Transforming obsolete military equipment into a circular economy solution while ensuring security, sustainability, and resource efficiency

Defence
Air

Thales site in Châtellerault, October 2023 — © Julien Lutt / CAPA Pictures - Thales

Type Insight
Published 10 Oct 2022

What happens to high-tech military equipment at the end of its lifecycle? Thales is pioneering a sustainable solution by dismantling and recycling reconnaissance pods. This initiative ensures resource recovery, environmental protection, and compliance with security regulations. By leveraging existing expertise and partnerships, Thales is proving that the defence industry and the circular economy can go hand in hand.

Can military hardware be recycled sustainably? Thales is leading the way with an innovative approach to decommissioning high-tech defence equipment.

Recycling military equipment is more than just waste management—it’s a strategic move towards sustainability, security, and economic efficiency.

Pioneering Circular Economy Practices in Defence

For decades, decommissioned military hardware was either scrapped, stored indefinitely, or destroyed without efficient recycling solutions. The defence industry, packed with sensitive technology and rare materials, lacked a structured approach to sustainability—until now. Thales is tackling this challenge by launching a dedicated dismantling and recycling initiative as part of its environmental, social, and governance (ESG) strategy.

This initiative began in 2015 when a NATO country requested the dismantling of 40 reconnaissance pods supplied in 1993. These pods, featuring cutting-edge sensors, rare metals, and electronic components, were carefully decommissioned at Thales's Élancourt site in France. With a skilled team ensuring compliance with health, safety, and security protocols, the project became a model for sustainable military asset management.

Sustainable Dismantling: A Responsible Approach

Thales’s recycling approach prioritises resource recovery and security compliance, ensuring every component is handled appropriately. To enhance efficiency, Thales partnered with Paprec, France’s leading recycling contractor, which is authorised to process sensitive and strategic materials.

Sensitive elements, such as sapphire optics and high-grade aluminium, undergo meticulous dismantling to be reintegrated into manufacturing. Conventional recycling methods are employed for other recoverable materials. Clients receive official destruction certificates, reinforcing Thales's commitment to transparency and compliance.

You have to know the product and the precautions to take. That’s why it’s important for customers to return their pods to the manufacturer at the end of their service life.

- Thales Product Support Manager

Beyond Recycling: Transforming Military Assets into Museum Exhibits

In 2021, a NATO client made an unusual request—transforming five decommissioned pods into museum exhibits. This required a meticulous process: stripping out classified components while maintaining the pod’s external structure for public display. The result? A unique blend of military heritage and public education.

Thales has since leveraged this expertise to explore new opportunities, including mock-ups for trade fairs and aviation museums. By responding to custom client needs, Thales is not just recycling but repurposing military technology for public awareness and historical preservation.

Scaling Up: A New Standard for Defence Sustainability

Following the success of this program, the French Air Force has approached Thales for similar decommissioning services. With infrastructure and expertise already in place, Thales is well-positioned to scale this initiative globally, offering sustainable solutions for other obsolete military technologies.

By 2023, Thales aims for 100% of its new products and services to integrate eco-design principles—ensuring sustainability is embedded from the design phase onwards. This commitment aligns with broader industry trends, where circular economy practices are becoming a key driver of innovation.

Our latest assessments show that more eco-friendly technologies often tend to perform better. Things like extending battery life, reducing weight or increasing a product’s lifespan are really just design improvements. Today’s focus on the circular economy is pushing us to optimise everything we can. It’s a powerful driver of excellence in design.

Marc Heude - Eco-Design Manager at Thales

A Future Built on Sustainability and Innovation

With the defence industry increasingly focused on environmental responsibility, Thales’s pioneering recycling and decommissioning initiative is setting a new benchmark. This project underscores the strategic importance of sustainability in defence, demonstrating that military technology can be responsibly dismantled, repurposed, and reintegrated into a circular economy.

By leveraging its expertise and collaborating with industry leaders, Thales is not just adapting to sustainability trends—it is shaping the future of defence technology with innovation, responsibility, and vision.