Boost GWP cuts with recycled aluminum, no reformulation
Need a meaningful A1–A3 drop without touching alloy design, tooling, or performance claims? For most aluminum products, you can buy your way there by dialing up recycled content in the billet. It is one of the cleanest levers in LCA, and it shows up instantly in a product‑specific EPD that keeps you in more specs and out of last‑minute value‑engineer swaps.
Why recycled content hits A1–A3 hard
Primary aluminum is carbon heavy because it rides on electricity and anodes. The global average cradle‑to‑gate intensity for primary metal was 14.8 kg CO2e per kg in 2023, while processing scrap to metal adds roughly 0.52 kg CO2e per kg for the remelting step, a savings aligned with the long‑cited 95% energy advantage of recycling (International Aluminium Institute, 2024) (IAI, 2024). That delta lands squarely in Modules A1–A3 for most PCRs.
The math your EPD will show
Blend GWP ≈ r × 0.52 + (1 − r) × 14.8, with r as recycled content by mass using IAI factors above (International Aluminium Institute, 2024) (IAI, 2024). Every 10 percentage‑point increase in recycled content trims about 1.43 kg CO2e per kg of product. Example, 1 kg component moving from 30% to 70% recycled: r jumps by 0.4, so A1–A3 falls by ~5.7 kg CO2e per kg. Scale by part mass and annual volume to see the commercial impact.
No reformulation required, what actually changes
Most 6xxx extrusion and common sheet alloys can meet the same temper and mechanicals using higher‑recycled billet, provided scrap streams are well sorted and melt chemistry is controlled to spec. Your product geometry, tooling, and datasheets stay the same. Procurement shifts to specifying billet with minimum recycled thresholds and proof of content, not to changing alloy families.
Post‑consumer or pre‑consumer, say which
Both reduce A1–A3, but many buyers and rating systems prefer post‑consumer. Your EPD should report the split and the accounting method for scrap. IAI’s transparency guidance asks producers to be clear on cut‑off, co‑product, or substitution choices since those change how recycled content and Module D are tallied (International Aluminium Institute, 2025).
Why this lever is so powerful in extrusions
In North American industry‑average work, billet composition dominates A1–A3. The extrusion, finishing, and thermal break steps usually contribute less than one third of cradle‑to‑gate GWP, which means the billet mix is the big dial to turn. The same study documented an average billet around 47% prime and 53% recycled, a baseline many plants can beat with supplier qualification and contracts (Aluminum Extruders Council, 2022) (AEC, 2022).
Scrap supply is real, plan for it
Secondary production supplied about 36% of global aluminum in 2022 and is expected to rise, yet scrap availability and sorting capacity still limit how far and how fast you can push content in some regions (IEA, 2024). Lock in volumes, qualify more than one billet source, and request mill test data that separates post‑consumer and pre‑consumer fractions. When prices swing, the GWP advantage remains, which keeps specs sticky even if costs move.
Quality guardrails so properties do not drift
Keep alloy windows tight, especially for Cu, Fe, and Zn that can creep with mixed scrap. Align melt practices and filtering with your extruder or caster. Run periodic tensile, bend, anodize or paint‑adhesion tests on higher‑recycled heats. Your QA team definately notices if color and gloss shift after powder‑coat, so validate before you ramp.
What to hand your LCA partner on day one
- Monthly billet purchase records with recycled split, flagged as post‑consumer vs pre‑consumer.
- Electricity and fuel by site for the reference year, plus on‑site scrap loop yields.
- Transport distances and modes for billet to plant and finished goods to gate.
- Any supplier EPDs or carbon declarations for billet, coatings, thermal breaks, and hardware. Clean inputs accelerate verification and keep revisions low.
Where EPDs reflect the win
Increasing recycled content lowers A1–A3 right away, which is the number most project teams scope for upfront carbon. End‑of‑life matters too, and aluminum’s collection rates from buildings routinely test in the high nineties in European field studies, which strengthens Module D benefits in EN 15804 frameworks when declared transparently (European Aluminium, 2023). Just do not confuse Module D credits with A1–A3 reductions. Buyers read both.
A quick sanity check on claims
Two touchstones help keep marketing tight. First, cite current global averages so reviewers can reproduce your math. Primary metal at 14.8 kg CO2e per kg and remelt around 0.52 kg CO2e per kg are recent benchmarks for 2023 data, and recycling saves roughly 95% of energy, which triangulates the same story (International Aluminium Institute, 2024) (IAI, 2024). Second, if your supplier’s numbers are lower due to renewable power or ultra‑clean furnaces, document them and include third‑party verification.
Fast path to market
If the target is a lower GWP EPD in weeks, not quarters, make recycled‑content procurement the first move, then hand over precise data. Choose an LCA partner who owns the data chase inside your organization, keeps the PCR rules straight, and publishes with the operator your market prefers. That white‑glove wrangling is what reduces meetings and gets your declaration live while competitors are still hunting spreadsheets.
Frequently Asked Questions
How much can increasing recycled content lower the A1–A3 GWP of aluminum products?
Using recent global factors, every 10 percentage‑point increase in recycled content cuts about 1.43 kg CO2e per kg of product, derived from a primary intensity of 14.8 and a remelt burden of 0.52, both per kg (International Aluminium Institute, 2024).
Will higher recycled content force a change in alloy or temper?
Usually no. Most 6xxx extrusions and common sheet can meet the same temper and mechanicals with tighter scrap control and melt chemistry management. Validate with your suppliers via heat analysis and routine mechanical and finish tests.
Does post‑consumer scrap count more than pre‑consumer in EPDs?
Both reduce A1–A3. Some buyers prefer post‑consumer for circularity goals. Report the split and disclose the scrap accounting method as IAI guidance recommends for transparency (International Aluminium Institute, 2025).
Where do Module D benefits fit if I increase recycled content?
Module D reports net benefits from end‑of‑life recycling and is complementary to A1–A3. Do not claim Module D reductions as A1–A3 cuts. Aluminum’s high end‑of‑life collection in buildings strengthens Module D when declared (European Aluminium, 2023).
What if scrap supply is tight in my region?
Plan ahead. Qualify multiple billet suppliers, specify minimum recycled thresholds in contracts, and request mill proofs that separate post‑consumer and pre‑consumer. Global secondary share was about 36% in 2022 and rising, but availability varies by market (IEA, 2024).
About the Author
With a passion for sustainability and a love for complex data, Toby helps manufacturers efficiently collect data from across their organization and get their EPDs done right. He’s especially interested in how AI can support human expertise, helping R&D and factory teams work faster, smarter, and with less friction.
