Transforming plastics for the exemplary lead battery circular economy

EUROBAT member, ACCUMALUX GROUP plays an important role in the European battery value chain, supplying plastic components for a wide range of batteries, and forming part of the circular economy of lead battery production in Europe.

Europe’s lead battery manufacturing sector boosts the EU economy by employing more than 20,000 people across 15 member states, and many more through the value chain. ACCUMALUX’s  own five production plants spanning four European countries including Russia, supported by a workforce of over  420, is one such example.

The lead battery industry has long been known as the golden standard in circular economy – almost all batteries collected are recycled at end-of-life, with more than 90% of their material being recovered. The average lead battery made in the EU today contains more than 80% recycled materials, and almost all of the lead recovered in the recycling process maintaining its intrinsic value. The lead of a battery in a new car of today was most probably already used in another car battery 50 years ago. To make these credentials even higher is a real challenge, one where  ACCUMALUX’s focus in battery casings and covers can help make the difference.

Credit ACCUMALUX Group

To enable the lead battery’s high safety and reliability profile, battery case and lid materials must have high resistance to chemicals, flammability and impact. Few materials have these properties and at the same time maintain recyclability. Polypropylene (PP) is a recyclable thermoplastic copolymer that is extremely rugged, versatile, and acid resistant. PP is widely recyclable and therefore it’s use in lead battery casings can mirror the rest of the unit’s versatility and potential for extended life.

ACCUMALUX uses over 95% of recycled PP in traction containers, with many of our automotive customers using over 80% of recycled PP for the production of battery boxes and lids. Specific grades of PP have the characteristics to be used in automotive. Of course, a thorough quality control at the recycler as well as at ACCUMALUX, using special testing equipment, has to be done to make sure the recycled PP is fit for automotive use. The push for improved outcomes from our battery recycling customers has shown in an increased demand for PP use. Even more excitingly, these customers are able to provide the PP for casings themselves from the used batteries they recycle – a true circular economy partnership.

This push for excellence in plastics is also reflected in our membership of EUROBAT, a signatory of the Circular Plastics Alliance since 2020. This commits us to boosting the EU market for recycled plastics to 10 million tonnes by 2025. Achieving this requires producing an additional 3.4 million tonnes of recycled plastics in Europe by 2025, requiring over 80% of the increase in recycled plastics to come from packaging. Alongside us, EUROBAT members are contributing to this with many using 80% recycled PP in battery boxes for traction applications.