Knorr-Bremse Circular Technology Award Jury Portal

R3 Robotics (ehemals Circu Li-ion)

• Startup Description

  R3 Robotics (ehemalig Circu Li-ion) is a robotics company headquartered in Luxembourg with operations in Germany, developing AI-powered systems for the automated dismantling of end-of-life electric vehicle (EV) components. The company designs industrial disassembly platforms that safely and efficiently break down battery packs, e-drives, power electronics, and other high-value electrified systems. By combining robotics, computer vision, and AI, Circu Li-ion enables scalable, high-throughput dismantling for reuse, recycling, and material recovery. Its solutions support circular supply chains by turning end-of-life vehicle systems into reliable sources of critical raw materials and reusable components.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  1. Introduction

  R3 Robotics proposes a structured four-month proof-of-concept to demonstrate automated disassembly of brake discs at our certified recycling facility in Karlsruhe.

  Built on a proven system originally developed for EV battery pack disassembly—one of the most hazardous and mechanically variable industrial challenges—R3 brings the vision technology, robotic cell infrastructure, and process expertise to unlock automated end-of-life processing for complex industrial components at scale.

  This PoC is designed to produce three outputs:

  • A validated automated disassembly process for Knorr-Bremse brake disc variants
  • A quantified circular value case for material recovery over shredding
  • A joint blueprint for industrial-scale disassembly under R3’s Robotics-as-a-Service model

  2. PoC Structure (10 Phases)

  1. Product Scoping & Batch Definition — July
  Define specific brake disc variants in scope, axle-mounted and/or wheel-mounted, and agree on a representative batch of 50–100 end-of-life units sourced from Knorr-Bremse’s return or depot streams.

  Document the range of disc sizes, bolting configurations, and wear states present in the batch. Variability across units is the primary challenge this PoC is designed to address.

  2. Teardown Analysis & Material Mapping — July
  Conduct structured manual teardowns to map the full component anatomy: disc body (cast iron / steel alloy), friction ring, mounting bolts, and intermediate elements such as vibration-damping inserts.

  Identify material composition per sub-element, flag any hazardous content (friction material compounds, lubricant residues), and produce the disassembly sequence that drives robotic cell logic.

  3. AI Vision & Detection Model Training — July–August
  Train R3’s vision system on brake disc geometry, bolt pattern recognition, and surface condition classification.

  Drawing on models already validated for EV battery pack disassembly, the system is adapted to robustly detect bolt head location and torque resistance indicators across the full range of wear and corrosion states present in real field-condition units.

  4. Robotic Cell Configuration & Tooling — August
  Configure the disassembly cell for the mechanical demands of rail brake discs: heavy part handling, high-torque bolt removal, and secure clamping during unscrewing operations.

  Select or fabricate appropriate end-effectors and fixtures, and integrate torque sensing to handle seized or corroded fasteners without damaging the recoverable disc body.

  5. Safety & Process Compliance Validation — August
  Validate handling procedures for friction material dust (respirable particle containment), heavy part manipulation, and surface treatment residues.

  Establish a compliant dust extraction and containment setup within R3’s certified facility before any processing runs begin.

  6. Supervised Pilot Runs — Learning Phase - September
  Process an initial batch of 20–30 discs under human oversight, using each cycle to refine bolt removal sequencing, grip force parameters, and friction ring separation steps.

  Log all failure modes, stripped bolts, unexpected corrosion, part slippage, and feed corrections back into the system iteratively. Track cycle time, success rate, and intervention frequency from the first unit.

  7. Sustainable Autonomous Run - Optimisation Phase - September – October
  Process the remaining batch with reduced operator intervention, targeting a stable automated cycle time and a component separation yield above 90% by weight.

  The disc body (cast iron / steel), friction material, and fasteners should exit as distinct, uncontaminated material streams ready for downstream processing.

  8. Material Recovery & Circular Value Quantification — October
  Weigh and characterise each recovered stream. Quantify recoverable tonnes per input tonne and map against current scrap market values and Knorr-Bremse’s disposal costs.

  If friction material contains recoverable metal content (sintered copper-based pads), quantify that stream separately. This builds the economic case for why automated disassembly outperforms shredding as an end-of-life route.

  9. Benchmarking vs. Manual Disassembly — October
  Run a structured time-and-cost comparison against manual dismantling of the same disc type.

