UK's First Recycled EV Battery Cells Cut Emissions by 32%

Altilium and Jaguar Land Rover (JLR) have revealed the UK’s first electric vehicle battery cells produced from recycled cathode and anode components. The unveiling occurred at the Cenex Expo 2025 and represents progress toward creating a circular economy for EV batteries.

The collaborators exhibited new automotive-grade NMC 811 multilayer pouch cells. These were produced using cathode active material (CAM) reclaimed from end-of-life EV batteries via Altilium’s EcoCathode technique.

The proportion of recovered CAM already satisfies the 2036 recycled content targets specified by EU battery regulations.

Early evaluations indicated performance on par with conventional materials. JLR is now performing comprehensive validation trials at its advanced battery testing facilities.

Alongside the multilayer cells, the partners also manufactured single-layer pouch cells composed entirely of recycled cathode and graphite anode materials.

Attendees at Cenex observed the cells incorporated into a virtual reality representation of the Jaguar I-PACE battery pack. JLR employs the same VR tools in its engineering programs.

Dr Christian Marston, COO and co-founder of Altilium, described the milestone as “a major technical breakthrough and a vote of confidence in the UK’s ability to lead in battery recycling.” He noted that the team is demonstrating recycled materials can satisfy automotive standards while lowering emissions and reliance on imports.

An independent Life Cycle Assessment by Minviro validated the environmental advantages. Using 100% recycled CAM for NMC 811 pouch cells in the UK could reduce greenhouse gas emissions by 32% compared with cells made from virgin materials in Asia.

Other impact categories also showed substantial gains: 30% lower particulate matter formation, 58% reduced freshwater ecotoxicity, and a 38% decrease in pressure on metal and mineral resources.

Dr David Sellick, JLR’s project lead, said: “This project reinforces JLR’s leadership in sustainable innovation, marking a significant step forward in reducing the environmental impact of the largest contributor to an EV’s carbon footprint – the battery cell.” He added that the initiative demonstrates performance and sustainability can coexist.

Altilium’s EcoCathode method recovers more than 95% of cathode metals and over 99% of graphite from battery waste.

The retrieved metals are upcycled into high-nickel CAM, while graphite is further purified for anode manufacture.

The project is backed by the Advanced Propulsion Centre UK through its Advanced Route to Market Demonstrator program. It also assists UK manufacturers in aligning with forthcoming EU requirements on recycled content in EV batteries.

Scaling up in the UK

The Cenex presentation builds on earlier trials this year in which Altilium produced lithium-ion cells using its recycled NMC 811 CAM. Those tests already demonstrated performance equivalent to cells made from virgin mined materials.

Altilium recently launched ACT 2, the UK’s first commercial EV battery recycling facility, in Plymouth.

The company is now planning ACT 3, a large-scale plant anticipated to recover battery minerals from up to 24,000 vehicles annually.

By collaborating with JLR, Altilium intends to establish a domestic supply chain for recycled materials while ensuring that UK-made vehicles meet EU regulations.