As sustainable mobility gains momentum, the number of electric bicycles (e-bikes) on European roads has increased drastically, presenting a new challenge for the waste management sector. Saubermacher, Austria’s leading environmental services company, and the German firm Liofit GmbH have launched a joint project in February 2026 to address this issue. Through an innovative diagnostic system, they offer a “second life” for used batteries, or—if repair is not possible—recover valuable raw materials using state-of-the-art industrial recycling technology.
E-bike batteries are typically based on lithium-ion technology. While these batteries have a finite lifespan, they represent significant value even after they are no longer suitable for powering a bicycle. Saubermacher’s strategy is built on a “Zero Waste” vision, aiming to keep raw materials in the economic cycle for as long as possible.
Diagnosis Before Recycling: The “Second Life” Concept
A central element of the project is the intelligent battery diagnostic system developed by Liofit GmbH. The process does not begin with immediate destruction but rather with a thorough technical assessment:
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State of Health (SoH) Assessment: Every incoming battery undergoes a unique test to determine the residual capacity and safety status of the cells.
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Repair and Refreshing: If only individual cells or the Battery Management System (BMS) are defective, Liofit specialists can repair the units, allowing the battery to return to its original function in an e-bike.
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Secondary Use: If the capacity is no longer sufficient for an e-bike, the batteries are repurposed for stationary energy storage systems, such as buffer storage for solar power systems, extending their useful life by several years.
This approach significantly reduces environmental impact by prolonging the life of precious metals used during the manufacturing process.
Industrial-Scale Recycling: 10,000-Tonne Capacity
If a battery’s condition no longer allows for further use or repurposing, Saubermacher directs the units to the Redux plant (a German subsidiary of the group) in Bremerhaven. This facility is currently one of the most modern lithium-ion battery recycling plants in Europe.
According to technical measurements and source data:
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Annual Capacity: The plant is capable of processing 10,000 tonnes of lithium-ion batteries per year, covering a significant portion of the expected e-bike and small device battery waste in the region.
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Recovery Rates: Mechanical and hydrometallurgical processes can recover up to 95% of valuable metals such as cobalt, nickel, and copper.
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Lithium Extraction: Modern procedures ensure that the purity of the recovered lithium carbonate reaches 99.8%, making the material suitable for direct reintegration into the production of new batteries.
Preparing for the 2027 Regulatory Shift
The launch of this project coincides with the tightening of European waste management laws. Starting in 2026 and leading into 2027, new EU battery regulations (2023/1542) mandate stricter recovery quotas and documentation requirements for manufacturers and distributors.
The partnership between Saubermacher and Liofit assists companies in meeting these expectations:
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Safe Logistics: They provide specialized, UN-certified containers for the safe transport of used or damaged batteries.
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Transparency: Through a digital customer portal, the entire journey of every battery is traceable—from initial diagnosis to final recycling.
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Resource Efficiency: In its initial ramp-up phase, the project aims to process approximately 2,000 to 3,000 tonnes of used batteries annually.
Conclusion: Closing the Loop
The Saubermacher e-bike battery project demonstrates that e-mobility is only truly “green” when the entire lifecycle is managed. The combination of Liofit’s diagnostic expertise and Saubermacher’s industrial recycling infrastructure ensures that rare earth metals do not end up in landfills but instead serve as raw materials for future technologies.
Official Sources and References:
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Original Press Release: Saubermacher – Zweites Leben für E-Bike-Akkus