Novelis pioneers 100% recycled end-of-life aluminium coils for car bodies

Novelis has just pulled off something big! They have rolled out the world's first aluminium coil made entirely from 100 per cent recycled, end-of-life automotive scrap. This is one of the major breakthroughs for the European automotive market and a huge leap towards a more circular and sustainable future.

Image source: Linkedin (Novelis)

What makes this even more impressive? This pilot material isn’t just a green gimmick — it’s strong, sleek, and perfectly suited for car body outer skins, meeting the highest standards for surface quality and formability. In short, it’s proof that sustainability doesn’t mean compromising on performance.

Novelis has long been on a mission to boost the recycled content in its products, working hand in hand with automakers and industry partners. This latest innovation taps into the Automotive Circularity Platform (ACP), a joint initiative with thyssenkrupp Materials Services. The goal? To simplify access to high-quality end-of-life materials by digitising the secondary materials market, streamlining supply chains, and maximising the recovery of valuable materials from scrapped vehicles.

“Automotive customers are constantly looking for ways to decarbonise their products while keeping them light, safe and affordable, and that’s why they turn to us,” said Michael Hahne, Vice President and General Manager, Automotive, Novelis Europe. “Producing aluminium from 100% end-of-life vehicle scrap is not only a testament to our dedication to a circular future for aluminium and enhancing the supply of the critical material. It also is a groundbreaking achievement showcasing the potential for significant environmental benefits and the ability to meet the high-performance demands of modern automotive production.”

But Novelis isn’t stopping here. The company is already pushing to scale this technology, encouraging automakers to weave even more recycled content into future vehicle designs. The plan is to rally the industry, strengthen end-of-life scrap supply chains, and fast-track the shift to a circular automotive sector.

Novelis is no stranger to sustainable innovation. They’re already supplying carmakers with aluminium made from up to 85 per cent recycled content, thanks to closed-loop recycling systems for post-production scrap and strong partnerships with recyclable material suppliers. Their vision is clear: expanding the use of end-of-life scrap will help cut the auto sector’s dependence on virgin materials. And the numbers speak for themselves — recycling aluminium uses around 95 per cent less energy than producing primary aluminium, slashing carbon emissions along the way.

This game-changing move to introduce 100 per cent recycled aluminium coils into automotive production could seriously shrink the industry’s carbon footprint while driving the circular economy forward.

By continuously investing in recycling tech, building strong collaborations, and pushing the boundaries of what’s possible, Novelis is cementing its status as the go-to partner for automakers chasing high-performance, low-carbon aluminium solutions. It’s a bold step towards a more sustainable, resource-efficient future in car manufacturing — and this is just the beginning.