Daikin eyes mass production of heat exchangers from recycled aluminium

Japanese manufacturer Daikin is preparing to produce air-conditioner heat exchangers from recycled aluminium. It is eager to advance a ‘horizontal’ recycling process that keeps end use unchanged.

Traditionally, heat exchanger fins require high-purity aluminium. Scrap fins usually contain copper and other impurities, leading to downcycling into automotive or lower-grade parts.

Daikin partnered with two other Japanese firms, Nippon Magnetic Dressing and UACJ Corporation, to refine separation and press-formability technology. The goal is a closed-loop system where aluminium fins are recycled back into new fins.

Better sorting vital

Nippon Magnetic Dressing developed advanced sorting that lowers copper content from around 3% to below 0.1%. UACJ then produced aluminium with higher press-formability, enabling use despite trace impurities.

Using this material, Daikin successfully press-formed fins and assembled complete heat exchangers on a standard production line. Recycling aluminium can cut CO₂ emissions by up to 97% compared with primary metal.

Daikin now plans mass production, using discarded heat exchangers from its factories and after-sales service operations. The approach could set a benchmark for resource circulation in the HVAC industry.