Compound With 65% Recycled Polypropylene in Automotive First

Borealis has unveiled Borcycle GD3600SY, a glass-fiber-reinforced polypropylene (PP) compound with 65% post-consumer recycled (PCR) polymer content. It first will be used in automotive interiors in a landmark project delivered in partnership with Plastivaloire, a thermoplastic injection specialist and Tier 1 supplier to the automotive sector, and OEM Stellantis, the owner of 14 automotive brands including Chrysler, Jeep, and Fiat.

Borcycle GD3600SY is part of the Borcycle M portfolio of mechanically recycled polyolefins for demanding applications. It contains 30% glass fibers, meaning that almost the entire polymer portion of the product is made from post-consumer recycled PP. It will initially be used in center console carriers for the new Peugeot 3008, marking the first instance of a compound with 65% PCR PP being used in series production for large automotive interior applications.

End-of-life vehicle legislation

This development proactively addresses the expected requirements of the forthcoming European end-of-life vehicle regulation. This stipulates that 25% of the plastic used in new vehicles must come from recycled sources, with a clear focus on mechanical and post-consumer recycling. Given that PP accounts for about one-third of the plastic in cars, compounds like Borcycle GD3600SY will play a critical role in achieving these circularity goals.

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Producing consistent high-quality recyclate

Historically, mechanically recycled plastics from post-consumer waste streams have been of low and inconsistent quality, making them unsuitable for demanding automotive applications. However, advanced recycling technologies like Borcycle M have overcome these limitations: By combining sorting, cleaning, and extrusion steps, household waste streams are converted into high-quality PCR polymers that meet the demanding standards of the automotive industry while also advancing circularity.

The center console made from Borcycle GD3600SY incorporates 30% glass-fiber reinforcement, essentially meaning more than 90% of the resin matrix is made of recycled polypropylene. Image courtesy of Borealis.

Shanila Baseley, Borealis’ global commercial vice president, Advanced Products & Mobility, Commercial Excellence & Business Intelligence, stated: “Accelerating the transition to a circular economy requires strong partnerships and innovative approaches. We are proud that our collaboration with Plastivaloire and Stellantis in the spirit of EverMinds has resulted in this significant step toward sustainability in the automotive sector and is further evidence of our commitment to reinventing essentials for sustainable living.”

Shared journey toward circularity

“In the automotive market, Borealis introduced Borcycle GD3600SY in Q4 2023,” added Danielly Pierozan Cortes, global head of Resins & Compounds at Stellantis. “Stellantis is the leading OEM implementing this technology, deploying it in our center console carriers in vehicle interiors. This reinforces our commitment to sustainability by engaging our supply base in a shared journey toward circularity.”

“Developed and manufactured in France, the center console structure of the new Peugeot 3008, produced with Borealis’ new Borcycle M GD3600SY grade, is a major step toward a more sustainable automotive industry,” said Dominique Manceau, innovation director at Plastivaloire.