  Demonstrate R3’s advantage in throughput, consistency, and material purity, the three dimensions where automation creates the clearest value over manual labour at scale.

  10. Final Report & Scale-Up Scenario — October
  Deliver a joint PoC report covering technical results, circular value potential, and a forward-looking deployment scenario: volumes, throughput rates, and integration with Knorr-Bremse’s existing reverse logistics and end-of-life operations.

  Include a commercial model outline for scaling under R3’s Robotics-as-a-Service offering.

  Facility

  All PoC work will be conducted at R3 Robotics' certified recycling and disassembly facility in Karlsruhe, Germany.

  The facility is equipped with the robotic cell infrastructure, safety containment systems, and material handling capabilities required for this scope.

  Knorr-Bremse is invited to observe supervised pilot runs in person.

  Contact

  • Antoine Welter — CEO, R3 Robotics
  • Carolina Lopez — Head of Business Operations, R3 Robotics

  Download the proposal

Hiro Robotics

• Startup Description

  Hiro Robotics develops advanced robotic and AI-based systems for the automated disassembly and treatment of electronic waste.
  Today, most end-of-life electronics are manually dismantled or mechanically shredded, destroying high-value components and reducing the quality of recovered materials. This leads to mixed and downgraded output fractions with lower market value, making recycling processes economically fragile and highly dependent on volatile raw material prices. As a result, a significant share of valuable resources contained in e-waste is lost or undervalued.
  Hiro introduces automation into the most complex and labor-intensive phases of WEEE treatment. Our modular systems, today, automate flat-screen and TV disassembly, ICT and data center equipment unscrewing, and AI-based PCB sorting. These solutions are designed for seamless integration into existing recycling plants, increasing throughput, improving operational safety, reducing labor intensity, and enhancing material recovery performance.
  Beyond current industrial deployments, Hiro is expanding its technology toward more complex electronic systems. This includes advanced domestic appliances and, at R&D level, electric mobility applications such as battery-integrated systems and power electronics from electric vehicles.
  Unlike traditional automation solutions that require product-specific programming or predefined disassembly sequences, Hiro’s systems autonomously interpret and process electronic devices without prior knowledge of the hardware. This enables universal, non-destructive, component-level disassembly across heterogeneous and unpredictable waste streams — unlocking significantly higher value recovery and redefining the economics of e-waste recycling.
  Hiro’s automation platforms are already operating in certified WEEE treatment centers, processing thousands of tons of electronic waste annually under full-scale industrial conditions. The systems are commercially available, with short lead times and turnkey deployment, enabling rapid integration into existing recycling infrastructures.
  By making electronic waste treatment more efficient, scalable, and economically sustainable, Hiro contributes to a circular economy where critical materials and electronic components are recovered more effectively and reintegrated into industrial supply chains.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  PoC Description

  The Proof-of-Concept proposed by Hiro Robotics aims to validate the application of Hiro Robotics’ AI-driven disassembly technology to selected Knorr-Bremse products, with a focus on enabling scalable circular treatment and recycling of complex industrial components.

  The PoC will begin with the joint selection of one or two representative product categories, such as electronic braking systems, brake discs or entrance systems, based on their relevance in terms of volume, complexity, and recovery potential. A set of end-of-life units will be collected and analyzed to capture real-world variability, including different product generations, wear conditions, and assembly configurations.

  Based on this input, Hiro will perform a detailed disassembly mapping to identify key process steps and define the automation strategy. A pilot robotic cell will then be configured using Hiro’s modular platform, integrating computer vision, adaptive tooling, and AI-based control systems. Importantly, if needed, the system can potentially operate without predefined product-specific programming, leveraging autonomous interpretation of the components.

  This approach builds on Hiro’s proven industrial solutions already deployed in the disassembly of professional and industrial electronic equipment, as well as on ongoing R&D activities targeting more complex systems in the field of electric mobility, including e-mobility components, battery-integrated systems, and advanced electronic assemblies.

  During the testing phase, the PoC robotic cell will execute iterative disassembly cycles, progressively optimizing handling, unscrewing strategies, and process reliability. Performance will be measured against jointly defined KPIs, including throughput, recovery rate, capacity, and system autonomy.

