The automotive industry is facing enormous challenges. Increasing sustainability requirements, growing customer expectations and changes in consumer behaviour are colliding with the need for economic efficiency. Global filtration expert MANN+HUMMEL has a long tradition of developing new and pioneering technologies. According to the company, sustainability is firmly anchored in its corporate philosophy and in the DNA of its premium brand MANN-FILTER. With a new product innovation made from renewable raw materials, at the same price and with the same performance, the technology leader is now taking another major step towards sustainability.

CO2 footprint reduced

Filters with cellulose media have previously been impregnated with fossil-based phenolic resin, which ensures stability, rigidity and chemical resistance. The filtration expert is partially replacing this crude oil-based impregnation with the plant-based raw material lignin, which is a natural product derived from wood. Lignin is responsible for the stability of wood and can also impart this property to filter media. This technology will first be used in selected MANN-FILTER air and oil filters, with other filters to follow. This will enable MANN+HUMMEL to reduce the CO2 footprint of the lignin impregnation used in production by up to five percent compared to regular phenolic resin impregnation. In addition, around 27 percent of the crude oil used for impregnation will be saved.

Savings confirmed by external testing laboratory

The calculation of CO2 values and the calculation method used to determine the crude oil savings were externally verified and confirmed by ClimatePartner. ClimatePartner is a German company that supports companies in calculating, reducing and offsetting CO2 emissions and offers climate neutrality labels. Thanks to the switch to lignin, MANN-FILTER's C 17 237 air filter, for example, will reduce CO2 emissions by 3.93 tonnes per year and save more than 4,500 litres of crude oil based on 2024 sales figures. The material used comes from certified sources. Lignin is a waste product that is produced in large quantities in paper and pulp production – several million tonnes worldwide every year.

Everything should remain as simple as possible for users

These more sustainable air filters are now available in the independent aftermarket as MANN-FILTER applications for almost 70 million passenger cars and vans in Europe, while oil filters are available for almost 17.6 million vehicles. The improved impregnation will now be incorporated into defined series products. Gradually, more and more MANN-FILTER products will be converted to lignin. ‘This means that customers do not have to choose between different versions, no additional storage space is required, and no further part numbers are necessary,’ explains Dr. Lars Spelter, Lead Engineer Filtration Materials at MANN+HUMMEL. "Everything should remain as simple as possible for our customers. Externally, the filters impregnated with plant-based materials differ from conventional filters. They are slightly brownish due to the characteristic colour of the lignin they contain and have a pleasant natural smell. The innovative products are easily recognisable by the green leaf pictogram on the packaging. Our lignin impregnation is a successful example of how ambitious CO2 reduction targets in product development can also be implemented in series-production products."

Green electricity and environmentally friendly packaging

For a holistic view of sustainability, not only the components and materials of a filter must be included in the environmental balance sheet, but also its manufacturing process. In order to further reduce CO2 emissions during production, MANN+HUMMEL intends to use only electricity from renewable sources or a combination of green electricity and certificates as well as guarantees of origin from hydro, solar or wind power plants from 2025 onwards. Energy sources for generating process heat are also to be CO2-neutral from 2035 onwards in order to achieve a significant milestone in CO2-free production. MANN-FILTER packaging offers another approach to improving the ecological footprint. The global filtration expert is aiming for a minimum of 90 percent recycled cardboard from certified raw material sources at its largest filter plant in Marklkofen. "We consistently use sustainable materials for the yellow-green box and employ mineral oil-free, plant-based inks as well as water-based adhesives and lacquers. We also attach great importance to conserving resources in production: more than 95 percent of the waste generated during the manufacture of our filters is recycled. This means that almost all production waste is recycled or thermally recovered,‘ confirms Marian Anton, Business Development Manager at MANN+HUMMEL. ’Even with the increasing spread of more sustainable electric cars, the contribution of combustion engines to achieving climate neutrality by 2050 remains important and necessary," Anton explains. "Although only new cars that are CO2-emission-free when driving will be registered in the EU from 2035, millions of petrol and diesel-powered passenger cars and commercial vehicles will still be on the road after that, not only in the EU but worldwide. Our filtration solutions therefore play a crucial role in improving the sustainability of new and existing vehicles, especially those with combustion engines."

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