Extra low fogging recycled PP for headlamp housings: New launch by Sumika

As recycled content targets move closer to becoming a regulatory requirement in Europe, the automotive industry faces a growing challenge: increasing the use of post-consumer materials while maintaining the performance standards required for technical vehicle components. Headlamp housings represent one of the more demanding applications, where fogging performance, thermal stability, and long-term durability remain critical requirements.

Developed by Sumika Polymer Compounds Europe, the new rPPGF Thermofil Circle Extra Low Fogging is designed to address these constraints.

Response to future ELV requirements

Made from European post-consumer recycled materials, the glass-fiber reinforced polypropylene compound meets the stringent requirements of headlamp housing applications, where fogging performance is a key criterion. The development comes as automotive manufacturers prepare for stricter recycled content requirements under future European regulations.

 

With this innovation, Sumika claims to provide a concrete answer to the growing challenges of automotive manufacturers: to integrate more recycled content without compromising on technical performance, perceived quality or regulatory compliance.

 

The announcement comes in a context of major regulatory acceleration for the European automotive sector. At the beginning of 2026, a provisional agreement on the future ELV (End-of-Life Vehicles) directive reinforced the objectives for the integration of recycled materials in new vehicles.

 

In particular, manufacturers will have to incorporate an increasing proportion of post-consumer recycled content:

 

15% by 2032

then 25% by 2036

 

Beyond the quantified objectives, this transformation raises considerable industrial challenges: securing supplies, traceability of materials, quality compliance and management of regulatory penalty mechanisms.

 

In this context, the development of technical solutions integrating recycled materials is becoming a strategic lever for anticipating future obligations in the European automotive market.

 

With the Thermofil Circle Extra Low Fogging, Sumika confirms its commitment to accelerating the circularity of engineering plastics in demanding automotive applications.

 

According to the company, this new generation of compounds illustrates the rapid evolution of the market: recycled materials are no longer limited to secondary applications but are now used in technical components with high added value.

Preserves the optical performance of lighting systems

With Thermofil Circle Extra Low Fogging, the goal is clear: to enable OEMs and automakers to incorporate more recycled materials into demanding technical applications, without compromising on performance or regulatory constraints.

 

Headlamp housings impose particularly high requirements in terms of thermal stability, resistance over time and, above all, a very low level of fogging in order to preserve the optical performance of lighting systems.

 

According to the company, the new Thermofil Circle meets these constraints thanks to its controlled technical performance:

 

50% of post-consumer recycled content

Extra low fogging according to VW50181 standard: ≤ 50 μg/g

Vicat B50: 132 °C

Compliance with future ELV requirements

Tensile modulus: 6,500 MPa

 

Sumika states that reducing the carbon footprint has been a major focus of the development of this new grade. With a carbon footprint of 1.4 t CO₂ eq., the Thermofil Circle offers a significant environmental gain compared to conventional materials. Compared to a virgin PP GF, it reduces CO₂ emissions by 22%, and up to 48% compared to a PBTGF30.

 

Source : Sumika Polymer Compounds/Specialchem