  In the final phase, the PoC will validate the system under realistic operating conditions by processing a representative batch of components. The results will be used to assess technical feasibility, economic viability, and scalability potential. Based on these outcomes, a roadmap for industrial deployment will be defined, including integration into existing recycling or remanufacturing workflows and extension to additional Knorr-Bremse product lines.

  PoC Plan

  1. Selection of target product category (July)
  Joint definition of one or two reference products from Knorr-Bremse portfolio (e.g. electronic braking systems, brake discs, entrance systems or others), based on volume, structural complexity, and circularity potential.

  2. Sample collection and characterization (July – early August)
  Collection of representative end-of-life units, capturing variability in wear conditions, product generations, and assembly configurations to reflect real-world scenarios.

  3. Disassembly mapping and task analysis (July – August)
  Detailed analysis of product architecture to identify disassembly sequences, fastening types (screws, clips, welds), and component hierarchies, defining the technical scope for automation.

  4. Definition of PoC KPIs (July – August)
  Alignment on key performance indicators, including e.g.:
  o disassembly time per unit
  o recovery rate of valuable components and materials
  o system uptime, repeatability, and operational stability

  5. Adaptation of Hiro robotic technology (August)
  Configuration of Hiro’s modular robotic platform (vision systems, adaptive tooling, AI control) to process selected components, leveraging existing industrial solutions without the need for product-specific programming.

  6. AI training and perception setup (August – September)
  Training and calibration of computer vision models on real samples to enable robust detection of screws, interfaces, and structural features under high variability conditions.

  7. Pilot cell installation (late August – September)
  Deployment of the pilot robotic cell at a Hiro facility.

  8. Iterative testing and optimization (September – October)
  Execution of iterative disassembly cycles to progressively refine:
  o handling strategies
  o unscrewing paths and sequencing
  o force and torque control
  o error detection and recovery logic

  9. Performance validation under realistic conditions (October)
  Processing of a representative batch of components to validate system performance in terms of throughput, robustness, and recovery efficiency under near-industrial conditions.

  10. PoC evaluation and industrial scale-up roadmap (October)
  Joint evaluation of results and definition of next steps, including:
  o integration into existing recycling or remanufacturing workflows
  o extension to additional product categories within the Knorr-Bremse portfolio
  o preliminary business case and ROI assessment for industrial deployment

  Download the proposal

Desoltik

• Startup Description

  Desoltik develops AI-powered inspection technology that dramatically reduces the time required to diagnose electronic products returning from the field. By shortening inspection time by up to a factor of 12, we remove one of the largest economic barriers to electronics repair and remanufacturing, where diagnostics typically account for 40–60% of total repair costs. Our system enables fast, scalable condition assessment of high mix electronic assemblies, making reuse, refurbishment, and component recovery economically viable. In doing so, we help extend product lifetimes, reduce electronic waste, and unlock profitable circular value chains in the electronics industry.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  CONFIDENTIAL – FOR INTERNAL USE ONLY

  Proof of Concept for AI-Based Diagnosis of Electronic Assemblies at Knorr-Bremse (July to October 2026)

  Desoltik is proposing a proof of concept to validate its AI-based Current-over-Time (CoT) diagnostics for electronic assemblies at Knorr-Bremse.

  We understand diagnostics as a key prerequisite for cost-effective repair and remanufacturing processes. Especially with complex electronic assemblies, we see the use of AI as a crucial lever for detecting fault patterns early on and efficiently deriving appropriate follow-up processes.

  The goal of the proof of concept is to assess whether selected electronic units or PCB-based assemblies can be quickly and reliably classified into relevant circularity paths such as reuse, repair, remanufacturing, or scrap using Desoltik’s AI-based diagnostics.

  In doing so, the project specifically examines the unique challenges faced by Knorr-Bremse in the diagnostic process and evaluates the concrete procedural benefits that Desoltik’s solution can deliver on the shop floor.

  The proof of concept consists of the following nine steps:

  1. Scope Definition and Product Selection
  Joint selection of a suitable family of electronic products for the pilot project, such as braking, steering, door, or other control-related systems. In this process, the use case, process steps, and success criteria are coordinated.

  2. Definition of Samples and Data Set
  Compilation of a representative sample set consisting of known good parts as well as defective or suspicious units, supplemented where possible by repair findings, test results, or return information.

