How advanced cable stripping and recycling systems are promoting the circular economy in Europe

By Marco Arezio

The growing demand for conductive and plastic materials, particularly copper and polymers, has driven the development of effective and sustainable recovery and recycling processes.

Electrical cables, which are a key component in many infrastructures, are primarily composed of copper, aluminum, and plastic coatings.

At the end of their life, these materials become a valuable resource for recovery and recycling, reducing the need to extract new resources and minimizing environmental impact.

In this article, we will explore the main systems for stripping electrical cables, the recycling processes associated with copper and plastic, and recycling statistics in Europe. Finally, we will analyze the destinations of recycled materials and how they are reused in various sectors.

Electrical Cable Stripping Systems

The process of stripping electrical cables is crucial for separating conductive metals from plastic or rubber coatings.

There are several methods and technologies for stripping cables, each offering specific advantages based on cable size, material quantity, and industry needs.

Manual Stripping

Although obsolete for large volumes, this method is still used in some contexts for small cables or situations where volumes do not justify the use of more advanced technologies.

It involves using manual tools such as pliers and knives to separate copper or aluminum from the plastic coating. However, this process is labor-intensive and inefficient, with a higher risk of damaging the metal during stripping.

Automatic Strippers

Automatic stripping machines are systems capable of processing large volumes of cables. They work by precisely cutting and separating the plastic coating from the inner metal, minimizing losses and increasing efficiency.

Strippers can vary in size and capacity, with industrial models able to handle different types of cables, from small wires to large cables used in energy infrastructures.

Shredding and Separation

An alternative to the stripping process is shredding the cables. This method breaks the entire cable into small fragments, allowing the copper (or aluminum) to be separated from the plastic through processes such as flotation, electrostatics, or gravity separation.

This system is particularly useful for treating cables that cannot be efficiently stripped but requires advanced technology and careful waste management.

Cryogenic Processes

In cryogenic systems, the cables are cooled to extremely low temperatures, making the plastic coating brittle. This allows the copper to be mechanically separated from the insulating material with minimal impact on the conductive metal.

Although more expensive, this process offers high efficiency for certain types of cables, especially those with composite coatings that are difficult to treat with other methods.

Recycling of Copper and Plastic

Once the materials are separated, the recycling process varies depending on the material being processed.

Copper Recycling

Copper is one of the most valuable materials to recycle due to its conductive properties and its ability to be reused indefinitely without losing its qualities.

After stripping or shredding, copper is typically melted to remove impurities and transformed into ingots or wires ready to be used in new products.

Recycled copper is used in a wide range of industries, including:

Electronics: for producing components such as wires, cables, and printed circuits.

Construction: used in pipes, electrical cables for buildings, and other applications.

Automotive: for the manufacture of electrical components and wiring.

In Europe, about 50% of copper demand is met through recycled materials, highlighting the importance of recovering this metal in the supply chain.

Plastic Recycling

The plastic coating of cables, generally composed of polyethylene, PVC, or thermoplastic materials, is treated separately. Unlike copper, recycling plastic is more complex due to the degradation of the material's properties over time and the difficulty of completely separating impurities.

There are two main methods for recycling plastic:

Mechanical Recycling

Plastic is washed, ground, and transformed into granules, which can be used to produce new plastic products. However, recycled plastic materials may have inferior quality compared to virgin polymers, limiting their applications.

Chemical Recycling

In some cases, polymers can be chemically treated to break them down into their basic monomers, which are then reused to produce new plastic with characteristics similar to the original materials. This process is more expensive but allows for the recycling of plastic with superior quality.

Recycling Quantities in Europe

In Europe, the recycling of electrical cables is a growing sector, with policies increasingly oriented toward the circular economy and reducing environmental impact.

According to Eurostat, the recycling rate of electrical and electronic waste, which includes cables, has steadily increased in recent years. In 2020, the average recycling rate for these materials in Europe reached about 42%, with countries like Germany and the Netherlands exceeding 50%.

As for copper, the European Union recovers over 2.5 million tons of copper per year, with a recycling rate exceeding 40% of total demand. The main countries involved in copper recycling include Germany, Italy, France, and Spain.

Plastic recycling is also a growing sector, although the recovery rate is still lower than that of metals. It is estimated that about 32% of plastic waste is recycled in Europe, with initiatives aimed at improving waste management and the efficiency of recycling processes.

Destination of Recycled Materials

Recycled materials from electrical cables find new applications in various sectors:

Copper: Recycled copper is primarily reused for producing electrical cables, electronic components, and automotive wiring. Its high conductivity and ability to be reused without quality loss make it one of the most versatile and valuable materials in the production cycle.

Plastic: Recycled plastic is often used to produce less technical materials, such as pipes, packaging, or everyday objects. Some types of recycled plastic can be transformed into materials for thermal or acoustic insulation.

Conclusion

The recycling of electrical cables is a key element in the transition toward a circular economy, reducing environmental impact and limiting dependence on virgin natural resources.

Stripping systems, combined with advanced separation and recycling technologies, allow valuable materials such as copper and plastic to be recovered and reintroduced into production processes.

With increasingly sustainability-oriented policies, Europe is playing a leading role in expanding these systems, laying the foundation for a more environmentally friendly and low-impact future.