Automotive recyclers strive to utilize as many elements of an end-of-life vehicle as possible. To separate various components of autos, recyclers need to dismantle vehicles in a streamlined, effective and safe manner.
Environmental engineer and sustainability consultant at Green Hive, Cristina Solis said that technology continues to play a key role in end-of-life vehicle recycling.
“In the past, car leftovers like plastic, glass and textiles were discarded, and scrapyards mainly served as a source of spare parts for amateur mechanics. Today, the industry has improved and the dismantling process is conducted by skilled mechanics,” Solis said. Indeed, specialized tools have made the dismantling process more efficient and safer, while sustainable practices have been adopted, thanks to technology.
As Solis pointed out, this includes energy efficient machinery, waste reduction, and a lower carbon footprint due to improved logistics throughout the entire dismantling process.
Steve Mott is the vice president at Greenwave Technology Solutions, Inc. and owner of Scrap App, which purchases and scraps tens of thousands of junk cars every year. Greenwave recently commenced operations on a downstream processing system to recover millimeter-minus metals from automotive residue produced when shredding cars.
“This has significantly boosted recovery yields, revenues and margins from our car recycling operations,” Mott said. “As Greenwave continues to optimize the operation of its downstream processing system and brings a copper extraction component online, revenues generated by its downstream processing will rapidly expand our margins.”
Dismantling Safety Concerns
Technology aside, there are several big safety concerns surrounding the auto dismantling process within recycling facilities. In Mott’s opinion, lithium batteries present a significant fire hazard. Additionally, if oils or gas are still in the car when it goes through the automotive shredder, they could catch fire and cause injuries.
Solis added that employees interact with machinery, chemicals and tools, elevating the risk of on-the-job injuries. Within the dismantling process, dangers range from moving engine parts and electrical shocks to burns and eye injuries. In addition, the physical demands of the job, such as lifting heavy items, pose risks like musculoskeletal issues and eye injuries are common due to falling debris and chemicals, especially when working under cars.
End-of-life vehicles also are filled with flammable liquids, the handling of which can result in chemical burns, and the use of power tools increases the risk of losing a limb.
“Slippery floors from greasy liquids add to the hazards, as do fire and explosion risks from handling fuel,” Solis said.
Establishing Safety Protocols
It is paramount that auto recyclers establish solid safety protocols, especially for the dismantling process.
“They should familiarize themselves with safety guidelines at local, state, and federal levels, carry out a detailed analysis of the facility to identify potential hazards, and consistently update an emergency action plan that covers various crisis scenarios, such as fires and chemical spills,” Solis said. To help identify the best safety protocols to put in place, the Occupational Safety and Health Administration (OSHA) offers comprehensive online resources for maintaining employee safety and regulatory compliance.
For example, chemical labeling should also adhere to OSHA standards, including the inclusion of specific elements like pictograms, hazard statements, a warning word such as “danger,” as well as safety handling instructions and emergency procedures.
When it comes to establishing safe dismantling practices, Solis pointed to several key guidelines that should be followed. First and foremost, protective gear such as goggles, gloves, and ear protection should always be worn, tailored to the specific type of repair being conducted.
“Disconnecting the battery is crucial when working on electrical systems to prevent electrical hazards,” Solis said.
Employee training is another vital component of auto dismantling safety. Auto recyclers and their employees should be educated about proper operating procedures, including using safety shields and wearing protective gear. Certification programs further validate an employee’s competence in adhering to auto recycling industry standards and best practices that have been established within the auto recycling industry.
Greenwave has invested significant resources ensuring its employees are well trained. “We maintain an effective safety system and regularly update it while ensuring our equipment is well-maintained and utilized in accordance with our policies,” Mott said.
Of course to capture the ever-increasing types of material used in vehicles today, it is important for auto recyclers to dismantle vehicles to ensure the variety of metals can be sorted and sold for the best value.
Throughout the entire dismantling process, specific paperwork must be completed, including all vehicle records, waste check sheets, waste disposal records and certificate of destruction to name a few. Again, the regulations mandated by an automotive recycler’s location will indicate exactly the type of information the dismantler must record.
Streamlined Efficiencies
As with any complex procedure within the auto recycling industry, there are some common mistakes that auto recyclers should try to avoid when dismantling vehicles. Solis said these include not having a well-defined emergency response plan to not providing or enforcing the use of appropriate PPE, like gloves, goggles, and ear protection.
Also, overlooking critical safety procedures, such as neglecting to disconnect the battery, failing to adequately secure the vehicle, or omitting the use of essential PPE are also common mistakes that recyclers make. Addressing safety challenges in dismantling autos requires a proactive approach on the part of employers and employees that includes knowledge about hazardous materials management, adherence to PPE guidelines, and proper training coupled with certification programs.
Industry experts state that by prioritizing these measures, auto recyclers can create a safer working environment for those involved in this industry while minimizing potential risks associated with auto dismantling operations.
Looking ahead, Solis believes the dismantling process will be fueled by technological advancements and changing automotive paradigms.
“The rise of electric vehicles is adding a new layer of complexity to auto recycling, particularly in the area of lithium-ion battery recycling,” Solis says. “The industry will increasingly shift its focus towards not only the efficient extraction of valuable metals like lithium, cobalt, and nickel, but also towards the innovative refurbishment of partially damaged batteries.”
It is expected that automation and robotics will cease to be mere science fiction and will become essential elements in future auto recycling facilities.
“Programmed for precise execution, these robotic systems will revolutionize the extraction of valuable components like engines and airbags from vehicles,” Solis said.
Safety training also is expected to undergo a technological transformation, as virtual reality (VR) and augmented reality (AR) become standard tools for workforce development.
“These immersive technologies will provide a secure, virtual environment where workers can refine their dismantling skills, consequently minimizing the likelihood of accidents in real-world settings,” Solis commented.
Mott also expects that an increasing number of fluids in the car, along with tires, will soon be recycled. “Then, components that typically generated a disposal cost will instead generate a new revenue stream,” Mott said.