  3. Mapping of Relevant Failure Patterns
  Identification of the most important defect classes and decision-making logic for the selected product family, e.g., functional vs. defective or specific failure patterns.

  4. Measurement Setup and Test Design
  Setup of the simple CoT measurement environment and definition of relevant measurement parameters such as power supply, sampling rate, and measurement duration.

  5. Recording of Electrical Signatures
  Measuring the current consumption of selected samples to capture boot and activation signatures as non-invasive electrical fingerprints.

  6. Pattern Analysis and AI-based Classification
  Automated analysis and classification of the measured current waveforms to identify relevant fault classes.

  7. Comparison with Reference Results
  Comparison of AI-based results with existing reference information from Knorr-Bremse, such as repair diagnoses, functional tests, or expert assessments.

  8. Assessment of Procedural and Economic Benefits
  Evaluation of the extent to which the method supports early decisions regarding reuse, repair, or disposal, and its contribution in terms of reproducibility, time and cost savings, and integration into existing repair processes.

  9. Summary of Results and Roadmap for Next Steps
  Completion of the proof of concept, including a concise summary of the technical results, suitable application areas, and a recommendation for a potential integration project in an operational environment.

  Expected Outcome of the Proof of Concept

  The proof of concept is intended to demonstrate whether Desoltik’s Current-over-Time method is suitable as a rapid initial assessment step for electronic assemblies in circular processes at Knorr-Bremse and what technical and procedural benefits it can provide.

  Outlook for Production Operation

  A successful proof of concept would form the basis for a subsequent 6–12 month implementation project aimed at deploying an operational solution at Knorr-Bremse.

  This would include measurement hardware, product-specific pipelines and AI models, connection to Desoltik’s compute infrastructure, and support during the initial phase of production.

  Beyond implementation, Desoltik could provide long-term maintenance and service support to ensure stable operation and continuous improvement.

  Download the proposal

36Zero Vision

• Startup Description

  36ZERO Vision is a Munich‑based technology company specializing in AI‑powered visual quality inspection for industrial manufacturing. Our solution is a software‑defined, hardware‑agnostic platform that detects defects with extremely high accuracy while requiring far fewer training images than conventional systems. By leveraging proprietary deep‑learning models, the platform identifies even subtle irregularities under changing conditions and significantly reduces false alarms and pseudo‑defects, thereby increasing reliability and efficiency in production processes. 
  Through our robust defect‑detection capabilities, we help manufacturers minimize scrap, rework, and unnecessary material usage, all of which are essential pillars of a circular economy. Our system’s ability to operate with fewer data, simpler integration, and higher precision leads to more efficient production cycles and reduced resource consumption. This not only lowers operational waste but also supports longer product lifecycles and more sustainable manufacturing practices — key elements in advancing circularity across industries.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  A) Objectives

  • Demonstrate the technical feasibility and business case for automating selected steps of Knorr-Bremse’s refurbishment production process using 36ZERO Vision.

  B) Project Setup

  • Start: July 2026
  • Dedicated 36ZERO Vision Project Manager
  • Remote meetings as required, plus a weekly jour fixe with the full project team
  • Monthly project status meetings including sponsors/decision makers and the 36ZERO Vision Management

  C) Project Scope

  1. Identify refurbishment process steps suitable for full automation using 36ZERO Vision

  2. Prove technical feasibility of the most critical process steps on three representative products
  o Phase 1: In lab
  o Phase 2: On site

  3. Define a detailed technical solution concept and implementation timeline

  4. Calculate total costs and develop a comprehensive business case for the complete solution (software & hardware)

  D) Project Timeline and Phases – 60 days / 12 weeks

  1. Definition of Process Steps for Proof of Concept (PoC) – 5 days
  • Kick-off meeting (in person at Knorr-Bremse)
  • Analysis of existing refurbishment process steps and their suitability for automation with 36ZERO Vision
  • Selection of PoC process steps and definition of requirements and success criteria

  2. Technical Feasibility – 45 days

  Phase 2a: Software / AI Feasibility – 10 days
  • Image generation in office/lab environment
  • Model training in the cloud
  • Validation of results

  Phase 2b: On-Site Proof of Technology (PoT) – 35 days
  • Installation of representative hardware setup on site
  • Basic integration into the existing factory automation environment
  • End-to-end feasibility validation

