Vehicle Recycling & Salvage - A Guide for Fleets
Every vehicle your fleet acquires will need to be disposed of eventually. Whether it’s sold on for further use, salvaged for parts and components, or recycled back to raw materials - it’s important that the outcome is both environmentally sustainable, and cost-effective for your business.
Recycling or salvage is usually the most common outcome for these vehicles - the specific route depending on their end-of-life condition, salvage value, and age.
For this article, we’ve teamed up with SYNETIQ to provide an in-depth overview of how commercial vehicles can be recycled at the end of their lives.
“Fleet recycling is essential for businesses looking to manage their environmental impact, and recent trends highlight the growing importance of sustainable fleet management. Recycling your fleet’s vehicles not only reduces the environmental burden but also unlocks the financial value.”
Helen Carling, Commercial Director, SYNETIQ
Here we discuss the ins and outs of vehicle recycling and salvage, including the different options available to fleet operators, when they might be used, and how they work in practice.
How Vehicles can be Recycled
‘Vehicle recycling’ is a catch-all term for the processing & reuse of vehicles, their parts, components, and raw materials. Here are some of the different ways in which end-of-life vehicles are recycled:
Parts Salvage & Reuse (Green Parts)
One of the most common vehicle recycling practices is parts salvaging - the process of removing reusable parts and components from end-of-life assets for reuse in future repairs. These recovered components are often referred to as ‘green parts’, and are quality checked thoroughly for quality, safety, and compatibility before they’re shipped to and used by repairers.
Only non-safety critical parts can be reclaimed from vehicles, with the most common parts including mirrors, doors, panels, wheels, and bumpers. When reused effectively, green parts salvaging can help fleets to reduce repair time and cost - by harnessing their own end-of-life stock as an evergreen resource.
Helen Carling comments, “Our comprehensive recycling process ensures that fleet vehicles at the end of their life are handled responsibly—from safe dismantling and salvage to the recovery of quality-assured green parts.”
Raw Materials Extraction & Recycling
Raw materials recycling is the process of reverting vehicles and their components back to their raw form, such as plastics, steel or aluminium. These materials can be recycled incredibly effectively, and harnessed for reuse by manufacturers - rather than being sent to landfill.
This process can either follow parts salvage, to dispose of unused components/chassis, or can be used as a first port of call for vehicles with more serious damage (such as category A write-offs) which cannot legally have parts reclaimed for reuse.
Common products from this process include malleable plastics, rubber pellets from tyres, eco sand from glass, or raw metals from panels, chassis, and wiring looms. These materials can then be sold on to manufacturers for reintegration - promoting a completely circular automotive supply chain.
Battery Recycling (EVs)
With the growth of electric and hybrid vehicles in today’s automotive market, battery processing and recycling has become a critical focus for salvage experts. EV batteries contain incredibly valuable and useful raw materials - like lithium, cobalt, and nickel - which can be extracted and reused for a variety of purposes.
Crucially, disposing of EV batteries incorrectly poses extremely hazardous consequences for the environment, and future developments on affected land. It’s for this reason that the recycling supply chain is increasing its focus on developing new and more effective methods for processing and refining battery materials, and ensuring any waste is disposed of responsibly.
However, there’s still some way to go before EV battery recycling becomes a completely circular practice, whereby all their materials can be extracted and reused effectively. The processes currently in use by many suppliers, such as pyrometallurgical recycling, still leave some degree of waste material behind - notably lithium, which can be a challenge to separate from the other metals. They’re also incredibly energy-intensive, due to the need for heat and heavy machinery, meaning they pose environmental concerns of their own.
Helen Carling of SYNETIQ comments, “According to the Society of Motor Manufacturers and Traders (SMMT), 2023 saw a record number of zero-emission light commercial vehicles (LCVs) enter service”
“This shift toward electric fleets underscores the importance of efficient end-of-life vehicle recycling and the role of businesses like SYNETIQ in providing green solutions.”
Can all scrap vehicles be salvaged for parts?
Some vehicles aren’t suitable for parts salvaging, and therefore enter the recycling process right away - meaning all components and materials are reprocessed rather than being reused.
This includes Category A write-offs, which are deemed to have sustained such severe damage that their parts and components are unsafe for future use by repairers. However, if safe to do so, recycling experts work to ensure all materials onboard can be put to good use elsewhere, rather than ending up in landfill.
