Bosch, MKV Kunststoffgranulate and HolyPoly lead the way in the circular economy for power tools
Bosch, MKV and HolyPoly close the loop for power tools: no compromises on quality and durability in pilot project
- As part of a pilot project, Bosch Power Tools is recycling technical plastics from used power tools in collaboration with HolyPoly GmbH and MKV GmbH Kunststoffgranulate.
- The UniversalImpact 800 special edition features an impressive 78 % recycled housing material*.
- Bosch is recovering high-quality, virgin-grade technical plastic from recyclates.
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 together with HolyPoly GmbH and MKV GmbH Kunststoffgranulate, 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 high durability or resistance – are currently mostly incinerated rather than recycled. These plastics are often stronger and more resilient than others and are therefore primarily used in machinery, automotive parts, or electronic devices.
Because adapting established recycling processes to the specific requirements of technical plastics is complex and not yet economically viable, the recycling chain currently focuses heavily on metal recovery. A significant portion of the CO₂ emissions of power tools comes from the materials used in production. Bosch recognized the potential to reduce its carbon footprint and envisioned creating a closed material cycle for technical plastics from power tools – paving the way for a true circular economy in this segment.
"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.
The Vision: Recycling Without Compromise
The biggest challenge of the project was ensuring material quality. Power tools require plastics that can withstand changing thermal stresses and impact loads occurring during drop tests. Plastics typically available as recyclates often cannot meet these requirements or are not available on the market in the necessary quality or color.
The goal of the pilot project was therefore to produce a special edition of the UniversalImpact 800 whose housing* contains the highest possible proportion of recycled technical plastic from end-of-life devices – without compromising appearance, haptics, or Bosch’s well-known quality standards. In addition, the recyclate had to integrate seamlessly into Bosch’s regular production lines, since mass-production viability under standard industrial conditions was a key requirement from the start.
"The challenge was to achieve series-production 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 these challenges, Bosch adopted a multi-stage approach. An initial feasibility study examined technical viability and economic parameters, focusing particularly on the availability of target plastics such as PA6 in sufficient quantity and quality.
For this study, several thousand discarded power tools were collected, disassembled, and analyzed in detail, generating over half a million data points stored in a database. This data-driven pre-sorting ensured that only technically suitable and legally compliant plastics were selected for further processing.
The UniversalImpact 800 Closed-Loop Edition
Based on the findings of the feasibility study, an innovative recycling process was developed for the special edition of the UniversalImpact 800. Old electrical devices were collected, pre-sorted, and processed to produce a small pilot batch that meets Bosch’s stringent product standards.
"In fact, we were able to process the material directly without additives or additional glass fibers," comments Thomas Hampel. "The glass-fiber-reinforced plastic obtained in this way meets all the quality requirements we also apply to virgin material."
A Pioneering Pilot Project
The UniversalImpact 800 Closed-Loop Edition has become a pioneering example of circular economy in the power tool industry. This is further confirmed by TÜV Süd, which certified the closed loop.
The 22 % not included in the loop come from components such as switches, chucks, and soft-grips, which are made from different or differently colored plastics. The pilot project provides valuable insights into material procurement timelines, usable material quotas, and the effects of additional process steps on planning and scheduling – forming a foundation for potential future recyclate-based projects.
* All externally visible components of the main product, excluding cables and accessories.
About HolyPoly
HolyPoly offers brand manufacturers comprehensive consulting, development and production services on the path to a circular economy. The mission of the impact business is to make plastic recycling a matter of course and to work with brands to bring recycled products into series production. Customers of HolyPoly include well-known brands such as Mattel, Bosch, NUK and Lamy.