  → Presentation / written report of results

  3. Detailed Solution Concept – 5 days
  • Definition of the detailed technical solution
  • Development of a realistic implementation roadmap and timeline

  4. Business Case & Final Presentation – 5 days
  • Detailed cost calculation covering software, hardware, and required resources
  • Joint evaluation of operational impact and financial benefits
  • Business case calculation
  • Final presentation of results to Knorr-Bremse stakeholders

  Download the proposal

WeSort.AI

• Startup Description

  Europe faces critical raw material shortages: annual demand stands at around 20 billion tonnes, with virtually no domestic reserves available. Yet today, only 23% of recoverable materials from end‑of‑life vehicles are reclaimed—over 90% of valuable raw materials are lost. End‑of‑life vehicles and electronic waste act as “rolling mines” containing batteries, circuit boards, and cables, but inadequate sorting technologies prevent recovery. Valuable resources end up incinerated, and import dependency grows.
  WeSort.AI addresses this with an AI‑powered, sensor‑based sorting system that precisely separates shredded streams from vehicles and e‑waste. It extracts critical raw materials like copper, lithium, and rare earths that were previously inseparable, allowing these materials to be recovered and recirculated. This keeps resources in the loop, generates up to €500 per processed car, cuts CO₂ emissions, conserves primary materials, and strengthens Europe’s strategic independence.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  1. Project Outcome (The Goal)

  The primary goal of this PoC is to demonstrate that complex, multi-material products from Knorr-Bremse (e.g., electronic braking units) can be automatically separated into high-purity fractions.

  We aim to prove that these recovered materials meet the quality standards required for re-entry into the production cycle, effectively turning industrial waste back into a strategic resource.

  2. Step-by-Step Implementation (The Process)

  Phase 1: Requirement engineering (Month 1)
  Joint workshop to define target products, material specifications, and KPIs for purity and recovery rates.

  Phase 2: Shredding & material preparation (Month 2)
  Identification of the ideal mechanical pre-treatment. We test different shredding methodologies to ensure optimal liberation of individual components without destroying valuable fractions.

  Phase 3: AI training & sensor calibration (Month 2–3)
  Feeding Knorr-Bremse specific component data into our AI. We calibrate our patented sensor fusion (Optical and X-Ray) to recognize the specific alloys and plastics used in your products.

  Phase 4: Industrial Sorting Trials (Month 3)
  High-speed sorting of the shredded batches in our tech center (500 kg/h) to generate pure fractions of copper, aluminum, and high-tech plastics.

  Phase 5: Validation & Deep Dive (Final 6 Weeks)
  Intensive laboratory analysis of the output. We verify purity levels and document the consistency of the sorting results.

  Phase 6: Final Presentation & Scaling Roadmap (End of October)
  Delivery of a comprehensive business case, showing how this solution can be integrated into your global supply chain.

  3. Strategic benefits (The Value)

  Resource sovereignty
  By recovering critical raw materials from your own products, you reduce dependency on volatile global markets and third-country imports.

  Future competitiveness
  Directly fulfill the requirements of the European Critical Raw Materials Act and the ELV Directive, positioning Knorr-Bremse as a leader in circularity.

  Carbon footprint reduction
  Recycled materials require significantly less energy than primary mining, directly contributing to your corporate sustainability goals.

  Economic value
  Transform disposal costs into revenue by recovering high-purity metals and components that can be sold or reused as high-value feedstock.

  Download the proposal 

DEScycle 

• Startup Description

  DEScycle is building the next generation of metals processing infrastructure for a circular economy.
  
  We replace centralised, carbon-intensive smelting with a distributed, modular metals recovery platform powered by proprietary ionometallurgy. By operating at significantly lower temperatures and deploying directly at material sources, we convert electronic waste into high-purity, traceable critical and precious metals with substantially lower carbon intensity.
  
  Electronic waste is the fastest-growing waste stream globally, yet most high-value materials are exported and processed in ways that destroy provenance and embed emissions. DEScycle addresses this structural gap by enabling in-country recovery of critical metals, shortening value chains and preserving material traceability.
  
  Our platform transforms domestic waste streams into sovereign metal supply. This enables true material circularity and the reintegration of verified, low-carbon metals back into European industrial supply chains.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  Detailed PoC Plan (July–October)

  The PoC will validate DEScycle’s ability to recover critical metals from complex industrial electronic waste streams under operational conditions aligned with future deployment.

