Tesla Model Y (4680 Structural) battery recycling in Stuttgart, Germany
Stuttgart, Germany is a diagnostics site: Tesla Model Y (4680 Structural) packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
3,545 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
28,000 TPA
Cell Grading & Diagnostics
Cities served
12
From Stuttgart, Germany
Where a Tesla Model Y (4680 Structural) pack goes from Stuttgart, Germany
- 1
Collected via Dubai, UAE
Whole packs enter the network at Dubai — Jebel Ali Logistics Yard, 4,759 km away, where they are weighed and de-energised.
- 2
Module grading at Stuttgart, Germany
All 3 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 3
Second life at Zwickau, Saxony
At 80% SOH about 47% of the pack qualifies for reuse and goes to Zwickau — Saxony Second-Life Works (321 km). Moderate — structural pack bonding limits module harvesting; cell-level grading required.
- 4
Refined at Lyon, France
Remaining modules are shredded to black mass and refined at Lyon — Auvergne-Rhone-Alpes Refinery, 469 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dubai — Jebel Ali Logistics Yard | 4,759 km |
| Nearest second-life works | Zwickau — Saxony Second-Life Works | 321 km |
| Nearest refinery | Lyon — Auvergne-Rhone-Alpes Refinery | 469 km |
Faster option
Inside the Tesla Model Y (4680 Structural) battery
The Tesla Model Y (4680 Structural) (2022) carries a 82 kWh NMC 811 Cylindrical 4680 pack with 3 modules at 355 V, weighing roughly 418 kg. Structural tabless format requiring specialised disassembly cells. High nickel yields offset elevated processing cost.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 94.2% | A — BESS ready | USD 4,607 |
| Year 4 | 89.9% | A — BESS ready | USD 4,425 |
| Year 6 | 85.6% | A — BESS ready | USD 4,162 |
| Year 8 | 81.3% | B — Second life | USD 3,674 |
| Year 10 | 77% | B — Second life | USD 3,281 |
What the chemistry means here
How it ages
Fade mechanisms mirror other NMC 811 cells. The tabless design lowers internal resistance and heat generation, which can slow resistance growth relative to older cylindrical formats.
Thermal behaviour
4680 cells carry the same high-nickel chemistry as 2170s but in a larger can with more energy per cell, so a single failing cell releases more heat. Structural packs also make it harder to isolate an individual failing cell during handling.
Handling NMC 811 (4680)
Collecting a Tesla Model Y (4680 Structural) pack
82 kWh, 3 modules, about 418 kg — this is how the Stuttgart, Germany team plans the job.
Removal
Packs are dropped on a vehicle lift using the OEM procedure and a rated battery table, then isolated at the service disconnect.
Packaging
One pack per UN-rated pallet box, strapped and restrained, with terminals capped and coolant ports sealed.
Consolidation
Dealer and workshop returns are consolidated into full truckloads, typically eight or more packs per run.
Before the truck arrives
- Pull the service disconnect and record pack voltage
- Drain or cap coolant lines before lifting
- Photograph the pack casing and any impact damage
- Keep the VIN and pack serial together on the manifest
Stuttgart, Germany site notes
- Engineering packs should come with architecture information.
- Suppliers can book recurring collections for returns.
- Damaged packs need ADR-compliant packaging.
- Send a serial list with each delivery.
What this pack yields
lithium
4.49 kg
nickel
29.01 kg
cobalt
2.91 kg
manganese
3.03 kg
copper
12.26 kg
aluminium
14.08 kg
Refining-route estimate at 80% SOH. Measured module health on the bench sets the final split.
Rules in Germany
EU Battery Regulation (EU) 2023/1542 and national implementing law
Regulator: Umweltbundesamt (UBA) with registration through stiftung ear
The works operates under German environmental permitting and battery law aligned with the EU Battery Regulation (EU) 2023/1542. Transport follows ADR rules for dangerous goods, including the special provisions for damaged or defective lithium batteries.
Tesla Model Y (4680 Structural) in Stuttgart, Germany: common questions
Can I drop off a Tesla Model Y (4680 Structural) battery at Stuttgart, Germany?
Stuttgart, Germany is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Dubai, UAE, 4,759 km away.
What happens to Tesla Model Y (4680 Structural) modules after Stuttgart, Germany?
Collected via Dubai, UAE, then Module grading at Stuttgart, Germany, then Second life at Zwickau, Saxony, then Refined at Lyon, France. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Tesla Model Y (4680 Structural) pack be prepared for pickup?
Pull the service disconnect and record pack voltage. Drain or cap coolant lines before lifting. Photograph the pack casing and any impact damage. Keep the VIN and pack serial together on the manifest.
Which rules apply to Tesla Model Y (4680 Structural) recycling in Germany?
EU Battery Regulation (EU) 2023/1542 and national implementing law, overseen by Umweltbundesamt (UBA) with registration through stiftung ear. Road transport follows ADR, and shipments out of Germany fall under the EU Waste Shipment Regulation.
Cities collected by Stuttgart, Germany
Tesla Model Y (4680 Structural) at other sites
Other passenger packs at Stuttgart, Germany
Retiring Tesla Model Y (4680 Structural) packs near Stuttgart, Germany?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.