Onshore Recycling Solution for Automotive Plastic Waste

Client:

Global automotive manufacturer

Pile of discarded car dashboards and interior parts in a junkyard.

Waste Type:

Composite rigid automotive polymer components (out-of-spec parts)

Client Overview

A global automotive manufacturer partnered with Circular Futures to address a major sustainability challenge

finding a domestic recycling solution for out-of-spec automotive plastics in Australia.

Challenge: Lack of Onshore Polymer Recycling in Australia

The client was struggling to manage composite rigid plastic components with no viable onshore recycling options available.
 The only existing process involved exporting plastic waste to India, which raised serious concerns over chain-of-custody compliance, transparency, and modern slavery risks.
In addition to high export costs and an increased carbon footprint, this approach did not align with the client’s corporate sustainability goals or circular economy principles.
 Circular Futures was engaged to design a sustainable, compliant, and scalable waste management solution within Australia.

Approach: R&D, Trials, and Collaboration for Polymer Recovery

Our waste management consulting team collaborated with university research partners to conduct extensive R&D trials aimed at understanding the polymer types, melting properties, and recycling potential of the materials.
Since no automated processing system existed for these complex plastics, we worked directly with the client to manually source-separate materials on-site.
 Through real-world recycling trials using larger sample volumes, we assessed commercial viability, scalability, and environmental performance.
This evidence-based approach helped us identify practical, circular economy recycling pathways that could be implemented domestically.

Outcome: Creating Sustainable Manufacturing Opportunities

Circular Futures successfully developed onshore and export market applications for the recovered polymer materials, including:

  • Cold friction processing technology — converting composite plastics into pellets that serve as low-carbon concrete aggregate substitutes.

  • Shredding and optical sorting technology — transforming materials into flakes for extrusion into new manufacturing products, such as construction panels and consumer goods.

These solutions allowed the client to close the loop by reintroducing recovered plastics into local manufacturing, reducing environmental impact, and creating new revenue-generating opportunities.

Impacts & Benefits

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100% landfill diversion achieved through circular recycling solutions

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Reduced carbon footprint and measurable sustainability outcomes

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Cost savings from avoided export and waste disposal fees

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Full chain-of-custody transparency and regulatory compliance

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Support for local circular economy markets and sustainable manufacturing

Driving Circular Economy Solutions in Australia

This project demonstrates Circular Futures’ expertise in polymer recycling, waste management consulting, and sustainable product development.
 By combining R&D innovation, industry collaboration, and real-world trials, we help Australian businesses transform waste into valuable resources — driving measurable progress toward a circular economy.