End-of-life vehicles (ELV, End of Life Vehicles) are a major source of recyclable metals: steel in the body, copper in the electrical system, aluminum in components. An ELV automotive recycling line processes pre-treated bodies through shredding, then automatically separates the metals through magnetic and eddy current separation, recovering steel, copper, and aluminum at high purity from each vehicle processed.
An ELV automotive recycling line is the choice of authorized auto dismantlers and vehicle recycling centers that want to maximize the recovery of metals from car bodies. Processing in accordance with ELV regulations ensures environmental compliance and the material recovery required by European directives. See the full range of recycling equipment and the solutions for vehicle recycling.
Key Advantages for Shredding End-of-Life Vehicle Bodies
• Complete body processing, shreds pre-treated bodies and automatically separates the recoverable metals.
• Shredder sized for bodies, the capacity to process whole pre-treated bodies, reducing them to processable fractions.
• Magnetic separation for steel, recovery of the steel from the body, the largest fraction by mass.
• Eddy current for copper and aluminum, recovery of the valuable non-ferrous metals from the electrical system and components.
• ELV compliance, the process meets the material recovery requirements of the ELV directive.
• Separated light fraction (ASR), separation of the light fraction (plastic, textiles, foam) from the metal fractions.
• Three sellable metal fractions, steel, copper, aluminum, each at its market price.
• PLC control, automated flow with monitoring and reporting of recovered materials.
Technical Specifications, ELV Automotive Recycling Line
| Parameter | Value |
|---|---|
| Feedstock | Pre-treated ELV bodies (no fluids, tires, battery) |
| Stage 1, Shredding | Shredder for bodies, reduction to fractions |
| Stage 2, Magnetic separation | Steel recovery |
| Stage 3, ASR separation | Light fraction separation (plastic, textiles) |
| Stage 4, Eddy current | Copper and aluminum separation |
| Recovered products | Steel, copper, aluminum; light fraction (ASR) |
| Compliance | ELV recovery requirements |
| Control | PLC, continuous flow, material reporting |
| Components | CE marked where applicable |
Applications for Recovering Metals from Vehicles
An ELV automotive recycling line is used by authorized auto dismantlers, by vehicle recycling centers, and by operators who process large volumes of end-of-life bodies. Vehicles contain a significant amount of metals: approximately 65 to 70% steel, plus valuable copper and aluminum, all recoverable through an appropriately sized shredding and separation line.
The recycling of end-of-life vehicles is strictly regulated in Europe through Directive 2000/53/EC on end-of-life vehicles, which sets targets for the recovery and reuse of materials. For integration into a complete ELV-compliant flow, see also the complete industry solutions.
Pre-treatment of the bodies before shredding is mandatory under the ELV directive: removal of fluids (oil, fuel, coolant, brake fluid), tires, the battery, and other hazardous components. Only after this depollution can the body enter the shredder. The line processes the depolluted body, recovering the metals without the risk of contamination with hazardous fluids.
The light shredder fraction (ASR, Automotive Shredder Residue), made up of plastic, textiles, foam, and rubber, is separated from the metal fractions. Managing this light fraction is a requirement of the ELV directive; its automatic separation allows separate treatment or use, while the clean metal fractions go to smelters.
Steel recovery represents the largest fraction by mass: the body is predominantly steel, recovered through magnetic separation at high purity. The recovered steel is sold to steelworks for re-melting, closing the material cycle. At large volumes of bodies processed, the recovered steel represents a constant and significant revenue stream.
The recovered copper and aluminum, although in a smaller quantity than steel, have a much higher unit value: the copper from the electrical system and the aluminum from components (wheels, engine blocks in some vehicles) sell at premium prices. Their automatic separation through eddy current captures this value, which would otherwise be lost in the mixed waste.
Materials Recovered from Bodies
| Fraction | Approximate percentage / Notes |
|---|---|
| Steel | 65 to 70% of the body mass |
| Copper | Electrical system, component motors |
| Aluminum | Components, sometimes wheels, engine blocks |
| Light fraction (ASR) | Plastic, textiles, foam, rubber |
How It Works
1. The pre-treated (depolluted) bodies are fed into the shredder.
2. The shredder reduces the body to fractions of a few centimeters.
3. The magnetic separator extracts the steel, the largest fraction.
4. The light fraction separation system extracts the ASR (plastic, textiles, foam).
5. The eddy current separator separates copper and aluminum from the non-ferrous fraction.
6. The metal fractions and the ASR are collected separately; the materials are reported.
The PLC system coordinates the flow and reports the recovered quantities, useful for ELV compliance. A correctly sized ELV automotive recycling line recovers steel, copper, and aluminum at high purity from each body, maximizing value and meeting the ELV recovery targets.
Frequently Asked Questions
What pre-treatment do bodies require before shredding?
Under the ELV directive, bodies must be depolluted before shredding: removal of fluids (oil, fuel, liquids), tires, the battery, airbags, and other hazardous components. Only the depolluted body can enter the line, to avoid contamination of the metal fractions and environmental risks.
What is the ASR fraction and how is it managed?
ASR (Automotive Shredder Residue) is the light fraction resulting from shredding: plastic, textiles, foam, rubber. The line separates it from the metal fractions. Managing ASR is an ELV requirement; it can be treated thermally, used for energy recovery, or processed further to recover residual materials, in accordance with local regulations.
What percentage of materials is recovered from a body?
The metal fractions (steel ~65 to 70%, plus copper and aluminum) represent most of the recoverable mass. The ELV directive sets recovery and reuse targets of up to 95% of the vehicle mass. A line with complete separation contributes greatly to reaching these targets through the efficient recovery of metals.
How many bodies per hour can it process?
The capacity is configured according to the project, from a few bodies per hour to larger industrial capacities. The sizing of the shredder and the separators is done according to the volume of vehicles processed and the recovery requirements. The exact capacity depends on the chosen configuration.
Why URSTAG?
URSTAG is a premium brand of recycling equipment, with over 15 years of experience. You don't just get a machine, you get a solution engineered by specialists, built from top-tier components and backed by a team that supports you from design through commissioning.
• European engineering, every machine and every complete line is designed by our engineering teams in Europe, with a focus on reliability, safety and energy efficiency.
• Premium components, we build on motors and automation from industry leaders: Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli.
• Over 15 years of experience, we know how materials and machines behave in real-world operation, and we configure each solution for your flow and volume.
• New equipment, configured for you, we supply new units, made to order for your application, with complete technical documentation.
• Delivery, installation and training included, we handle transport, commissioning and operator training, with support throughout the equipment's life.
As a premium brand, URSTAG relies on European engineering, top-tier components and experience. You choose a partner that supports your production long term, with equipment built to run reliably in demanding industrial environments.
