How circular economy targets are driving new strategies in automotive design, sourcing and supply chain integration across EVs, batteries and interiors Leading OEMs and suppliers are no longer treating circularity as an end-of-life concern. Design, sourcing and localisation strategies are being rethought to prioritise reuse, remanufacture and material traceability from day one. Ilkhan Ozsevim
Inside JLR’s circular manufacturing push: How reused tools and digital systems are driving EV production and decarbonisation across its global network Tomasz Jozwiak explains how Jaguar Land Rover is driving circularity across its operations by reusing and refurbishing manufacturing assets, cutting emissions, saving millions, and supporting electrification. Ilkhan Ozsevim
UK competition regulator fines 10 carmakers and trade bodies over collusion in green advertising and recycling disclosures The UK’s competition watchdog has fined major carmakers and two trade bodies over £77m for colluding on green advertising. A whistle-blower tip from Mercedes-Benz exposed years of consortium activity that limited consumer choice. Ilkhan Ozsevim
Renault expands circular economy with new polish repair facility for sustainable used car refurbishment The French car manufacturer Renault has just opened a special workshop in the largest eastern EU market - even though Poland is not necessarily one of its strongest locations. The issue of sustainability plays an important role. By Sebastian Becker
JLR and partners push seat foam circularity forward through digital tools and collaboration, accelerating sustainable material reuse in luxury vehicle production JLR’s breakthrough in seat foam circularity is powered by digital tools, data-driven traceability and production/supply chain collaboration. The Circularity Lab’s ‘learn through doing’ approach is setting new industry benchmarks for material reuse and sustainable innovation. Ilkhan Ozsevim reports. Ilkhan Ozsevim
Nissan to amplify green steel usage in Japan by 500% aligning with global automakers in pursuit of carbon neutrality by 2050 In an important move towards enhanced sustainable production, Nissan has declared a fivefold increase in the utilisation of green steel in its vehicle manufacturing. The initiative is part of the OEM’s wider carbon neutrality targets and reflects a growing industry trend. Ilkhan Ozsevim
BMW Group strengthens circular economy through SK tes battery recycling, advancing sustainability in Europe and beyond The BMW Group has launched a partnership with SK tes to recycle high-voltage batteries across Europe. This closed-loop process reclaims critical materials such as cobalt, nickel, and lithium, boosting sustainability and reducing supply chain risks. Ilkhan Ozsevim
BMW’s San Luis Potosí plant in Mexico is driving global sustainability with solar power, water reuse, and AI-driven carbon reduction BMW’s San Luis Potosí facility in Mexico exemplifies sustainability in action. From solar energy to water recycling and AI-driven efficiency, the plant demonstrates how local, effective green innovation can reshape automotive production on a global scale. Following a site visit, AMS delves into the facility’s world-leading sustainability intiatives. Ilkhan Ozsevim reports. Ilkhan Ozsevim
2024 wrap up and 2025: EV batteries, gigafactories, sustainability and smart factories in auto manufacturing Take a look back at AMS’ biggest stories in automotive manufacturing in 2024, and our predictions for 2025 from smart factories to digital twins and more AMS
How algae can turn CO2 emissions into sustainable carbon fibres CO2 to carbon? Yes, it’s possible! Researchers at the Technical University of Munich are binding carbon dioxide using algae and using it to produce high-quality carbon fibers. The process works, there’s just one hurdle. Chris Löwer
PowerCo partners with Alterric and EnviTec to power Salzgitter Gigafactory with 3 Terawatt Hours of green energy over the next decade PowerCo SE has secured 3 terawatt hours of green electricity for its Salzgitter gigafactory through long-term agreements with Alterric and EnviTec Biogas. These partnerships will cut 115,000 tonnes of CO2 emissions annually and support Europe’s renewable energy goals. Ilkhan Ozsevim
JLR advances circular economy with closed-loop seat foam recycling, reducing waste and emissions in luxury vehicle production JLR’s Circularity Lab leads an industry breakthrough by creating closed-loop recycled seat foam for luxury vehicles. This innovation addresses recycling challenges, reduces emissions, and supports the Reimagine strategy for an all-electric future. Ilkhan Ozsevim
BMW group plant Regensburg integrates hydrogen to reshape production logistics by 2030 The Regensburg plant is transitioning its logistics fleet from electric to hydrogen power. With hydrogen filling stations and efficient refuelling, this shift aligns with the bmw iFACTORY vision of a digital, sustainable production future. Ilkhan Ozsevim
