Roland Berger: Plastic & Automotive Production

As the automotive industry pivots towards EVs, a new era of design and material usage innovation is emerging. Roland Berger, a leading global consultancy, is pivotal in guiding EV manufacturers through this transformation, particularly in the quest for sustainable plastic practices.

The EV plastic challenge

While EVs are celebrated for reducing emissions and environmental benefits, their production still heavily depends on plastics.

The reliance is becoming a focal point of scrutiny, especially with regulatory mandates such as the European Union's requirement for automotive manufacturers to incorporate 25% recycled materials by 2030. For EV producers, it presents both a challenge and an opportunity to innovate.

According to Roland Berger's analysis, using plastics in EVs comes with distinct challenges:

Lightweighting: Reducing the weight of EVs is essential to extend their range, making lightweight plastics an attractive option. However, this has created an urgent need to develop recyclable alternatives to conventional plastics.

Battery Enclosures: EV batteries often utilise plastic components, introducing a unique recycling challenge specific to the sector. The need for innovative recycling solutions is greater than ever.

Interior Design: The shift to EVs allows for completely reimagining vehicle interiors. It opens new possibilities for using innovative and sustainable materials that enhance the vehicle's environmental footprint.

Roland Berger's approach to reducing plastic in EVs

Roland Berger has developed a comprehensive strategy to support EV manufacturers in addressing these challenges and advancing towards sustainable plastic use. The approach focuses on four key areas:

1. Material innovation: Roland Berger collaborates with suppliers to develop bio-based or easily recyclable plastics suitable for EV applications. The partnership aims to replace traditional plastics with materials that have a smaller environmental impact.
2. Design for circularity: The consultancy advises manufacturers on designing EVs that facilitate easy disassembly and recycling at the end of their lifecycle. It includes integrating materials that are easier to recycle or repurpose.
3. Supply chain optimisation: Establishing closed-loop recycling systems is another critical focus area for Roland Berger. The systems are tailored to handle the specific components used in EVs, ensuring materials are reused effectively and efficiently.
4. Technology assessment: Roland Berger evaluates emerging recycling technologies specifically tailored for EV plastics, including advanced chemical recycling methods that can handle the complex mix of materials used in modern EVs.

Erwin Douma, Senior Partner at Roland Berger, underscores the consultancy's vision, stating:

"The EV revolution offers a unique chance to rebuild automotive supply chains with circularity in mind. Our role is to help manufacturers seize this opportunity."

Transforming Sustainable Mobility

Roland Berger's expertise makes them a leader in driving the EV industry towards a more sustainable future.

By combining strategic insights with practical implementation plans, they are helping manufacturers not only comply with regulatory requirements but lead the way in sustainable manufacturing practices.

As Stefan Schaible, Global Managing Partner of Roland Berger, explains:

"Our work in the EV sector exemplifies our commitment to driving positive environmental impact. We're not just advising on business strategy, but shaping the future of sustainable mobility."

With Roland Berger's guidance, EV manufacturers aim to transform propulsion technology and their entire approach to materials use and circularity in automotive production. As the industry navigates this complex landscape, Roland Berger remains a key partner in ensuring that the shift towards EVs is as sustainable as it is transformative.

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