Rethinking aircraft recycling

Derk-Jan van Heerden, founder and board member of Aethos, shares how the foundation is contributing to make aviation recycling more effective, and more sustainable.

At the end of 2005, I earned my MSc degree. As part of my studies, I completed a project on end-of-life aircraft to obtain a special ‘sustainability engineer’ certificate. I received a 9 out of 10 – not only because of the quality of my work but also because I developed a business plan for a company. That company, Aircraft End-of-Life Solutions (AELS), is still thriving and well known today.

As the chief executive of AELS, I met many professionals in the aircraft disassembly and dismantling industry. My network expanded further during my time on the board and as president of the Aircraft Fleet Recycling Association (AFRA). Through these experiences, I gained deep insight into how the market handles retired aircraft.

Aircraft disassembly is a highly specialised process, focused on carefully removing reusable components to keep other aircraft flying. However, not everything can be reused. The remaining airframe is dismantled, and as much material as possible is recycled to create new products.

Recently, I took a step back from AELS – not because I lost interest, but due to a personal battle with glioblastoma. I also wasn’t able to become a father, so I decided to donate all my money to a foundation I created: Aethos. Its mission is to advance recycling efforts in aviation.

The aviation industry should be proud of its progress in reuse and repurposing. But how effective is its recycling? Many believe that aircraft materials are already being recycled, but when you look closer, the reality is more complex.

Much of what is called ‘recycling’ is actually downcycling. True recycling would mean using materials from retired aircraft to build new ones. While this happens with some materials, aluminium is a major challenge. Aircraft are made from a mix of aluminium alloys that are difficult to separate. When melted together, the resulting material isn’t suitable for aircraft manufacturing, so it gets downcycled into lower‑grade products.

Meanwhile, the shift to carbon fibre reinforced plastic (CFRP) in modern aircraft reduces fuel consumption but creates a new problem – CFRP is currently landfilled because no effective recycling solution exists yet. Research is ongoing, but a breakthrough is still needed.

Despite these challenges, progress is possible. Better tracking of materials and improved collection and processing methods can make a real difference. Aviation has traditionally focused its sustainability efforts on noise reduction and fuel efficiency, but recycling must also become a priority.

The industry has an opportunity to lead by example and demonstrate that better recycling practices can be implemented today. Some solutions may not be profitable, and some will require more effort or investment. But Go aims to bridge the gap between aviation, recycling and research, ensuring that available solutions are explored and applied.

Aviation should take pride in these steps toward reducing its environmental impact – starting now.

This feature was first published in MRO Management – April 2025. To read the magazine in full, click here.