Some older or less common vehicles may also present less value for parts salvage - due to low demand for their components on the market. In this case, it’s likely that raw materials recycling is most appropriate - both from a financial perspective for the fleet, and an environmental viewpoint.
The Vehicle Recycling Process Step-by-Step:
Here’s an overview of some of the key steps usually involved in the vehicle recycling process, from identifying a vehicle’s requirements, to reducing its components back to raw materials…
1 - Salvage & Recycling Requirements are Ascertained
In majority of cases, the vehicle will have already been categorised by the insurer by the time it arrives at the salvage yard. However, recycling experts, such as SYNETIQ, can conduct a quality check to determine the category status, and salvage requirements.
This check is carried out by a AQP qualified engineer who will assess the level of damage and eligibility for green parts reclaimation.
2 - Depollution & Dismantling Takes Place
If the vehicle is a category B, it means it can be dismantled for parts and the remaining components can be recycled. The first step at this stage is to remove all fluids and hazardous materials.
Crucially, this process ensures that any fluids or materials which may be environmentally harmful are removed, and processed responsibly to avoid ecological damage.
Fluids like fuel, oil, and coolant can often be reclaimed, cleaned, and reprocessed for future use - so effectively, in fact, that many manufacturers use them in brand-new vehicles.
3 - Tyres Can be Reused, or Recycled into Rubber Crumb
After the vehicle has been dismantled, it’s time for all eligible parts and components to be reprocessed - the specific method depending on their condition and material makeup.
Tyres, for example, may either be restored and reused, or refined into rubber crumb - depending on their remaining tread depth and condition at the point of recycling.
The rubber crumb produced from reprocessed tyres can be used as a sustainable resource in construction and manufacturing, directly combating the deforestation and pollution produced by agricultural rubber harvesting.
4 - Alloy Wheels are Processed to Extract Aluminium
Most alloy wheels found on vehicles today are made up primarily of aluminium - one of the most widely recycled materials on the planet! In fact, over 70% of aluminium ever produced is still in use today, thanks to the fact it doesn’t corrode, and is very easy to shred, melt, and recast.
The wheels are cleaned, with any trim, bolts, or rubber residue removed, before being shredded and heated to extract the raw aluminium, in a ready-to-use form for remanufacturing. This could be used to create anything from tin cans, to panels and wheels for brand-new vehicles.
Alternatively, many alloy wheels reclaimed from vehicles are often in good enough condition to be sold on for direct reuse, at enormous discounts compared to RRP of brand-new wheels.
5 - The Vehicle’s Shell and Glass are Baled
With all suitable green parts and components removed, what’s left of the vehicle is now an empty shell - with just the chassis and glass left for processing.
All wiring is carefully removed and split down into separate materials including copper, which is then sold on for recycling.
The shell is crushed into a tight square bale using a large hydraulic press. This makes the remainder of the vehicle easier to store on-site, and process in bulk to extract the individual materials in their purest form.
6 - Raw Materials are Separated using a Fragmentiser
The crushed shell of the vehicle is fed into a fragmentiser, which uses large industrial hammers to break it up into small pieces. These fragments are then fed along a conveyor, where the glass falls through small holes for collection, and magnets are used to separate out the metals.
The glass can be ground up into ‘eco sand’, often used in construction as a sustainable alternative to quarrying, while metals can be melted down for direct remanufacturing.
7 - Any Onboard Batteries are Recycled
Both batteries found in internal combustion vehicles, and in EVs & hybrids, can be recycled to reclaim the precious metals and minerals they use to generate electricity…
A. How Lead Acid Batteries are Recycled
Lead acid batteries, such as those found in ICE vehicles, are placed in a fragmentor to break them into smaller pieces, and separate the solid materials from the liquid.
The sulfuric acid is neutralised into sodium sulphate - commonly used in agricultural fertilisers and detergents. The solid fragments are then placed into a vat, in which plastics float to the top, and lead sinks to the bottom - allowing both to be reclaimed, heated, and processed for remanufacturing.
B. How Lithium Ion (EV) Batteries are Recycled
Lithium-ion batteries, such as those found in EVs, are first fully discharged, before being safely dismantled. The plastic casing and connectors are removed and recycled, leaving behind the core cells - which contain the valuable raw materials.
These cells are broken down into smaller pieces, and shredded into fragments. Magnets are then used to separate out the more precious materials. What remains is a powder known as 'black mass,' which contains lithium, cobalt, and nickel.