BMW conquers Mexico with sustainable production at San Luis Potosí: "It's about more than cars" The BMW factory canteen in San Luis Potosí serves cactus salad made from nopal leaves – harvested in the gardens on the factory premises. An example of the site philosophy: using local resources, promoting sustainability and delivering the highest quality. By Andrea Hoffmann-Topp
Dürr builds an energy-efficient paintshop for Stellantis’ Kenitra plant Stellantis’ new paintshop to double capacity at Kenitra plant and reuse paint robots from other facilities. Nick Holt
Scania progresses production by integrating remanufactured components on its main assembly line, reducing material use by 50% and cutting carbon emissions by 45% Scania has become the first truck OEM to integrate remanufactured components directly into the main assembly line. The innovative approach aims for a circular economy in vehicle production. Ilkhan Ozsevim
How BMW is ‘Designing for Circularity’ to become a sustainability leader in automotive production BMW’s Roberto Rossetti, Total Vehicle Life Cycle Development, elucidates BMW’s innovative ’Design for Circularity’ approach. From using recycled materials to optimising vehicle disassembly, BMW is redefining how vehicles are produced and consumed. Ilkhan Ozsevim
Lowering costs through sustainable manufacturing Sophisticated and complex technologies could be used to reduce costs and make manufacturing more eco-friendly, but simple solutions might be the most effective Michael Nash
BMW’s ‘motionless’ and ‘silent’ wind energy system installed at Oxford plant in collaboration with Aeromine BMW’s commitment to sustainability shines through again as the OEM installs the UK’s first “motionless” wind energy system, offering a unique and efficient solution to traditional wind power challenges. The technology, developed by Aeromine Technologies, has the potential to revolutionize renewable energy production. Ilkhan Ozsevim
VW in cooperation to develop sustainable materials for vehicle interiors Volkswagen will work with Revoltech to develop sustainable bio-based leather alternative made from industrial hemp. Nick Holt
Reinventing the wheel: the race towards sustainable tyre production Nokian Tyres is building the world’s first zero-carbon tyre factory, with Michelin, Continental, Bridgestone, and Pirelli leading the charge with recycled materials, bio-based components, and innovative sustainable production methods. Ilkhan Ozsevim
Rockwell Automation appoints Emmanuel Guilhamon as sustainability leader Emmanuel Guilhamon brings extensive experience in sales, strategy, and renewable energy to drive Rockwell Automation’s sustainability initiatives, helping manufacturers achieve their ESG goals. Ilkhan Ozsevim
BMW’s Debrecen plant hits fossil-free milestone with gas-free, sustainable Paintshop The Debrecen plant, set to launch pre-series production of the Neue Klasse, boasts a modern paint shop powered by renewable energy. Innovative technologies like power-to-heat, Heat Grid, and eRTO look to achieve maximum resource efficiency and sustainability. Ilkhan Ozsevim
GM continues path towards 2040 carbon neutral target General Motors (GM) boosts renewable energy sourcing and reduces natural gas consumption to support sustainability targets. Nick Holt
Gestamp signs agreement with Acciaieria Arvedi for the supply of low-emissions steel Gestamp will return high-quality steel scrap from stamping parts production to Acciaieria Arvedi, who will reprocess and reintroduce it into the production cycle. Nick Holt
GKN Automotive reduces direct CO2e emissions in 2023 GKN Automotive has published its second sustainability report, revealing a 10.5% reduction in CO2e emissions in 2023. Nick Holt
APK 2024 – Increasing circularity in automotive production Circular economy programmes are becoming a key part of automotive manufacturing sustainability strategies, but these should be more ambitious says Dr Michael Riesener, speaking at this year’s Automobil Produktion Kongress. Nick Holt
Bosch Ventures invests in battery recycling startups Bosch Group’s venture capital unit, Bosch Ventures, has made significant investments in Cylib and Li Industries, two battery recycling startups. Megan Kelly
Volvo’s Taizhou plant achieves climate neutrality with biogas shift Despite the Taizhou plant’s smaller share in the company’s total emissions, this initiative is critical to Volvo’s goal of climate-neutral manufacturing by 2025 and achieving net-zero greenhouse gas emissions by 2040. AMS and Anushka Dixit
How BMW is ramping up its circular production and sustainability principles as it drives towards electrification BMW’s Dr. Irene Feige, Head of Climate Strategy and Circular Economy says that circular economy is becoming central to BMW’s automotive production landscape, part of its wider push for sustainable production and supply chains. Ilkhan Ozsevim
