Klass.-Nr./Class. No. 97410
February 2007 Environmental Standard for Vehicles
Recycling Requirements, Use of Recycled Material, Type Approval with Regard to Recyclability
VW 91102
Konzernnorm Descriptors: environmental standard, recycling, use of recycled material, type approval with regard to recyclability, processing, reuse Preface
. n r e v o g l l a h s n o i s r e v n a m r e G e h t s e i c n a p e r c s . i ) d f 0 0 o 0 e 1 s 0 a c W n V I . e e t e s a r ( u e c i c c t a c e a b r p o O t d I S e v t o e i l e g n b i r s d i o n c o c i t a a n l s i o n t a a r t t o n h l s i l a g i c n r E e e m h u T N
This standard provides guidelines guidelines for both the t he determination of the recyclability of new vehicles and the improvement of the subsequent processing of vehicle components and assemblies. The objectives of the specifications contained in this standard are: obtaining the system approval "recyclability" in the type approval process, ! meeting the legally required processing ratios, ! reducing the waste to be disposed of and the pollutant burden to the legally required minimum ! value as well as conserving energy and material resources. ! This standard contains Supplement Supplement 3: Requirements Requirements for a Processing Concept The operational framework is specified in particular by the Directive 2000/53/EC of the EUROPEAN PARLIAMENT AND OF THE COUNCIL on End of Life Vehicles (referred to as "Directive 2000/53/EC" in the following) and its national versions. All M 1 and N1 vehicle classes are concerned. Changes The following changes have been made as compared to VW 911 02, 2002-03: ! ! !
Completely revised Supplements 1 and 2 withdrawn Supplement 3 revised
Previous issues 1994-02; 1996-03; 2002-09 1
Scope
The requirements set forth in this standard pertain to !
!
! ! !
the vehicle design suitable for further processing as processing as a means for fulfilling the 2000/53/EC Directive, measures necessary for obtaining the system approval "recyclability" in the type approval process (Directive 2000/64/EC), new and recycled materials used materials used in the vehicle, in vehicle parts and in units, operating fluids used fluids used during vehicle operation, repair and maintenance as well as to the ban on using used parts in parts in new vehicles.
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6 0 . 9 0 1 4 E F m r o F
Definitions
B release
Procurement release in the product emergence process
Energy recovery
Utilization of materials for direct energy recovery excluding thermal treatment whose main objective consists in the disposal of hazardous substances. Page 1 of 5
Fachverantwortung/Technical responsibility
Normung/Standards (E2TC, 1733) Mr. Bartels Tel.: +49-5361-9-25644
K-GA/R
Mr.
Vertraulich. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group. Parties to a contract can only obtain this standard via the B2B supplier platform “www.vwgroupsupply.com”. © VOLKSWAGEN
AG
. e g a s u o t r o i r p e u s s i t n e r r u c r o f d r a d n a t s k c e h C / n e f ü r p t ä t i l a u t k A f u a g n u d n e w n A r o v m r o N
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IMDS
Internet-based input system for material data
Class M1
Vehicles for passenger transportation with no more than eight seats except the driver's seat
Class N1
Vehicles for the carriage of goods with a maximum weight of up to 3,5 tons
KSE
Design master data acquisition (German abbreviation)
KVS
Design data administration system (German abbreviation)
MISS
Intranet-based material data input and evaluation system (only for Volkswagen Intranet)
P release
Planning release in the product emergence process
PPF
Production process and product release (German abbreviation)
Recyclability
Recycling rate for new vehicles calculated in accordance with ISO 22628
RQ
=
weight used in material processing overall weight
Recycling rate Recycled material
Material (recycling material) made from waste or manufacturing residues.
Material processing/recycling
The reprocessing of waste materials for the original purpose or for other purposes (using the material properties, utilization of raw materials) which forms part of the manufacturing process. Energy recovery is, however, exempt from this reprocessing process.
Processability
Processing rate for new vehicles calculated in accordance with ISO 22628
Utilization rate
The utilization rate (VQ) is the sum of recycling rate and energy recovery rate.
VQ Reuse
3
=
weight used in material processing and energy recovery overall weight
Reuse of components with or without reprocessing for their original purpose. Requirements
On principle, the environmental objectives of the brands apply. In addition, the specifications contained in the General Environmental Performance Specifications (Volkswagen) and in the AUDI performance specifications LAH 893 060 "Environmental and Human Compatibility" shall be complied with.
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3.1
Proof of recyclability
According to Directive 2005/64/EC, a recyclability of at least 85 % and a processability of at least 95 % shall be proven in the type approval process (calculation according to ISO 22628:2002). In order for these values to be determined, weights and material specifications for all components shall be entered into the respective data processing systems until B release (see also Section 3.5.1). 3.2
Banned materials
According to Directive 2000/53/EC Article 4, Paragraph 2, materials and components must not contain lead, mercury, cadmium or hexavalent chromium except for the cases specified in Appendix II. Specific components must be marked or otherwise identified and removed when vehicles are recycled. Thus, the utilization of the aforementioned materials shall be avoided wherever possible. If such materials cannot be substituted by others, the marked components shall be easy to remove. Appendix II to Directive 2000/53/EC is changed on a regular basis in keeping with the latest scientific and technological developments. The valid version shall thus be taken into consideration. Further banned substances and substances subject to mandatory declaration are specified in VW 91101 and VDA 232-101. 3.3
Requirements for component/assembly removal
According to Appendices I and II of the Directive 2000/53/EC, all operating fluids and specified components/assemblies must be removed in the processing of vehicles. The components/assemblies concerned must be easy to remove. Complete removal of all operating fluid must be possible wherever applicable: a)
According to Directive 2000/53/EC, Appendix I, the following parts shall be removed in the further processing of vehicles: I)
Removal of batteries and liquid gas tanks,
II)
Removal or neutralization of potentially explosive components (e.g. air bags, belt tensioners),
III)
If possible, removal of all components verifiably containing mercury,
IV)
Removal of catalytic converters,
V)
b)
Removal of metal components containing copper, aluminum or magnesium if these metals are not separated during shredding,
VI)
Removal of tires and large plastic components (bumpers, dashboard, fluid containers, etc.) if the respective materials are not separated during shredding in a manner allowing raw material recycling,
VII)
Removal of glass.
