PureCycle Technologies, a US-based plastic recycling expert, and Motherson, a global automotive component manufacturer, successfully produced a Class-A surface automotive bumper prototype incorporating 30% PureFive recycled polypropylene (rPP).

PureCycle and Motherson collaborated on a bumper prototype with 30% rPP.

In time for EU’s ELV regulation

The timing of this achievement is critical – with the EU’s End-of-Life Vehicles (ELV) Regulation, by 2032, pending final adoption, new vehicles must contain at least 15% recycled plastic content, with a minimum of 3% sourced from end-of-life vehicles. Exterior components such as bumpers are directly within scope.

PureCycle’s patented recycling process

PureCycle’s patented dissolution recycling process removes color, odor, and contaminants from post-consumer polypropylene.

PureFive resin delivers properties similar to virgin material. The recycled material is also third-party certified for recycled content, providing the traceability and documentation that OEMs and regulators will require for mandate compliance.

To serve European customers directly, PureCycle is further expanding its production footprint in the region with a new dissolution recycling facility under development at the port of Antwerp in Belgium, expected to be operational in 2029.

In addition to the Belgium facility, PureCycle is building a new dissolution recycling facility in Rayong, Thailand. Both facilities are expected to be operational before 2030, expanding PureCycle’s global capacity to serve the automotive supply chain as ELVR mandate deadlines approach.

Bumper prototype proved by multiple tests

The bumper prototype was produced at Motherson’s facility in Tuscaloosa, US, with feasibility assessment and testing led by the Global Innovation Team in Germany. The component has since undergone rigorous performance tests, including climate testing and mechanical properties evaluation.

Next step: Bumper-to-bumper recycling

The collaboration between Motherson and PureCycle lays the foundation for continued work on automotive-grade material specifications, evaluating mass production with PureFive, and advancing the long-term goal of a closed-loop recycling system “from bumper to bumper”.

Future development goals also include increasing the recycled content to over 30% and expanding into additional PP applications for exterior and interior applications.