JLR has made a significant technical breakthrough in the closed-loop recycling of polyurethane seat foam from its used vehicles by successfully reintegrating it back into the production of new seats.

In collaboration with Dow’s MobilityScience material innovations and global leader in automotive seating Adient, this is the first time closed-loop seat foam content has been successfully used in automotive production.

Luxury vehicle manufacturer JLR is now putting the material through its full production process aiming to test its use at scale in pre-production vehicles early next year.

Polyurethane foams are known to be challenging when it comes to recycling and are designed for durability, meaning they end up in landfill and can remain in the environment for several generations. By creating a closed-loop supply chain, JLR will be able to reduce emissions, eliminate waste and enable a secure supply of low carbon seat foam for its vehicles.

The recycled foam will be one element to a new ‘circular seat’ that it is estimated will half CO2e emissions impact while maintaining high performance, avoiding over 44kg of CO2e per seat, the equivalent of charging almost three thousand smartphones.

Andrea Debbane, Chief Sustainability Officer, JLR said: “I am so excited about the potential of this way of working. It represents a collective commitment to doing things differently, challenging us to rethink our approach from all angles to find the solutions needed to design and build the cars of the future.”

“Close collaboration with experts from the recycling and materials science industries, with our supply chain partners, and colleagues from design and engineering is key – we need to work as a collective value chain to unlock meaningful change at scale. The knowledge and applications found demonstrate that full circularity is feasible and as a business this is critical to our transition.”

Jon Penrice, Mobility President, Dow said: "This collaboration highlights Dow's MobilityScience initiative to drive sustainable mobility through advanced material science. By leveraging our expertise and collaborating with Adient and JLR, we are developing technologies that support our net-zero carbon emissions and our circular and renewable solutions goals. Through Dow's RENUVA™ sustainability program, Dow addresses the growing demand for recycled materials by converting End of Life waste into new raw circular materials, helping our customers meet their recycled content targets. Through chemical and advanced recycling processes, this breakthrough depolymerization closed-loop recycling solution meets the requirements and maintains the superior comfort and quality of JLR seats.”

Mick Flanagan, Vice President Customer Group at Adient said: “At Adient, we are proud to lead the change in integrating closed-loop recycled materials into our seating solutions. Our collaboration with JLR and Dow not only showcases our commitment to sustainability but also demonstrates how innovative partnerships can drive significant advancements in the automotive industry. By leveraging recycled polyurethane, we are setting new benchmarks for environmental responsibility while ensuring our products deliver the luxury and comfort our customers expect.”

The breakthrough is a result of ongoing research and testing at JLR’s Circularity Lab in Gaydon, which aims to reduce waste and boost the recyclability of its luxury vehicles.

JLR’s Circularity Lab aims to troubleshoot these challenges by bringing together cross-disciplinary squads comprising sustainability, engineering, procurement and design. The teams disassemble vehicles in a collaborative ‘learn through doing’ approach, working closely with suppliers and experts in materials to understand and overcome the barriers to reuse and recycling.