Gasgoo Munich- Covestro has officially commissioned an elastomer pilot plant in Leverkusen, Germany — one of the first facilities of its kind globally for such high-performance materials. With an investment running into the tens of millions of euros, the project leverages German expertise in chemistry and engineering to advance the company's circular vision and help Europe build a circular value chain for end-of-life elastomers.
Image Source: Covestro
The facility's technology centers on Vulkollan, a high-performance polyurethane elastomer widely used in forklift tires, railway buffer elements, automotive shock mounts, and vibration control components. Its chemical recycling process breaks down specific end-of-life Vulkollan materials into reusable chemical building blocks, achieving a recovery rate of over 90% by mass. Compared to fossil-based feedstock routes, this process can reduce the carbon footprint by up to two-thirds.
With the pilot plant now operational, the recycling technology moves out of the laboratory, allowing Covestro to test waste streams from various sources, continuously optimize the process, and gather data for future industrial-scale production. Beyond Vulkollan, the facility will also explore circular solutions for specialty cast elastomers and thermoplastic polyurethane (TPU).
Covestro is partnering with customers, recyclers, waste collectors, and logistics providers to build the collection and processing infrastructure needed for closed-loop recycling. This collaboration ensures a stable supply of end-of-life materials and controllable raw material quality, driving the establishment of an economically viable circular value chain for high-performance elastomers.
Furthermore, insights from this project will eventually be introduced to China. As one of the world's largest markets for polyurethane elastomers, China sees growing demand for Vulkollan in automotive, material handling, and smart manufacturing, alongside an increasingly urgent need for material recycling and carbon reduction. The Leverkusen pilot plant will provide a critical technical foundation and reference path for Covestro to explore localized circular solutions for end-of-life elastomers in China.