  1. Feedstock definition & selection (July)
     Identify & agree on the relevant material streams from Knorr-Bremse operations. Define material specifications, volumes and success criteria.
  2. Regulatory & logistics setup (July)
     Establish cross-border shipment under TFS (Transfrontier Shipment of Waste) regulations if a large volume of waste materials. Shipments of less than 20kg will allow lab work to start quickly, as they are exempt from waste transport regulations. Coordinate compliant transport of material to DEScycle’s UK demo facility.
  3. Material receipt & characterisation (Late July)
     Conduct detailed sampling and assay to determine metal content, grade variability and economic potential.
  4. Pre-processing & preparation (Late July–August)
     Undertake shredding, liberation and separation to produce fractions suitable for processing.
  5. Laboratory validation (August)
     Run initial lab-scale trials to optimise process parameters for the specific feedstock (chemistry tuning, selectivity, recovery conditions).
  6. Pilot-scale processing (August–September)
     Process data runs through lab pilot systems, replicating industrial operating conditions.
  7. Metal recovery & output generation (August-September)
     Produce high-purity target metals, with remaining metals captured in controlled concentrates for downstream refining.
  8. Performance validation (September)
     Measure recovery efficiency (>99% target). Conduct third-party assay on outputs.
  9. Techno-economic & carbon analysis (September–October)
     Assess processing cost per tonne, value recovery, and carbon intensity versus smelting baseline.
  10. Reporting & scale-up roadmap (October)
      Deliver full PoC report including yield, purity, economics, carbon impact and integration pathways. Define next steps for further commercial collaboration.

  Outcome

  The PoC will demonstrate that distributed, low-temperature metals recovery can convert complex waste streams into industrial-grade, low-carbon metal supply,  validating both technical performance and integration into European circular value chains, consistent with DEScycle’s infrastructure-led model.

Recupere Metals

• Startup Description

  We upcycle copper scrap into high-quality electrical copper products. Our mechanical process converts sorted copper granulates into winding wire, with the same technical properties as primary copper (conductivity and tensile strength).

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  - We recycle end of life cables to form enameled wires

  - We could send a 3kg sample of winding wire around October for testing by Knorr-Bremse, for example for their engines (Motoren von Kompressoren)

  - We provide material certificates for the material, as well as conductivity, elongation, and tensile strength measures. Other tests can be realised in an external laboratory or by Knorr-Bremse   

Elmery

• Startup Description

  Elmery develops and deploys patented pulse-based electrochemical technology that selectively recovers metals from dilute or complex recycling and refining streams using only electricity. We help recover EU-critical raw materials such as cobalt, copper, germanium, nickel and platinum (and other high value metals including Au, Ag, Pd and Rh) that would otherwise be lost to residues and bleed streams. We return these metals as high-purity fractions for reuse, reducing waste, chemicals and the need for primary mining.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  Proposed detailed PoC (July-October):

  • Scope definition
    • Joint selection of target streams from Knorr-Bremse products, e.g. electronic control units, connectors, power electronics or copper-rich scrap fractions.
    • Identification of target metals to be recovered.
    • Definition of key performance targets (recovery rate, purity, processing time)
  • Sample preparation & logistics
    • Delivery of representative materials or existing process solutions (e.g. plating, etching, or recycling fractions) to Elmery.
  • Pre-treatment (if required)
    • Dissolution (leaching) of selected materials into liquid form, either by Knorr-Bremse partners or jointly defined recycling route.
  • Laboratory testing
    • Bench-scale parameter screening (50 mL scale) followed by optimization (1 L scale)
    • Regular joint meetings to review progress and adjust targets
  • Data analysis & reporting
    • Recovery rate and product purity determined using ICP-OES (primarily) and XRF
    • External laboratory validation possible if required
  • Evaluation and next steps
    • Joint assessment of technical and economic feasibility
    • Decision on progressing to pilot phase and definition of pilot scope

