Audi launches a pilot project with which the Q4 e-tron will use recycled glass

Audi is one of the brands most committed not only to making its vehicles cleaner but also to making its factories cleaner. An example of this is that in 2021 the brand managed to save more than 480,000 tonnes of carbon dioxide thanks to reducing emissions in the supply chain and, among other measures, by using green energy during the production of HV battery cells and by recycling aluminium scrap from the press shop.

Now, from Audi wants to carry out a manufacturing cycle similar to the one it uses for aluminium, but with the glass used for the windows of its vehicles. It will do so with the support of the companies associated with Audi in this project: Reiling Glas Recycling, Saint-Gobain Glass and Saint-Gobain Sekurit. Once the pilot project gets under way and the suitability of the final product is verified, Audi will begin installing this recycled glass in the Q4 e-tron.

First phase of recycling

Until now, recycling broken vehicle glass was not considered due to the higher safety requirements, so this glass, discarded after any window was broken, was reused for different purposes where the requirements are not as demanding. Audi, together with its partners, believes it is feasible to return the glass to its original quality, so the first step of this recycling begins at the brand’s dealerships.

When a piece of glass cannot be repaired, it is replaced with a new one and the broken glass is handed over to Original Teile Logistik GmbH & Co. KG, a subsidiary of Volkswagen that collects the parts the brand’s workshops no longer need. This damaged glass then goes to the facilities of Reiling Glas Recycling, who break it into very small pieces, also sorting out other non-glass materials such as the PVB plastic layers, window edges, metals and cables, such as the heating filament and antenna cables.

Second phase of recycling

Once the glass has been processed and all possible waste materials have been removed, it arrives at the Saint-Gobain Glass facilities in Herzogenrath, Germany, to be converted into flat glass. To do this, the glass granulate is first separated by type and stored in containers, then mixed with quartz sand, sodium carbonate and chalk, among other materials.

When this granulate returns to its original form, as sheets, these are processed to be cut into rectangles of approximately 3 x 6 metres and, afterwards, they are sent to Saint-Gobain Sekurit, which produces automotive glass using an additional process that gives it its final shape and characteristics.

Third phase of recycling

Once the entire recycling process is complete, it is time for those responsible for the project involving the three companies to sit down and begin evaluating this pilot project, a pilot project that will last one year and during which they will have to learn about the quality, stability and costs of the material involved in carrying out this whole process.

After the year, if the project proves viable, that is, if the glass can be recycled economically and ecologically, this type of glass will begin to be fitted to the Audi Q4 e-tron, although the ultimate goal is undoubtedly even more ambitious: to recycle around 40 tonnes of automotive glass during the pilot project alone, so if it proves viable that figure will be significantly increased.