“In 2019, our company embarked on an ambitious journey: to revolutionise the recycling industry and support the flat steel sector while addressing the environmental demands of the European Green Deal. With industries across the board mandated to reduce CO2 emissions, we focused on creating solutions to help the steel industry achieve more CO2-neutral production today,” says Christian. “This vision led to the development of TSR40, a groundbreaking product that is not only suitable for the automotive sector but also for other industries that use high-quality steel grades, and that supports them in the transformation.”
Traditional flat steel production relies heavily on virgin raw materials, constituting 80–85% of its input, with some scrap used for cooling. However, the Green Deal’s CO2 targets necessitate a shift to electric arc furnace production, increasing the demand for high-quality, clean scrap materials. This transformation is critical for industries like automotive manufacturing, where steel purity is paramount. Tramp elements such as copper must be minimized, as even a slight excess can render the steel unsuitable for high-quality applications.
Recognising these challenges, TSR set out to develop TSR40, a pure, high-quality recycled raw material derived from post-consumer materials. This new product meets the requirements of flat steel production while reducing the carbon footprint of steel manufacturing and saving energy and natural resources.
By using ELVs as feedstock, we can produce high-quality materials for new car manufacturing, effectively closing the loop in automotive recycling
Implications for the car recycling sector
By keeping ELVs within Europe, we can harness their value as feedstock for high-quality recycled steel products as TSR40. This policy shift would align with the EU’s circular economy goals and moreover ensure that valuable materials like copper are not lost in low-quality recycling processes. Christian explains: “Compared to the standard shredding process, which leaves an average copper content of 0.35 – 0.4%, our innovative recycling methods reduce this to below 0.1%. This breakthrough enables the recovery of a significant additional volume of copper through high-quality recycling. By reducing the copper content in TSR40 to less than 0.08%, we can reclaim this critical raw material, essential for modern technologies, and significantly contribute to resource sustainability”.
A benchmark in recycled steel
TSR40 sets a new standard in recycled materials, offering a high-purity pre-product that can replace virgin raw materials in steel production without compromising strength, durability, or quality. Derived from post-consumer sources, it meets the stringent specifications required for flat steel applications. Advanced quality control measures, including continuous monitoring systems, ensure consistent purity and reliability, marking a significant innovation in the recycling industry.
“Thanks to the patented production process, we can precisely adhere to the limit values for numerous secondary elements to two decimal places. This not only represents a significant advantage for the steel industry but also enables a significantly higher recycling rate in the production of quality steel using products made from post-consumer materials”, says Christian, describing the quality management processes. By emphasizing its sustainability advantages, TSR40 reduces the need to mine natural resources, saves CO2 and energy in production, and mitigates dependencies on fragile supply chains, creating a resilient and eco-friendly alternative to primary raw materials for the steel industry.
Moreover, TSR40 enables a ‘car-to-car’ economy. “By using ELVs as feedstock, we can produce high-quality materials for new car manufacturing, effectively closing the loop in automotive recycling. This innovation not only conserves natural resources but also addresses Europe’s dependence on imports, leveraging existing domestic resources to build a sustainable future.”
The transition to TSR40 is already underway. Collaborations with industry leaders like voestalpine AG and AUDI AG have demonstrated its viability. For instance, TSR40 is now one of the standard materials being used to produce the exterior roof parts of AUDI’s new Q6 Sportback e-tron. These real-world implementations underscore the potential of TSR40 to become a cornerstone of CO2-reduced steel production.
Despite the usual scepticism that accompanies change, TSR40 has received positive feedback from the industry. It integrates smoothly into existing production lines and has already demonstrated its reliability in high-quality automotive applications. This makes TSR40 a practical, sustainable, and efficient alternative to traditional materials, proving its value in real-world manufacturing environments.
A sustainable vision for the future
The development of TSR40 represents more than a technological breakthrough; it embodies a commitment to sustainability and resource efficiency. By processing ELVs into high-quality recycled raw materials, TSR is advancing the circular car economy and contributing to broader resource conservation. Alongside TSR40, TSR also recycles aluminium and copper products with the same high-quality characteristics, ensuring a comprehensive approach to material reuse. Christian concludes: “Together, we can transform end-of-life challenges into opportunities for innovation, paving the way for a cleaner and greener future in the steel, automotive, and broader recycling industries.”
TSR40 is now one of the standard materials being used to produce the exterior roof parts of Audi’s new Q6 Sportback e-tron
ARN AWARD
TSR Group GmbH & Co. KG. specializes in processing ferrous and non-ferrous metals, providing industries with high-purity recycled materials. In the Netherlands, its subsidiary HKS Metals plays a key role in metal recycling, contributing to a circular economy by collecting and processing scrap metals.
In October 2024, its innovative product TSR40 won the prestigious ARN Award, a recognition of outstanding contributions to high-quality car and battery recycling. The award was accepted by Wout Kusters, director of HKS Metals, who emphasized the importance of this innovation for reducing CO₂ emissions and making steel production more sustainable.
With the ARN Award as proof of its impact, TSR40 is paving the way for a greener, more circular steel industry.
