Bosch shows the way in the circular economy for power tools

Bosch has successfully completed a pilot project on the circular economy for plastics from discarded power tools. With the Closed-Loop Edition of its UniversalImpact 800 impact drill, Bosch presents a pioneering approach, demonstrating that the recycling of technical plastics for the housing* of demanding products is possible.

The project, implemented by Bosch in collaboration with strong partners, provides important answers to central questions concerning the circular economy in the power tool industry.

Untapped Potential in Plastic Recycling

Power tools from Bosch stand for high-quality and durability. However, even these products eventually reach the end of their lifespan after years of intensive use. The technical plastics in these devices – special plastics with properties, such as being especially durable or resistant – are currently mostly incinerated rather than recycled. These plastics are often stronger and more durable than other plastics and are therefore primarily used in machines, cars, or electronic devices. However, because adapting established recycling processes to the specific requirements of technical plastics is very complex and thus far not economical, the focus in the recycling chain currently lies heavily on recovering metals. Typically, a large proportion of the CO₂ emissions from power tools comes from the materials used in production. Bosch recognized the potential here to reduce its own CO₂ footprint and had the vision to develop a material cycle for technical plastics from power tools, thereby showing the way for the circular economy in power tools. "With this project, we are demonstrating that we can indeed circulate technical plastic. The project targets several key areas of our sustainability strategy: responsible material use, circularity, and CO₂ reduction," explains Anne Purper, Circular Economy Project Manager at Bosch Power Tools.

Bosch's Vision: Recycling Without Compromise

The biggest challenge of the project was ensuring material quality. Power tools require plastics that can withstand both changing thermal stresses and impact loads occurring during drop tests. Plastics that are currently typically recycled often cannot meet these requirements or are not available in the necessary quality and color on the market. The goal of the pilot project was therefore to produce a special edition of the UniversalImpact 800 impact drill, whose housing* consists of the largest possible proportion of recycled technical plastic from old devices, without compromising on appearance, feel, and the well-known Bosch quality. In addition, the recyclate should be seamlessly integrated into regular production lines, as Bosch had a regular production under normal industrial conditions in mind from the beginning. "The challenge was to achieve a seriesproduction quality for our special edition based on old devices – this was completely new territory, without established standards or years of practical experience," explains Thomas Hampel, Sustainability Expert at Bosch Power Tools.

Creating an Extensive Database Paves the Way

To overcome all challenges, Bosch adopted a multi-stage approach. An initial feasibility study illuminated the technical viability and initial economic framework conditions. The focus was placed on the availability of target plastics, such as PA6, in sufficient quantity and quality. For this feasibility study, several thousand discarded power tools were collected, disassembled, and comprehensively analyzed. This generated over half a million data points, which were recorded in a database. This data-driven pre-sorting ensured that only technically suitable and legally approved plastics were used for subsequent steps.

The UniversalImpact 800 Closed-Loop Edition

For the special edition of the UniversalImpact 800, an innovative recycling process was then developed based on the insights from the feasibility study. Leveraging this study, old electrical appliances were collected, pre-sorted, and processed to ultimately produce a small-volume pilot product at the end of the cycle, one that meets the high standards of a Bosch power tool. "In fact, we were able to process the material directly without additives or additional glass fibers," comments Thomas Hampel, adding, "The glass-fiber reinforced plastic obtained in this way meets all the quality requirements that we also demand of new material."

Bosch’s Pioneering Pilot Project

Bosch's UniversalImpact 800 Closed-Loop Edition has become a pioneering example in the circular economy. This is further affirmed by the TÜV Süd certification of the closed loop. The 22 % not included in the closed loop are attributed to components such as switches, chucks, and soft grips, as these consist of other plastic types or were colored differently. The pilot project provides valuable key figures on the duration of material procurement, the proportion of usable material, and the impact of additional process steps on timing and planning, thus creating a first step for any potential future projects involving recyclates.

_{*All externally visible components of the main product, excluding cables and accessories.}