Toyota recycling alloy wheels into new engine blocks

Toyota has opened its first circular factory at its plant in Derbyshire, establishing a process in which aluminium recovered from end-of-life alloy wheels is recast into engine components for the Corolla.

The first vehicle built using this recovered material came off the production line earlier this month.

Recovered aluminium is sent from the Derbyshire site to Toyota’s Deeside plant in North Wales, where it is incorporated into hybrid power unit production before returning to Burnaston for Corolla assembly.

The facility also processes vehicles from other brands, generating broader insights into dismantling methods and material composition.

Leon Van Der Merwe, vice president, circular economy and energy business at Toyota Motor Europe, 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 new circular factory supports Toyota’s goal of achieving carbon neutrality across European products and operations by 2040.

A second circular factory is planned at Toyota’s Wałbrzych plant in Poland.