According to Directive 2000/53/EC, Appendix I, the following liquids shall be removed in the further processing of vehicles:
Removal as well as separate collection and storage of fuel, engine oil, power-transmitting fluid, transmission oil, hydraulic fluid, coolant, antifreeze agent, brake fluid, air-conditioning system fluid and any other fluids contained in end-of-life vehicles. This does not apply if the fluids are required for reuse of the respective components. c)
Parts marked in accordance with the currently valid Appendix II to Directive 2005/53/EC as well as parts identified otherwise as specified in Article 4, Paragraph 1 shall be removed.
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3.4
Processing concepts
Processing concepts serving as a means for documenting the processing properties of components shall be submitted upon request. This applies in particular to !
!
! ! !
new material concepts for which no information regarding possible processing methods are available yet components to be further processed that accumulate already during the usage phase in the service garages the removal of operating fluids (see also Section 3.3.b) the removal and neutralization of pyrotechnical components (see also Section 3.3.a) heavy metal-containing components that must be removed during vehicle processing (see Sections 3.2 and 3.3.c)
Notes on the creation of a processing concept are specified in Appendix 3 to this standard. 3.5
Material data acquisition
Weights and material specifications for all components, operating fluids and the process material products remaining in the vehicle shall be recorded in material data systems for the entire vehicle in order to prove compliance with legal requirements. Products not remaining in the vehicle when it is handed over to the end customer are exempt from this regulation. 3.5.1 In order to prove recyclability in the type approval process according to EC Directive 2005/64/EC, at least the weights, materials and material grades as specified in VDA 231-106 shall be entered into the data processing systems (KSE/KVS or IMDS/MISS) until B release. VDA Volume 2, Chapter 6, "Declaration of constituents" shall be taken into consideration. 3.5.2 The material specifications entered into the data processing systems in accordance with Section 3.5.1 until B release shall be further specified for the sampling check (complete material data with basic substance specification). The International Material Data System (IMDS) shall be used by suppliers (http://www.mdsystem.com/index.jsp). The Volkswagen internal Material Information System MISS is available for in-house manufactured parts of the Production department (http://miss.wob.vw.vwg/). Requirements for material data sheets are specified in Appendix A to VW 01155. 3.6
Marking of materials
In view of the statutory requirement for component and material marking (2003/138/EC) and the type approval for motor vehicles (2005/64/EC, Appendix IV), material markings shall be applied to all polymer and elastomer components (including textiles) in accordance with VDA 260. 3.7
Use of recycled material
In view of the statutory requirement for increased use of recycled material (2000/53/EC, Art. 4), recycled material or material to which recycled components have been added shall be preferred over new material. Prerequisites for the use of recycled material: ! !
Fulfillment of quality specifications Availability for standard production
The use of recycled material shall be documented in the IMDS/MISS system under "Substances" (recyclate information).
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3.2
Components not reusable in the manufacturing of new vehicles
According to Appendix V to Directive 2005/64/EC on type approval, specified components of M 1 and N1 class vehicles must not be reused in the manufacturing of new vehicles. The following components are concerned: !
!
! ! ! ! !
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all air bags including air bag cushions, pyrotechnical components, electronic control units and sensors; if the air bag is installed in the steering wheel, the steering wheel is concerned as well; automatic and non-automatic seat belt systems including belts, seat belt buckles, belt tensioners, pyrotechnical components; seats (only if belt anchoring devices and/or air bags are installed in the seat), steering locks affecting the steering column; engine immobilizers including transponders and electronic control units; exhaust gas treatment systems (e.g. catalytic converters, particulate filters); mufflers. Referenced standards1
VDA 231 – 106
Werkstoff-Klassifizierung im Kraftfahrzeugbau - (Material Classification in Motor Vehicle Construction - only available in German)
VDA 232 – 101
Global Automotive Declarable Substance List (German version)
VDA 260
Kennzeichnung der Werkstoffe - (Marking of Materials - only available in German)
ISO 22628
Road Vehicles - Recyclability and Recoverability; Calculation Method
VW 011 55
Vehicle Supply Parts; Approval of First Supply and Changes
VW 911 01
Environmental Standard for Vehicles; Vehicle Parts, Materials, Operating Fluids; Avoidance of Hazardous Substances
Supplement 3 to VW 911 02 Requirements for a Processing Concept Directive 2000/53/EC
End-of-Life Vehicles
Directive 2003/138/EC
Marking of Components and Materials
Directive 2005/64/EC
Type-Approval of Motor Vehicles with Regard to their Reusability, Recyclability and Recoverability
VDA Volume 2
Quality Management in the Automotive Industry
1
In this Section, terminological inconsistencies may occur as the original titles are used.