HyProMag 

• Startup Description

  HyProMag GmbH is operating a short-loop recycling and manufacturing plant for the recovery of rare earth permanent magnet materials(NdFeB) from end-of-life products and production scrap and convert them into high-quality powders, alloys and sintered magnets. The technology we utilise to recycle and recover these critical raw materials, is called hydrogen processing of magnet scrap (HPMS), an IP-protected patented process. By closing the loop from magnet-containing waste streams to new magnetic materials, we reduce the need for primary mining, significantly cut CO₂ emissions and toxicity, and enable EU industry to secure critical raw materials from domestic circular sources.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description

  A PoC demonstrator would use selected Knorr‑Bremse rail and truck actuators and compressors, treat their magnet‑bearing sub‑assemblies at HyProMag’s pilot/industrial HPMS plant, and supply recycled NdFeB powder or magnets back to Knorr‑Bremse and motor Tier 1 partners, with volumes progressively scaled from pilot batches to continuous operation.

Ionic Technologies

• Startup Description

  Ionic Technologies have created an innovation that addresses a major global supply chain risk, as well as protecting western economies from a key vulnerability; Rare Earth Elements. In three years, Ionic Technologies have progressed the technology from laboratory scale through to a unique Demonstration Plant, already supplying material to strategic customers across the world. 
  Ionic Technologies take end of life magnets, containing Rare Earth Elements and complete a patented long-loop recycling process that outputs high purity (99.5% plus), separated Rare Earth Oxides. This material can then be fed forward into the Rare Earth Permanent Magnet supply chain as a clean, high-quality product. By recovering a high-quality, high-purity product, Ionic Technologies enable true circularity within this supply chain, without any degradation in application performance or any introduction of primary material. This means that any grade of magnet can be made using the product, enabling absolute material independence and security, which distinguishes the technology from other magnet recyclers, who must compromise on quality, sourcing, performance or a combination of the three.

  Company webpage

• Video Pitch

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• Pitch Deck

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• Proof-of-Concept Description
  • Ionic Technologies will work with Knorr Bremse and other partners to deliver a Proof of Concept recycling and recovery demonstration project.
  • The primary focus of the PoC would be to demonstrate capability taking end-of-life magnets used in Knorr Bremse Electronic Braking Systems and Entrance Systems, and recovering essential CRMs (i.e. Rare Earth Oxides, REOs) from them. These Oxides will be at a purity grade equivalent to primary material, representing an innovative route to REO sourcing for Knorr Bremse’s supply chain utilising cutting-edge recycling technology and a circular supply chain concept. 
  • Ionic Technologies have already provided REOs, which have then been used in high specification magnets for a leading automotive OEM, who has created rotors using magnets containing 100% recycled REOs; a world’s first.
  • We expect a strong interest in a circular economy model for REOs from Rail Customers, owing to customer trends in Europe encouraging, and even specifying, European made components that are maximising recycling. Application of our technology for this Proof of Concept represents a strong opportunity in this regard, and we can scale this much quicker than any primary (i.e. mined) material equivalent sourcing.
  • Should the Proof of Concept be successful, Ionic Technologies can provide a rapid commercial co-operation opportunity to Knorr-Bremse, via our forthcoming commercial scale recycling facility. Ionic Technologies is building a 1200 tonnes per annum magnet feedstock/400 tonnes per annum REO capacity plant in the UK within the next 2 years. This can offer Knorr-Bremse a rapid route to 100% recycled CRMs in key magnet components within a few years.
  • The Proof of Concept would be delivered by our team of Chemists, Chemical Engineers and trained Operators at our unique Deomstration Plant in Belfast, which can produce 10 tonnes per annum of separated 99.5% plus purity REOs exclusively from recycling of magnets and production wastes. We have proven our capability to meet European CRM needs in the automotive sector and this Proof of Concept would represent an opportunity for all parties to apply this concept to the Rail industry across Europe.
  • Specifically, we would expect to receive end-of-life or pre-consumer magnet material from Knorr Bremse at an agreed quantity for the project and return high purity (99.5% plus), separated REOs powders within the 3-4 month window. If required, Ionic Technologies could co-operate further with Knorr Bremse over a longer period to generate next generation magnets with additional supply chain partners. Adjacent benefits, including design-for-disassembly and life cycle analysis improvements can also be pursued (i.e. Ionic Technologies process represents a 61% reduction in CO2 emissions versus primary material).
  • The proof of concept will provide Knorr Bremse with a sustainable and secure, circular supply chain route for Rare Earth Permanent Magnets, while optimising use of resources.