Vehicle manufacturers and suppliers share a responsibility to address climate change, reduce value-chain emissions and improve resource circularity. Because wheel production is energyintensive and material-dependent, wheels are a key priority in this transition. One of Maxion Wheels’ 2030 goals is to significantly increase the share of sustainable and recycled materials used in wheels.
Moving toward a circular economy means reducing primary raw material use, eliminating waste and keeping automotive-grade wheel materials in use for longer.
A global team from Engineering, Supply Chain, Operations, Sustainability and Marketing began work in February and, by August, demonstrated that pilot wheels could be produced using green materials and processes. The results were announced to the automotive industry at IAA Mobility in Germany.
A New Generation Built with Secondary Aluminum
This 15-inch wheel demonstrates both the potential for CO₂ reduction in serial production and the value of circular partnerships. Produced at Maxion’s Santo André facility in Brazil with recycling partners and an energyefficient melting process, the pilot wheels achieved cradle-to-gate CO₂ emissions 62% lower than the same wheel produced with primary aluminum.
The project used an existing customer design, with the automaker defining the style and technical specifications. Secondary aluminum was obtained by recycling post-consumer alloy wheels, which Maxion Wheels recovered with supply chain partners by separating them from other materials and contaminants.
The wheels were sandblasted, cleaned and then melted to align their chemical composition with OEM standards.
Maxion Wheels has mapped the CO₂-equivalent emissions of the recycled-material process to serial production standards. Produced with hydroelectric energy in Brazil, these wheels generate 2.14 kg CO₂ per kilogram of wheel.
By comparison, the same wheel produced with primary aluminum at the same facility generates 5.60 kg CO₂ per kilogram.
The Santo André and Limeira facilities in Brazil are well positioned for sustainable wheel production thanks to their energy mix. Although Scope 1 and Scope 2 profiles differ by region, replacing primary aluminum with secondary material creates a broad sustainability benefit.
Renewable energy can reduce a wheel’s CO₂ footprint, but the greatest opportunity lies in emission-intensive raw materials, which account for approximately 75–85% of a wheel’s total CO₂ footprint.
While steel offers a lower-carbon alternative in the short term, long-term solutions are still needed for mobility to reach net zero.
We support knowledge and experience sharing at national and international levels, helping strengthen capabilities and create a foundation for experimentation, innovation and effective planning.
Would you like to collaborate with us or learn more about our work?
