Cox Recycles 10M Pounds of EV Batteries Into New Power

Cox Automotive has processed more than 10 million pounds of electric vehicle battery materials, proving that battery recycling can work at real scale.

The material, called "black mass," contains valuable minerals like lithium, nickel, cobalt and manganese. These can be refined and reused to make brand new batteries instead of mining fresh materials from the earth.

"This milestone is proof that circularity in the EV battery ecosystem is moving from concept to scale," said Brian Skalovsky, Director of Battery Recycling for EV Battery Solutions by Cox Automotive.

The timing couldn't be better. Electric vehicles made up about 5 percent of lease returns in 2025, but that number is expected to jump to 12 percent this year and reach 23 percent by 2028. That means thousands of aging EV batteries will need somewhere to go.

Cox's recycling facility in Oklahoma City uses a dry processing system that avoids water and chemical treatments, making it safer and better for the environment. The process recovers up to 94 percent of battery materials for reuse.

But recycling isn't the only answer. Cox says it also focuses on refurbishing and remanufacturing batteries to extend their useful life before they ever need recycling. Some batteries that can't power cars anymore still have enough juice for other uses, like storing solar energy.

The Ripple Effect

This milestone shows the electric vehicle industry is maturing beyond just selling new cars. Building the infrastructure to handle battery lifecycles means fewer minerals need to be mined, less waste ends up in landfills, and EV ownership becomes more sustainable from start to finish.

"This is about building the infrastructure that makes electrification work in the real world," said Lea Malloy, Chief Product Officer of EV Battery Solutions.

As more people make the switch to electric vehicles, knowing that the batteries can be recycled into new ones makes the choice feel even better.