Research project on sustainable material recycling

The research project focuses on the question of how aluminium from the louvres of old luminaires can be converted into new housings for LED luminaires in the most efficient and high-quality way possible. Feasibility, CO₂ savings potential, product quality and marketability were analysed. The aluminium used was prepared by TRILUX for the recycling process and then further processed in the modern facilities at OTTO FUCHS. A process is used in which the aluminium is not melted – an aspect that has a particularly positive effect on the carbon footprint. For comparison: While so-called low-carbon primary aluminium (aluminium that is produced in a particularly resource-saving way, e.g. by using green electricity) has a global warming potential (GWP) in the range of 4 kg CO₂ equivalent per kilogram of aluminium, the primary material in the recycling process examined has a GWP of only approx. 0.1 kg.  

The material tests also show that the newly manufactured aluminium profiles meet all the basic requirements for use as luminaire housings. Various processes were tested for surface finishing – with a clear tendency towards anodising, as it fully preserves the recyclability of the material. 

"TRILUX and OTTO FUCHS KG are delighted to implement a project together which deals with the responsible use of resources. The results so far show that sustainable material cycles can be realised in lighting technology – even if further steps are still necessary," says Sebastian Trägner, CTO at TRILUX. "The close cooperation with TRILUX enables us to contribute our recycling expertise specifically to the development of sustainable applications. We see great potential in the material recycling of aluminium – even beyond this project," adds Dr Sebastian Wurth, Development Engineer at OTTO FUCHS.

The positive insights from the first project phase have encouraged both partners to continue along the path they have begun. The next step will be to further develop the process and test it under practical conditions.