For more than a century, car manufacturing followed a linear path: materials arrived at a factory, vehicles were built, and eventually they reached the end of their life. Today, the Toyota Circular Factory (TCF) is redefining this model, finding practical ways to keep materials in use for longer. One example of this is the aluminium loop now operating in the UK, where alloy wheels recovered at TCF-UK support the production of new engine components.
In Europe, Toyota Motor Manufacturing UK’s (TMUK) Burnaston plant in Derbyshire is home to the first Toyota Circular Factory, a first‑of‑its‑kind project establishing methods and standards for a future network of circular facilities across the region. Building on this progress, a second TCF will open in Poland this year.
At Burnaston, aluminium recovered from alloy wheels at TCF-UK is processed and prepared for re‑use, then supplied to Toyota’s Deeside plant where it is incorporated into engine component production. These hybrid power units then return to Burnaston for installation in new Toyota Corolla vehicles, effectively closing the loop from old wheel to new engine. The first vehicle benefiting from this circular process came off the line on 19th March, marking a significant step forward in Toyota’s ambition to expand the use of recovered, recycled and re‑used materials and parts.
“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,” – Leon Van Der Merwe, VP Circular Economy and Energy Business at Toyota Motor Europe.
