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TRILUX and the metal processing specialist OTTO FUCHS KG have developed a new recycling process for aluminium since 2024. In the joint research project, the feasibility of the process was demonstrated and analuminium profile made from 100% recycled material for a luminiare was created.
The new recycling process eliminates the need to remelt the aluminium scrap. As a result, the aluminium briquette achieves a COâ‚‚ footprint of less than 0.2 kg COâ‚‚e per kilogram of aluminium (source: Screening LCA based on ISO 14040/14044, Cradle-to-gate). The value refers to 1 kg of an ingot, i.e. the primary material for the extrusion of an aluminium profile.
Some of the aluminium comes from old luminaire louvres that TRILUX collects from customers in the field (post-consumer material). The collection takes place in the DACH and BENELUX areas in order to keep transport routes sufficiently short. The aluminium of the specular louvres is mixed with aluminium chips that are produced during production processes at OTTO FUCHS (pre-consumer material). The optimum mixing ratio was determined experimentally in the research project.
To prepare the louvres, the steel clamps that were used for fastening are removed. The material is then shredded into chips.
The two source materials are mixed in a fixed ratio and compressed into a briquette.
The briquette is then heated to extrusion temperature and pressed through a die. This gives the profile its final contour. Under pressure and temperature, the chips form a bond.
The new recycling process with subsequent anodising creates an aluminium profile with a finely structured surface. In this way, aluminium's recycling past remains confidently visible.
In the research project, a pendant luminaire system was developed as a prototype. The ceiling canopy and luminaire housing are made of the newly developed recycled aluminium. Modifications of the prototype are available as a bespoke luminaire.
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