ExxonMobil, Milliken & Ravago unveil high-performance recycled automotive material

Irving, TX – ExxonMobil Chemical, in collaboration with Milliken & Company and materials recycler Ravago, has published a new case study outlining breakthroughs in recyclable polypropylene (rPP) compounds for automotive applications.

The study highlights a novel formulation that incorporates ExxonMobil’s Exact™ polyolefin elastomers (POE) together with Milliken’s DeltaMax® performance modifiers to enhance mechanical performance of rPP materials — traditionally a challenge for high-stress automotive parts like wheel arches and fascia deflectors.

Trials demonstrated that the new blends, including a version with 20% Exact POE and certified post-consumer recycled content, met or exceeded key performance benchmarks such as impact strength and stiffness while also improving melt flow rate — a factor that can reduce processing time and energy use during manufacturing. In some tests, impact performance increased by more than 600% compared to baseline rPP compounds, and melt flow rate improved roughly 200%.

The development responds to evolving European Union end-of-life vehicle (ELV) regulations that mandate greater use of recycled plastics in automobiles, pushing material suppliers to balance sustainability with stringent mechanical requirements.

ExxonMobil said the collaborative effort puts high-recycled-content materials closer to performance parity with traditional virgin plastics, offering a promising path for automakers seeking both regulatory compliance and reduced environmental impact.