As electric vehicles (EVs) surge in popularity, the importance of sustainable and efficient battery management grows exponentially. Today, there are around 30 million electric cars on the roads globally, and this number is set to skyrocket, with the volume of EV batteries projected to reach 100,000 tons by 2030. With the lifespan of these batteries ranging from 8 to 10 years, addressing their end-of-life phase is crucial—not just for environmental sustainability, but for economic efficiency too.

At the core of this transformation is BatteReverse, a groundbreaking project that seeks to redefine how lithium-ion batteries are handled after their initial use. As part of this initiative, we are contributing to the development of a next-generation automated, connected, and standardised process for battery reverse logistics. This effort not only prioritizes safety and efficiency but also ensures that valuable materials like lithium, cobalt, and manganese are recovered and repurposed, aligning with the EU's push for a circular economy.

Understanding the Challenge

Batteries that reach the end of their first life still retain 70–80% of their capacity. While they may no longer be suitable for electric vehicles, they can be repurposed for stationary storage applications—powering cinemas, hospitals, schools, and even mobile charging stations. If repurposing is not viable, the batteries are recycled to recover key materials and electric components. However, achieving this in a safe and efficient manner is complex.

The EU Batteries Regulation, set to come into force in February 2027, will require all batteries to be equipped with a digital battery passport. This innovation will allow instant access to crucial data, such as usage history, health status, and safety information, ensuring transparency and traceability across the entire lifecycle. Our involvement in BatteReverse is already paving the way for this standard, developing technologies for automated dismantling, safety packaging, and data-driven diagnostics.

BatteReverse's Innovations: A Game Changer

Through BatteReverse, we are:

• Automating the Disassembly Process: Using robotic systems capable of identifying battery packs—whether from Tesla, Skoda, or Renault—and dismantling them safely and efficiently.

• Ensuring Safe Transport: Developing specialised packaging systems to prevent thermal runaway and reduce fire risks during transit.

• Standardising Data Exchange: Establishing a Battery Data Space that enables seamless communication between stakeholders, optimizing circular business models.

• Digital Twin Simulation: Implementing a Digital Twin (DT) simulation to mirror real-world processes, identifying bottlenecks, and optimizing the reverse logistics chain.

The goal? By 2026, BatteReverse aims to increase recycling efficiency by 5%, raise the share of repurposed EoFL batteries to 10%, and reduce severe events in reverse logistics to 1 in 10,000 shipments.

Building a Circular Economy for Batteries

The success of BatteReverse will contribute significantly to the EU's End-of-Life Vehicles Regulation, which emphasizes circularity, enhanced recycling, and stronger governance. By rethinking how batteries are collected, transported, and dismantled, we are moving closer to a sustainable, low-carbon future. This transition is not just about environmental responsibility; it is about energy sovereignty and economic resilience, reducing dependency on imported raw materials and ensuring Europe leads in sustainable urban mobility.

Watch the video below to learn more about the journey of electric car batteries and how innovative projects like BatteReverse are driving change:

Join us in reshaping the future of mobility, one battery at a time!

For more information about the BatteReverse project, visit our project page or check out the latest EU regulations on vehicle design and end-of-life management.

Learn More About BatteReverse

Read the EU Regulation Proposal