From shredder residue to steering wheels: Porsche and BASF show how unrecyclable car waste can be reused

From shredder residue to steering wheels: Porsche and BASF show how unrecyclable car waste can be reused Photo credit: Porsche AG

(IN BRIEF) Porsche AG and BASF SE, with partner BEST Bioenergy and Sustainable Technologies GmbH, have shown that automotive shredder residue — once considered unrecyclable waste — can be turned into high-quality raw materials through chemical recycling. Using gasification, the waste was converted into synthesis gas and then processed by BASF to create polyurethane strong enough for Porsche steering wheels. The project, which eliminated fossil inputs by combining bio-based materials with waste streams, represents a step forward in Porsche’s circular economy strategy and BASF’s commitment to developing complementary recycling methods alongside mechanical recycling.

(PRESS RELEASE) STUTTGART, 30-Sep-2025 — /EuropaWire/ — Automotive waste that was long destined for incineration may now have a future as new car parts, thanks to a pilot project led by Porsche AG and BASF SE with support from BEST Bioenergy and Sustainable Technologies GmbH. The partners have successfully shown that the complex mixture of plastics, foams, films, and coatings known as automotive shredder residue (ASR) can be given a second life through chemical recycling.

Chemical Recycling, Infographic, 2025 Photo credit: Porsche AG

Instead of burning this difficult waste, the project used a gasification process to transform it into synthesis gas, which was then fed into BASF’s existing production network. From there, the gas was converted into high-grade polyurethane — material strong enough to meet the strict requirements of steering wheels in Porsche vehicles. Notably, the process did not rely on fossil raw materials. Alongside ASR, renewable feedstocks such as wood chips were used, making the trial a milestone for fossil-free recycling.

Automotive Shredder Residue, Close-up, 2025, Photo credit: Porsche AG

For Porsche, the outcome is more than a technical success. It signals a pathway toward embedding circular economy principles in future vehicle design and production. The company is pursuing strategies that extend the life of resources, integrate recycled materials into its cars, and minimize the share of waste going to incineration. “These projects show us where the next leaps in sustainability can come from,” said Dr. Robert Kallenberg, Head of Sustainability at Porsche. “We are exploring technologies that can unlock materials previously thought to be lost.”

BASF sees the pilot as proof that recycling cannot be solved with a single technology. “Mechanical recycling will remain the backbone,” said Martin Jung, President of BASF’s Performance Materials division. “But to truly cut down on incineration, we need complementary solutions like chemical recycling to capture materials mechanical processes can’t handle.”

Porsche Steering Wheels in production, 2025, Photo credit: Porsche AG

The results underline that chemically recycled raw materials can meet the same standards as conventional ones, with certifications under international systems such as ISCC PLUS and REDcert² providing accountability. For Porsche and BASF, the success is also a signal to the wider automotive industry: circularity in vehicles is achievable, even for complex waste streams once written off as unusable.

This pilot complements Porsche’s wider initiatives in sustainable vehicle production, from closed-loop battery recycling to remanufacturing of components and the integration of circular materials across its supply chain.

Circular economy at Porsche

Media Contact:

Viktoria Wohlrapp
Spokesperson Procurement and Car-IT
viktoria.wohlrapp@porsche.de

SOURCE: Porsche