Toyota’s European-first chapter: End-of-life aluminium recycled in hybrid Corolla

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Toyota Motor Manufacturing UK has advanced its circular economy strategy by establishing a closed-loop aluminium recycling system at its Burnaston facility in Derbyshire, England. It has created what the company describes as a European-first process for recovering aluminium from end-of-life vehicles and reusing it in the production of new hybrid auto components.

The Burnaston site is a pilot facility, set to develop operational standards and processes that could be replicated across future circular manufacturing centres in Europe. A second facility is scheduled to open in Poland later in 2026. 

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Aluminium returns to the production cycle

A key feature of the Toyota Burnaston project is the recovery of aluminium from discarded aluminium alloy wheels. The recycled metal is transported to Toyota’s engine manufacturing plant in Deeside, North Wales, where it is processed into components for hybrid power units.

The newly produced hybrid units are then supplied back to the Burnaston assembly plant and installed in new Corolla vehicles. Toyota confirmed that the first vehicle incorporating aluminium recovered through this circular process was produced on March 19, 2026.

According to Umit Sengezer, Head of Toyota Circular Factory at Toyota Motor Europe, the project has already provided valuable operational insights during its initial year.

“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,” he noted. 

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Manufacturing principles meet circularity goals

According to Toyota, the Burnaston unit abides by Toyota Production System principles, adapting its efficiency-focused manufacturing philosophy to support circular resource management.

The company believes this approach can help maximise the value extracted from materials, parts and components throughout multiple product lifecycles, while improving resource efficiency and reducing environmental impact.

Burnaston was selected for the project partly because the UK represents one of Europe’s largest markets for end-of-life vehicles, providing a solid platform as well as a source of recyclable automotive materials. 

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Expansion plans in Europe

Toyota has already announced plans to carry the concept beyond the UK, planning the establishment of a second Circular Factory facility at its Wałbrzych manufacturing site in Poland.

Leon Van Der Merwe, Vice President for Circular Economy and Energy Business at Toyota Motor Europe, highlighted the principles of the “Toyota Production System”, a systematic approach that has set a benchmark for global automotive “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," he stated.

By keeping the recovered aluminium in use for longer periods, Toyota expects the step to improve material security, lower environmental impacts and uphold its long-term sustainability goals under the Toyota Environmental Challenge 2050 framework. 

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