UK automaker recovers metal for manufacturing hybrid components

Toyota UK is recovering aluminium from discarded vehicles to create new components for engines in its hybrid cars. 

A midway option between traditional cars, vans and electric vehicles (EVs), hybrids combine an internal combustion engine (ICE) with up to four electric motors.

The British-based arm of the well-known Japanese auto business is using its plant in the village of Burnaston for the cutting-edge recycling project, which is part of an initiative called “Toyota Circular Factory”. The facility in South Derbyshire is processing end-of-life vehicles (ELVs) to recover parts, recycle materials and remanufacture components.

Aluminium recovered from alloys at the plant is processed and sent to Toyota's Deeside facility in North Wales. The metal is then employed in engine component production onsite. After assembly, the power units are shipped back to Burnaston and installed in new Corolla vehicles. 

Hybrid car engine components commonly made from aluminium include cylinder heads, pistons, oil pans, electric motor housings and even engine blocks. However, aluminium is not durable enough to create smaller critical components used in engines, like springs. Manufacturing springs must be made from robust metals, such as high-strength alloy steels, to withstand repeated stress and demanding operating conditions.

The Burnaston plant will now establish processes and standards that will support a new network of circular facilities throughout the region. Following the foundations of the project in the UK, a second site is planned to launch in Poland later this year. The first vehicle manufactured using this sustainable circular process left the Toyota assembly line in March.