How JLR's New Aluminium Skin is 95% More Energy Efficient

JLR has completed successful scaled trials of a new aluminium skin alloy in collaboration with Novelis.

This innovative material is up to 85% recycled and up to 95% more energy efficient to produce compared to traditional methods.

“This is part of ongoing work by our passionate and dedicated teams in researching and developing more sustainable solutions for our next generation of luxury vehicles without compromising quality or performance,” explains Andrea Debbane, Chief Sustainability Officer at JLR.

“A fantastic result and perfect demonstration of how through collaboration, we are able to innovate and drive circularity forward.”

JLR and Novelis: A longstanding relationship

The development of the new aluminium skin alloy marks another successful chapter in JLR’s long-standing collaboration with aluminium recycling giant, Novelis.

Notably, in 2008, JLR and Novelis pioneered the REALCAR project, which resulted in Europe’s first closed-loop recycling system.

This system allows aluminium scrap from vehicle production to be collected, recycled by Novelis and reused in new car bodies, significantly reducing the need for primary aluminium — which is more energy intensive to mine and process.The use of Novelis Advanz 5F-s5754 RC alloy, which can be made entirely from recycled material, began with the Jaguar XE and now encompasses all JLR models.

To maximise efficiency and sustainability, this process includes a unique round-trip railway service between Germany and the UK.

The implementation of this closed-loop system has not only saved more than US$1m but also slashed CO₂e emissions by 80% compared to standard road transport.

JLR’s Reimagine strategy for sustainability

JLR’s Reimagine strategy aims to transform the company into a carbon net zero business by 2039.

There are four pillars to this strategy:

• Modern luxury
• Electrification
• Sustainability
• Enterprise

As part of its commitment to the environment, JLR is investing heavily in facility upgrades to focus on electrification and decarbonisation.

By 2030, all models in the Range Rover, Discovery and Defender collections will have 100% electric options and the Jaguar brand will transition to being entirely electric.

To support this transition, JLR has also upskilled more than 25,000 of its colleagues and partners in electrification and digital technologies through its Future Skills Programme.

Novelis' Commitment to Sustainability

“Sustainability has been core to Novelis since our founding,” the company says.

“Our fierce commitment to environmental stewardship defines who we are, what we do and why we do it.”Since 2016, Novelis has achieved a 27% reduction in absolute carbon emissions across Scopes 1, 2 and 3 and includes an average recycled content of 63% in its aluminium rolled products.

By 2030, the company aims to increase this figure to 75% by forging strategic partnerships and continuing to develop new technologies.

One exciting development is the successful trial of using hydrogen fuel to power a recycling furnace at its Latchford plant in Warrington, UK, reducing CO₂e emissions by up to 90% in the process.

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