First Toyota using ‘circular process’ produced at Burnaston plant

The first car to be made from a ‘circular process’ at Toyota Manufacturing UK’s Burnaston plant has come off the line.

A year ago, Toyota Motor Europe announced the establishment of the Toyota Circular Factory (TCF) at the Derbyshire plant, which processes vehicles at the end of their life to maximise the environmental benefits of recycling, repurposing and remanufacturing.

Toyota has now confirmed that the first new car to contain recycled materials from TCF came off the production line at Burnaston, which produces the Corolla, on 19 March.

Burnaston is the site of Toyota’s first TCF in Europe. As well as recovering materials for use in new cars it is also gaining insights for future vehicle design that will enable easier refurbishment and more efficient end-of-life dismantling.

The car giant said this circular approach supports its strategy for achieving global carbon neutrality in its products and operations.

Umit Sengezer, Toyota Motor Europe’s head of the Toyota Circular Factory, said: “In the first year of its launch, TCF Burnaston is already delivering excellent results and giving us valuable insights, not just in how we handle vehicle end-of-life processes, but also how we can build circularity into the planning and design of future vehicles.

“This will enable us to secure even stronger rewards, helping us maximise the potential of the materials, resources and parts we use.”

Historically, a car manufacturing plant would receive materials and components and use them to build new vehicles.

TCF Burnaston is redefining this concept, maximising opportunities for recycling, re-use and repurposing when vehicles reach the end of their lifecycle.

For example, aluminium recovered from alloy wheels at TCF Burnaston is processed, prepared for re-use, then supplied to Toyota’s Deeside plant in North Wales where it is incorporated in engine component production.

These hybrid power units are then sent back to Burnaston for installation in new Corolla vehicles.

Using Toyota Production System principles, the TCF goes beyond optimising the recovery of parts and materials from end-of-life vehicles.

It evaluates how circular approaches can support more efficient vehicle design, manufacture and lifecycle management in the future.

Leon Van Der Merwe, vice-president of Toyota Motor Europe’s circular economy and energy business, said: “Toyota has a proud history of establishing the Toyota Production System, principles that have become the global standard for manufacturing efficiency.

“Now we are applying the same concept to circularity, designing systems that will help ensure the maximum benefits are realised from end-of-life vehicle feedstock.

“Ultimately, the ambition is to progressively establish a circular economy model where resources flow through multiple lifecycles, reducing environmental impact, improving material security and supporting Toyota’s long-term environmental commitment.”

The Burnaston site was chosen as an ideal location to initiate the circular factory concept as the UK has one of Europe’s largest end-of-life-vehicle markets.

As it is one of very few right-hand drive nations in Europe, most of the vehicles sold here remain in the country through to the end of their lifecycle.

This has led to the development of a mature and highly experienced dismantling sector and learning eco-system.

Moreover, Toyota Manufacturing UK was the first Toyota operation in Europe to manufacture hybrid vehicles, putting in place a strong foundation of manufacturing expertise and technical know-how.

On the back of the success at Burnaston, Toyota will now open a second TCF in Poland this year.