Recycled fishing nets used as car trim by BMW

Motor manufacturers are introducing dramatic shifts to their supply chain, to adopt innovative and sustainable measures.

“We need to move the conversation beyond CO2 because it is just one metric and we need to focus on the entire value chain,” says Kevin Davidson, managing director BMW Group Ireland.

For example, the German auto company is planning a return system for battery cells, so that critical raw materials within them can be recycled.

“With our requests for tender, all suppliers have to be able to show their own sustainable practices too, so that commitment goes right the way through the supply chain,” he adds.

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With the models of the Neue Klasse due to make their début in 2025, the BMW Group is poised to enter a new era in electromobility and for the first time use round battery cells, which are optimally adapted to the new architecture centred around all-electric drive systems.

The innovative lithium-ion batteries for what will be the sixth generation of BMW eDrive technology will increase range by 30 percent and charging speed by around 20 per cent. There will also be a reduction in CO2 emissions in the production of the battery cells, while manufacturing costs for the entire high-voltage battery will be up to 50 per cent lower compared with the current, fifth generation.

BMW Group’s focus is on responsible procurement and the processing of raw materials that is as CO2-free as possible, continuously increasing the proportion of secondary materials with the aim of achieving a complete circular economy, including new recycling processes, increased use of natural fibres and the replacement of raw materials of animal origin.

The BMW Group plans to launch its first vehicles featuring completely vegan interiors in 2023. This is being made possible primarily through the development of innovative materials with leather-like properties. Replacing leather reduces the CO2 emissions along the value chain for the respective interior components by around 85 per cent.

In a first for the automotive industry, the models of the Neue Klasse from 2025 will feature trim parts made of plastic whose raw material contains around 30 percent recycled fishing nets and ropes. These waste materials from the maritime industry are proactively sourced at ports all around the world to ensure that they don’t end up being discarded in the sea.

“We are looking at the complete life cycle of all our parts and components with the aim to radically increase the share of secondary materials in our products, doing more with less with while using new technologies, new materials and new processes to ensure that we to deliver on our mission to produce the greenest cars,” says Davidson.

Chinese electric vehicle maker Polestar is focusing on sustainability too.

“Polestar is determined to improve the society we live in, using design and tech to accelerate the change to sustainable, electric mobility,” says Kieran Campbell, market lead of Polestar Ireland.

“By 2030 we are aiming to make a car that leaves the factory with a zero-carbon footprint. To achieve this we are improving electric car battery sustainability through repair, refurbishment and repurposing. To ensure responsibility in sourcing battery raw materials, we are using blockchain to trace risk minerals and promote an ethical and transparent supply chain.”

All of this is being done according to what it sees as the four key drivers of sustainability – climate neutrality, circularity, transparency and inclusion.

“All four key drivers can be seen in our Polestar 0 project, our ‘moonshot’ goal to create a truly climate-neutral car by 2030,” he says.

Electric vehicles do not emit any CO2 during use “but to be truly climate-neutral, we need to eliminate greenhouse gas emissions from all phases of the car’s life cycle and charge them using renewable energy. At this stage we’re collaborating with partner companies on research into key areas like steel, aluminium, electronics, safety and electric drive. Future project phases will focus on advanced engineering, followed by product development”.

Circularity, from design and materials, to sourcing and assembly, use and reuse, are all critical.

“We’re on our way to making our cars as circular as possible,” says Campbell, who points to five principles that inform its design process; longevity, repairability, remanufacturing, repurposing and recycling.

“This has also led us to redefine what premium can mean in the auto industry with sustainable materials,” says Campbell.