Bridgestone commits a European record €207m investment to its Burgos tyre plant in Spain, aiming for BCMA principles and sustainable production The record €207m investment aims at integrating BCMA to streamline production, boost capacity and promoting sustainable manufacturing Ilkhan Ozsevim
Additive manufacturing: Supporting sustainable production 3D printing is advancing, and while new materials and processes could make it more eco-friendly, experts think that component elimination may be the way forward. Michael Nash
Powertrain – Reducing waste in machining fluids Sustainability projects at plant and team levels are vital to reducing the operational carbon footprint in manufacturing operations. These range from simple energy management protocols to more involved process improvement related projects. JLR offers a very interesting case study on the latter at its Electric Propulsion Manufacturing Centre. Nick Holt
GKN Automotive – Embedding sustainability in the business GKN Automotive’s director of sustainability, Tom Salisbury discusses the importance of Science Based Targets, managing supply chains and the need to embed sustainability throughout the organisation. Nick Holt
JLR – Putting sustainability at the centre of its strategy Sustainability is a key of JLR’s Reimagine strategy, but this goes beyond developing and manufacturing a new generation of electric vehicles. The OEM’s manufacturing sustainability transformation lead, Garrett Bell, shared some insights in how the business is reducing its carbon footprint across its operations. Nick Holt
Green Revolution: How renewable energy is fuelling sustainable automotive manufacturing Adopting renewable energy in automotive production requires a comprehensive strategy, integrating solar, wind, biogas and electric solutions to drive sustainability and mitigate environmental impact effectively. OEMs, strategies and technologies are converging on different approaches to achieve sustainability goals across regions. Here are some notweworthy projects to keep an eye on… Ilkhan Ozsevim
Investment is main barrier to sustainable automotive manufacturing A lack of capital investment is the main barrier to meeting sustainability targets in automotive manufacturing, according to the latest AMS & ABB Automotive Manufacturing Outlook Survey 2023. Megan Kelly
A natural fit: how and why the automotive production industry is turning to bio-materials for sustainable solutions in pursuit of zero emissions and enhanced performance Bio-based materials like flax, hemp, kenaf, and jute are reshaping automotive production for sustainability. These natural fibres offer durable, lightweight alternatives for several vehicle components, from dashboards to electric vehicle batteries. Martin Kahl
SSAB and Gestamp forge automotive sustainability partnership for fossil-free steel Leading Swedish steel producer, SSAB, and Spanish metal component supplier, Gestamp, partner to transform automotive steel with sustainability and performance at its core. Ilkhan Ozsevim
Gestamp joins Catena-X to push digital and decarbonisation strategies Gestamp has joined the Catena-X data-sharing platform, which is designed to increase visibility in the supply chain and improve the flow of parts and materials. Marcus Williams
Renault strikes renewables supply deals to shrink carbon footprint, slash natural gas use The new contracts, one of which is France’s largest corporate renewable energy supply deal, will guarantee supplies to Renault over 15 years. Peter Murphy
Volkswagen-led research team to develop closed-loop battery recycling Consortium launches closed-loop raw material project with the aim to develop permanent recovery of valuable materials to increase sustainability and security of supply AMS
Europe’s biggest EV battery recycling plant starts work Hydrovolt, the biggest EV battery recycling facility in Europe has started operations in Norway, the owners of the joint venture, battery producer Northvolt and aluminum and energy company Hydro, announced on May 16 Peter Murphy
Playing catch-up in plastics recycling for automotive production A closed loop for plastics in the automotive industry has so far been a distant dream, as an unmanageable variety of mixed materials makes recycling them into new high-quality materials unviable. Fortunately, there are some promising new approaches on the horizon. Chris Löwer Illya Verpraet
OEMs keen to explore renewable power sources Vehicle manufacturers are keen to explore energy supplies from renewable sources as they look to reduce and offset emissions from their large-scale production operations Michael Nash
Digitalised energy saving Vehicle production has become increasingly digitalised, with a variety of different tools helping workers on production lines. These tools can also help reduce energy usage. Michael Nash provides an insight Michael Nash
The plastic problem Dealing with pollution caused by waste plastic is high on the agenda for governments and environmental agencies. James Bakewell reports on how vehicle makers are making use of recycled plastics James Bakewell
