nents.

BMW Award-winning innovation: shock-absorber oil A publication of the BMW Group www..com removal device An overview of selected published MINI The experts at RDC also continue to focus on the task of material in German and English is www.MINI.com testing and developing practical solutions for dismantling available from: technology. One result of these efforts is a special device Telefax: +49(0) 89/382-24418 BMW Motorrad forremoving shock-absorber oil – developed in concert E-Mail: [email protected] www.bmw-motorrad.com with a recycling partner – which was recognised with an Publisher Institute for Mobility award from the Bavarian government for superior innovative Bayerische Motoren Werke Research achievement in the specialist trades. This novel process Aktiengesellschaft www.ifmo.com employs a special hollow mandrel to siphon used oil from Technologiekommunikation D-80788 München CleanEnergy shock absorbers while they are still attached to the vehicle, www.bmwgroup.com/ a procedure that allows up to 1.6 litres of residual oil to be © BMW AG recovered. The old, more time-consuming (and therefore more expensive) methods involved either dismantling the Sustainability The contents of the brochure are valid www.bmwgroup.com/ shock absorbers or drilling into them using complicated at the time of printing. responsibility special equipment. All rights reserved. Printed: 04/04