In early 2024, Hansgrohe Group commissioned what is considered the first industrial-scale facility for electrohydraulic fragmentation and material separation of electroplated plastic components. The facility, designed in partnership with ImpulsTec GmbH, achieves a material purity of over 99.8% by mass, enabling the reuse of both plastic and metal fractions in premium sanitary products.

Electroplated plastic components have long posed challenges in recycling due to the complex bonding between metal coatings and plastic substrates. Conventional recycling processes typically focus on extracting only one material – most often the metal – while the remaining materials are downcycled or discarded. This has limited the potential for true circular use of resources and has made recycling these components economically inefficient. The new process developed by Hansgrohe and ImpulsTec addresses this limitation by enabling the separation of materials with high precision and minimal loss in quality.

At its production site in Offenburg-Elgersweier, Germany, Hansgrohe now operates a custom facility that integrates pre-shredding, shockwave fragmentation, and magnetic separation. The facility processes chrome-plated ABS plastic components—such as shower housings, pipe collars, and control knobs—which are commonly used in Hansgrohe’s high-quality product lines. Due to stringent durability requirements, these components require a strong bond between plastic and metal, which historically made material separation difficult during recycling.

David Zapf, a surface technology specialist at Hansgrohe, played a key role in initiating this project. His exploration of ImpulsTec’s technology during his academic studies in 2019 led to a collaboration that began in 2021. The development phase included adapting the shockwave process for Hansgrohe’s specific components and integrating additional steps such as pre-shredding and magnetic separation. After extensive testing and optimization, the facility began operations in early 2024.

The shockwave fragmentation process, based on electrohydraulic principles, uses a high-voltage arc discharge within a water bath to generate shockwaves. These mechanical pulses pass through the pre-shredded material, separating the bonded layers of metal and plastic without excessive damage to either material. The water used in the process is continuously filtered and reused in a closed-loop system.

The facility is modular in design, comprising three weather-resistant container units. This setup accommodates Hansgrohe’s need for outdoor installation within a limited footprint of 22 metres by 10 metres. The first container houses the pre-shredding and screening system, producing uniform granulate. The second container contains the shockwave treatment unit. The final container is used for drying the output and separating the material fractions using magnetic processes.

The result of this multi-stage treatment is a plastic fraction – making up 70 to 80% of the output – that meets the required >99.8% purity level for use in new, high-grade components. The remaining fraction, composed of copper, nickel, and chrome from the galvanic coating, is sent to metal recyclers. According to ImpulsTec Managing Director Stefan Eisert, each step of the process was developed and refined to meet Hansgrohe’s performance criteria for purity and operational reliability.

Operating on a standard 8-hour shift for approximately 250 days per year, the facility can process around 100,000 kg of chrome-plated plastic annually. Zapf notes that the process enables reuse of approximately 98% of the raw materials from production waste. This directly supports Hansgrohe’s circular economy goals, reducing the demand for virgin resources and lowering the environmental impact associated with sourcing and manufacturing materials. The company has already applied some of these recycled materials in commercial products, including the Pulsify Planet Edition, introduced in 2023.

The successful integration of electrohydraulic fragmentation marks a notable development in recycling technology for complex material composites. It demonstrates a practical, scalable solution to separating tightly bonded material layers, which could otherwise not be processed effectively with existing methods.

The collaboration between Hansgrohe and ImpulsTec also opens the door to further applications. Zapf mentions that the company is now exploring whether this technology could be applied to complete, end-of-life products returned by customers. This would represent a further advancement in Hansgrohe’s sustainability strategy, potentially closing the loop on the full product lifecycle.

From ImpulsTec’s perspective, the Hansgrohe facility serves as a proof of concept with broader industrial relevance. Eisert sees potential for this technology in other sectors, such as automotive and electronics, where composite materials are common and difficult to recycle. Future applications may include the separation of materials from circuit boards, electronic housings, and vehicle components at the end of their usable life.

Electrohydraulic fragmentation, while still relatively uncommon in Germany, has shown that it can address some of the limitations of traditional recycling methods, particularly in cases involving tightly bonded materials with differing properties. The development and commissioning of Hansgrohe’s pilot facility show how targeted innovation and cross-sector collaboration can lead to practical improvements in materials recovery and reuse.

With an emphasis on precise separation and high material purity, this approach may serve as a model for other manufacturers seeking sustainable solutions for production waste. The process does not rely on high-temperature incineration or chemical treatment, offering an energy-efficient and environmentally responsible method of recovering valuable resources.

Hansgrohe and ImpulsTec have shown that, with the right investment in technology and development, it is possible to overcome one of the more stubborn challenges in modern industrial recycling. The integration of this system not only aligns with corporate sustainability targets but also enhances resource efficiency and economic viability.

www.hansgrohe-group.de

www.impulsetec.xom

An in-house-designed facility for stripping chrome-plated plastic parts through shockwave treatment, in combination with pre-shredding and magnetic separation, was commissioned at sanitary engineering manufacturer Hansgrohe at the start of the year

As the galvanised parts to be recycled are of different sizes and complexity levels, the first container deals with pre-shredding and includes a screening column

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