The pioneering circular economy factory

Let's take the road west to Flins, in Yvelines, a historic stronghold of Renault. Arriving there, it is difficult to miss the huge industrial complex of the diamond brand. In front of us stand more than 200 hectares from which some of the most emblematic models of the French car fleet have emerged: 4CV or Dauphine for the oldest, Twingo or Clio for the youngest. When we push open the doors of the factory, a reality strikes us: the 70-year-old factory is in the process of giving itself a second lease of life. Gradually, the Renault Zoé, the latest model to be assembled on site, saw their production relocate in favor of one of the Renault Group's new raison d'être: the circular economy. Named Refactory, this future-oriented factory is positioned as a pioneer in an era marked by the metamorphosis of our mobility.

While the metamorphosis of the ancestral model of the automotive industry seems inevitable, we are still in a position to ask ourselves a question: why did we choose the Flins site as the scene for the transformation of a supercentenary company? To find out, you have to delve into the history of the factory. Opened in 1952 to power post-war France, the factory has always been a center of innovation for the Renault group. Since its opening, more than 18 million vehicles have emerged from the belly of Flins, from the runner-up, emblematic of the 1950s, to the Zoé model, well anchored in the third millennium.

In reality, the factory has never stopped reinventing itself, so its metamorphosis into a refractory is far from being a heresy. But in addition to this historical justification, François Evrard, the director of the project, tells us that the very location of the site is ideal because of its proximity to large urban areas. “The sphere of influence of a site like this is about 200 kilometers,” he said. “By being located in the Yvelines, we are within reach of the entire Paris basin, part of Normandy, and the Loire Valley, this location was originally competitive for distribution reasons, and is even more so today in order to achieve a circular economy where flows come and go from our site.”

In Flins, this Refactory therefore benefits from a beautiful historical heritage, a large customer base, but also from a vast area of 200 hectares, which formerly welcomed more than 20,000 employees. Today, 2,000 employees work on site to assemble the Zoé models, which not only leaves space for new activities to set up, but also makes it possible to imagine the future of the factory with a workforce already on site. François Evrard recalls: “One of the main objectives of this project is not only to maintain these 2,000 jobs, but also, by 2030, to create an additional 1,000”.

François Evrard wishes to remind us: “we should not confuse the group's general circular economy strategy and the activities of the Refactory as such. At the group level, the strategy is divided into 3 main areas: The creation of a subsidiary called “Future Is Neutral” dedicated to raising funds from partners dedicated to the financing of activities related to The circular economy. The launch of a program dedicated to the reuse of used car batteries, for example in the storage of renewable energies or the supply of buildings. And finally, the launch of this Refactory, which within it, brings together several activities.

As project manager, François Evrard helps us to dissect the segmentation of new activities at the Flins site: “Here, our actions are organized around four main areas” He says “Re-Trofit”, in charge of the renovation and customization of thermal or electric vehicles, in particular to extend their lifespan or adapt them to new standards. “Re Energy”, dedicated to the management of the life cycle of electric batteries, from their production to their recycling through their repair, their reuse or their energy valorization. “Re-Cycle”, the center in charge of recycling materials from end-of-life vehicles, or used batteries, in order to manufacture new parts. And finally, “Re-Start”, a center for innovation, training and incubation of start-ups.

According to François Evrard, “Without this fourth component, it is impossible to imagine a sustainable circular economy strategy [...] We have to learn from each other, our relationship with start-ups is very interesting, they allow us to think about the industry differently, and we allow them to carry out certain projects with the provision of equipment. There is something for everyone and everyone is moving in the same direction.”

If the Renault Group is implementing this entire strategy, it is to achieve a list of ambitious goals, whose deadline is fast approaching. Committed to reducing its carbon footprint and contributing to the fight against climate change, in line with the Paris Agreements (which aim to achieve carbon neutrality in Europe by 2040 and worldwide by 2050).

On the agenda, Renault plans, first of all, to continue developing its electric range, with the objective of becoming 100% electric in Europe by 2030, which would make it possible to reduce emissions during the use of its vehicles by 35% in 2025 and 65% in 2030. In addition to this electrification, the models in circulation will see their life cycle change drastically, going through the repair, renovation or recycling process instead of ending up in the junkyard.

To conclude on this metamorphosis, François Evrard says he is obviously confident about the future of the automotive industry “We are at the very beginning of a new era, our business is in full transition, so our goal in this context is to position ourselves as pioneers right now, in the hope that others will follow us along this path”.