Closing the loop on aluminum scrap in auto manufacturing

Gerhard Lang Recycling GmbH recently became one of the first companies globally to implement TOMRA Recycling's AUTOSORT PULSE system that precisely sorts aluminum alloy stamping scrap generated from automotive production.

The German metal recycling company has installed an AUTOSORT PULSE unit at its metals sorting plant in southwestern Germany as part of a research project funded by the German Federal Ministry for Economic Affairs and Climate Action. 

The KANAL project is an initiative aimed at closing the loop on aluminum scrap generated in automotive production. TOMRA, Gerhard Lang Recycling, and Pforzheim University of Applied Sciences and engineers from Jeanvré have teamed up for the 3.9 million euro-funded project to prove that aluminum production scrap can be effectively sorted and transformed into high-quality secondary aluminum. 

Sorting aluminum wrought alloys

The plant's infeed material consists of stamping scrap - the excess metal material that is removed during the metal stamping process - generated during the production of car parts and panels. While highly efficient, the stamping process generates large amounts of scrap, with an estimated 30-50 percent of the material being discarded. The aluminum scrap comprises a mixture of 5xxx (high-magnesium) and 6xxx (low-magnesium) aluminum wrought alloys that are employed in different components within automotive production. 

Upon arrival at Gerhard Lang Recycling's metals sorting plant in Gaggenau, the material is shredded before undergoing a multi-stage magnetic separation process to remove the ferrous metals. In the next step, the non-ferrous material is then fed into the AUTOSORT PULSE for advanced sorting. 

With the AUTOSORT PULSE now in place, and TOMRA's dynamic laser-induced breakdown spectroscopy (Dynamic LIBS) technology, these alloys are sorted into different products, allowing Gerhard Lang Recycling to produce exceptionally high-purity 5xxx and 6xxx aluminum scrap. 

Highly advanced dynamic laser detection

Given the alloys' identical appearance and density, traditional sorting methods are ineffective. However, the AUTOSORT PULSE separation process is based on the precise analysis of the elemental composition of each material and on highly advanced dynamic laser detection, making it capable of distinguishing between alloys.

Additionally, object singulation allows the AUTOSORT PULSE to accurately identify and separate even overlapping and adjacent materials, maximizing yield in the sorting process. Its 3D object scanning feature recognizes the shape, height, and position of the object and identifies the ideal shooting point for the Dynamic LIBS laser. 

Another key benefit of AUTOSORT PULSE is its ability to minimize contamination and subsequently enhance the value and marketability of recycled materials. The system's precision sorting reduces the risk of cross-contamination.

Boosting purity levels 

Maximilian Lang, managing director at Gerhard Lang Recycling, comments: "With the integration of AUTOSORT PULSE, we are able to process a throughput of around 4-7 tons per hour and achieve exceptionally high purity levels, exceeding 95 percent and potentially reaching 97 percent. As a result, our material is suitable for use in the production of aluminum without downgrading. We can now sell the recovered materials to leading aluminum manufacturers and recyclers for direct integration into the production of new aluminum alloys. What's more, we are considering the potential to explore additional applications for other aluminum alloys." 

Frank van de Winkel, market strategy manager - metal at TOMRA Recycling, adds: "This is a very exciting project for TOMRA to be involved in. With the European Union's commitment to climate neutrality by 2050, as outlined in the Green Deal, and the specific target of a 55 percent reduction in greenhouse gas emissions by 2030 under the ‘Fit for 55' initiative, there has never been a more crucial time to explore ways of making the aluminum supply chain more sustainable. 

"Our AUTOSORT PULSE system empowers aluminum manufacturers to enhance the utilization of recycled aluminum in their production processes. This innovative solution unlocks access to previously untapped scrap sources, enabling the recovery of high-quality, ‘alloy-true' recycled aluminum. By preventing downcycling and conserving material value, we are closing another gap towards full material circularity. The successful implementation of our technology at Gerhard Lang Recycling's plant demonstrates the feasibility of closed-loop recycling for production scrap and paves the way for a less carbon-intensive aluminum supply chain." 

Recyclers in North America can test their aluminum materials at the new WENDT Test Center in Buffalo, N.Y., featuring advanced metal sorting technologies, including the AUTOSORT PULSE.