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

This standard provides guidelines for both the 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 3:
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 M1 and N1 vehicle classes are
concerned.

Numerical notation according to ISO practice (see VW 01000).

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Supplements 1 and 2 withdrawn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 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 in the vehicle, in vehicle parts and in units,
operating fluids used during vehicle operation, repair and maintenance as well as to
the ban on using used parts in new vehicles.

Form FE 41 - 09.06

The English translation is believed to be accurate.In case of discrepancies the German version shall govern.

Preface

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

K-GA/R

Tel.: +49-5361-9-25644

Mr.
Terlinden

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

Norm vor Anwendung auf Aktualitt prfen / Check standard for current issue prior to usage.

Klass.-Nr./Class. No. 97410

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VW 91102: 2007-02

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 =
Recycling rate

weight used in material processing

overall weight

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

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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VW 91102: 2007-02

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)

b)

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)

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 M1

and N1 class vehicles must not be reused in the manufacturing of new vehicles.
The following components are concerned:

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

In this Section, terminological inconsistencies may occur as the original titles are used.