This powder is then sent on to specialist refineries, who use a range of methods to attempt to refine the composite materials back to their purest form. The results of this process can vary significantly with current available methods, although global recycling experts are working closely with manufacturers and industry partners to develop more efficient recovery methods.
8 - Catalytic Converters Recycled for Precious Metals
Catalytic converters contain a number of precious metals, which are an incredibly valuable resource for manufacturers.
These include platinum, palladium, and rhodium - one of the world’s rarest and most desired metals. These materials can be easily separated and reprocessed, and used for all sorts of purposes; from producing precious jewellery, to electronic devices, or even dental crowns!
9 - Wiring Looms & Electronics are Recycled
The vast array of wires and electronics found onboard modern vehicles are a valuable resource for materials like copper, and even gold. During the recycling process, wiring looms and electronics are removed, and processed to reclaim the raw metals and plastics for future use in manufacturing.
Wires are stripped, coiled, and melted down, while complex circuitry is fragmented, and passed through a density separator to isolate the different materials. The acrylics used in circuit boards, and insulating rubber from wires, are recycled as well as the metals.
10 - Some Core Components can be Remanufactured
Some core components, like engines and gearboxes, can actually be remanufactured to restore them to usable condition, and fitted as replacements on vehicles that need them.
This usually depends on the age of the vehicle, and the projected value of these core components at market. If they’re unsuitable for remanufacturing, these parts can also be dismantled, shredded, and broken down to extract their raw materials for recycling - ensuring minimal wastage in any scenario.
How much of a scrap car is actually recycled?
Regulatory targets in the UK, EU, and United States currently require that 95% of total materials (by vehicle weight) are recovered and recycled from end-of-life vehicles. These targets are accompanied by stringent framework for everyone from manufacturers to breakers, governing how vehicles should be designed, produced, and disposed of in order to promote maximum, safe recovery of their raw materials.
This framework seeks to ensure that vehicles are built from the ground up with material recovery in mind, making the job of salvage agents easier, less hazardous, and more beneficial to the environment.
Sustainable Fleet Asset Disposal with sopp+sopp
Chris Beeby, Director of Business Development:
"At sopp+sopp, we understand that sustainable asset disposal goes hand-in-hand with protecting our clients' brand reputation. By working closely with industry-leading recycling partners, we ensure that every vehicle is managed with precision – from secure removal of branding to the responsible recycling of components.
“Our approach not only minimises environmental impact, but also helps fleets build a sustainable, circular supply chain that aligns with their long-term financial and reputational goals."
sopp+sopp’s in-house engineering team are driven by commercial vehicle expertise, and work closely with our sale, salvage, and recycling partners to ensure every end-of-life vehicle is handled with both cost & environmental efficiency in mind.
Whether the vehicle being disposed of is a total loss, or simply a previous-generation asset, we work with our fleet partners to ensure a risk-averse disposal process that aligns with their financial and environmental goals.
Working with Industry-Leading Recycling Partners
We’re proud to say that our vehicle recycling partners currently work ahead of the European End-of-Life Vehicle Directive, achieving recycling rates above 96% of total vehicle materials. Our partners are fully accredited in safe & secure asset disposal across all vehicle types, and share our commitment to helping fleet operators reduce the environmental footprint of every vehicle’s lifecycle.
As Helen Carling from SYNETIQ explains, “At SYNETIQ, we are committed to driving sustainability in fleet management through innovative vehicle recycling solutions.”
“We surpass the European End-of-Life Vehicle Directive, leading the way in reducing waste and promoting a circular economy.”
Total Loss Salvaging & Green Parts Ringfencing
Through our sister company, Activate Parts, we source parts through suppliers such as SYNETIQ, and work with fleets to help them make direct use of ‘green’ parts and components reclaimed from their end-of-life vehicles.
Through our ‘total loss ringfencing’ solution, we can proactively identify assets which may be eligible for parts salvage, and work with our partners to dismantle them, and store their parts on-site for use in future repairs.
This not only helps our customers to reduce future repair outlay, and parts turnaround, for similar vehicles - but also means they’re able to build their own circular parts supply chain in-house, enhancing their sustainability commitments.
Protecting your Brand’s Reputation
Before sopp+sopp releases any vehicle for salvage or recycling, we harness our network of UK bodyshops to securely remove any branding, liveries, telematics, and company equipment - shielding your brand’s reputation. We always provide visual proof that this process has been followed, giving you peace of mind that your end-of-life assets are disposed of with consideration and care.
Learn more about our secure & sustainable fleet vehicle disposal solution here: