EV battery recycling
GreenTech Industries handles end-of-life EV battery packs for businesses across the UK, from three facilities in Warwickshire. It built the precision disassembly line that sits in front of the shredder, recovering the components, cells, data, and remaining usable life before anything is destroyed.
The recycling route
The first life ends when the pack can no longer do its job. A battery’s useful life runs well past its warranty. Most are shredded for raw materials, which wipes out the components, cells, data, and remaining usable life inside every pack. SMMT forecasts 235,000 tonnes of EV batteries reaching end of life in the UK by 2040.
Before recycling
Every battery that arrives at Westfield Road moves through the same four stages of the precision disassembly line.
The high-voltage bus is isolated, the coolant drained and the casing removed, then every pack goes through multi-stage HV verification: isolation, bleed-down, external discharge and thermal imaging.
Every pack is assessed on arrival for safety, electrical and mechanical integrity, state of health, chemistry and pack family.
Every pack is opened and its components harvested: modules, connectors, fuses, clamps, cooling plates and busbars.
Components, modules and cells are assessed against state-of-health thresholds and routed pack by pack: into Asset Management for module-level reuse, into Product Innovation for second-life storage and replacement packs, or into refiner streams as pre-sorted, clean material.
Shredding comes last, and never by default.
The UK chain
EV battery recycling in the UK runs as a chain: collection, precision disassembly, shredding to black mass, then refining. GreenTech Industries works at the start of it.
Handing packs to GTI is straightforward. We arrange the most appropriate transport for each collection.
GTI
It is the first stage in the chain, ahead of black mass and bulk shredding. 74% of every pack, including components, cells, and remaining usable life, is recovered and routed back into the right supply chain (aluminium to aluminium, copper to copper, cells to cells). That’s around 186 kg of every 250 kg pack.
Refiners get better feedstock, shredders get safer material to process, and OEMs and fleets get reusable parts with the data that comes with them.
That work matters: refiners need feedstock, and the materials inside every pack need to make it back into UK supply chains.
EV battery recycling firm to expand Warwickshire operationsNational BBC coverage of GTI’s expansion plans at Sucham Park in Warwickshire, at the heart of the UK’s emerging EV battery processing sector.Read at BBC NewsEach sector needs something different, and each gets the same precision outcome.
End-of-life battery management for production runs. Material passports, type approval support, and closed-loop supply chain data.
OEM services
Extended life for EV fleets. Vehicles stay on the road on the packs they already own, and PSV fleets stay compliant on ULEZ and clean-air routes. Depot logistics, residual value recovery, asset reporting.
Fleet services
Permitted sub-contract HV battery processing for the packs that exceed an in-house line. Full compliance documentation returned, and the liability transfers with the pack.
ATF services
Incident-damaged and total-loss EV battery processing. ADR-compliant intake, state-of-health report, asset valuation and disposal.
Insurance & Data services
High-performance EV and hybrid race programmes generate battery data no one else sees. Forensic recovery, cell-level analysis, and IP-secure disassembly documented from collection to destruction.
Motorsport
Rules and deadlines
Three frameworks shape what happens to end-of-life packs: Duty of Care, the EU Battery Regulation and producer responsibility.
2027
When battery passports become mandatory in 2027, the audit trail is already there.
Every pack stored, transported, or transferred carries a legal duty of care. Full Duty of Care documentation on every transfer.
Battery passport, material recovery quotas, and Extended Producer Responsibility land in stages through 2027.
Material flowing through GTI carries the documentation downstream refiners and producers will increasingly need.
FAQ
It depends on what's still inside. GTI pays ATFs to take the problem away, where sending it the other way costs £400–1,200 a pack.
74% of every pack, including components, cells, and remaining usable life, is recovered and routed back into the right supply chain (aluminium to aluminium, copper to copper, cells to cells). That's around 186 kg of every 250 kg pack. Conventional shredding recovers less than 8%. That's typically 15–20 kg from a standard 250 kg pack.
When shredding is the only step, components, cells, performance data, and modules with years of usable life are destroyed on the way. Where conventional shredding sees black mass, GTI sees cell-level data, recoverable materials, and components with a second life.
GTI is developing second-life battery energy storage systems for deployment across commercial and industrial sites, manufactured from precision-recovered components at a fraction of the cost and embodied carbon of new-build storage. Components the precision disassembly line recovers are engineered into energy storage and replacement packs from the outset, so the second life is designed in.
A battery's useful life runs well past its warranty. The first life ends when the pack can no longer do its job.
Handing packs to GTI is straightforward. We arrange the most appropriate transport for each collection. Tell us the pack format, current location and requested collection date.
GreenTech Industries works before recycling. It is the first stage in the chain, ahead of black mass and bulk shredding. Refiners get better feedstock, shredders get safer material to process, and OEMs and fleets get reusable parts with the data that comes with them.
The high-voltage bus is isolated, the coolant drained and the casing removed, then every pack goes through multi-stage HV verification: isolation, bleed-down, external discharge and thermal imaging. Every pack is made safe before anyone works on it. GreenTech Industries is certified to ISO 9001, 14001 and 45001.
From the industry
The market is moving fast. We’re watching it closely and helping to shape it.
GTI's first three apprentices start in September 2026, training in robotics, business and management at its EV battery disassembly sites in Warwickshire.
Used EV sales rose 67% in the second quarter, to a record 110,761 cars. A second-hand market that barely existed three years ago is now real, and it runs entirely on confidence in the battery.
A government-backed project, AutoDMR, will take GTI's live Southam operation from manual work to high-rate automation, in collaboration with the Manufacturing Technology Centre and Coventry University.
