Vehicle Recycling

Published by : Environmental Affairs Div., Toyota Motor Corporation

Published : April 2014
Contact : Environmental Affairs Div. TEL : +81-565 -28 -2121
 T a b l e o f C o n t e n t s

・ Table of Contents 1

・ Introduction 2

・ Resource saving and recycling,

 looking at the entire life cycle of vehicle 3

・ Specific content of efforts

Development and design with the environment in mind 4

Development
and Design
Development Easy to dismantle vehicle structure 5
and
Design Examples of efforts other than recycling 6
・Development and wider use of plastics derived from plants

Promotion of effective use of resources 7

and Logistics
Production
Production
・Reduction of discarded materials from the plants
and
・Reduction of water usage
Logistics
・Reduction of packaging and wrapping materials

Recycling at the Sale Stage 8

Sales
Sales
・Reuse of used parts

General overview of the recycling 10・11

End-of-life
Recycling of automobile shredder residue from
End-of-life
end-of-life vehicles 12・13
Research and development of recycling technologies 14∼16
Resource recycling of rare metal and rare earth 17∼21

・ Compliance with the domestic act for

 promotion of use of recycled resources 22

・ Compliance with overseas recycling laws 23

・ Result of Toyota Group’

s Efforts 24

〈 Vehicle recycling 〉Character profiles

N a m e : Kurukuru
Gender : Unknown
Interest : Driving
(The most recommended place to go is
Toyota Automobile Museum.)
Search by "Toyota Automobile Museum"!
Horoscope : Virgo

1
 Introduction Resource saving and recycling,
looking at the entire life cycle of vehicle
T O D A Y F O R T O M O R R O W
It is necessary to consider recycling through the entire life cycle of a car,
from its production to the end of its usefulness.
Make effective use of We also contribute

the earth’s limited resources, to sustainable Toyota applies the following activities
Toyota is constantly ●Suppress the generation of waste.
so the children of progress for society within these stages,
working towards that goal ●Repeatedly use reusable items.
s.
the future can always and the earth. Development Production
and Design and Logistics ●Recycle waste. It keeps going
through the most advanced
live affluent lives. round and round!
efforts in the field of
resource recycling. End-of-life Sales

which from the life cycle of vehicle

To make more effective use of limited resources, we feed the results back into the development and design stages,
Toyota Environmental Action Plan system working on creating cars with recycling in mind.
Universal guiding principles

Guiding Principles at Toyota

and policies

Life cycle of vehicle

Toyota Earth Charter (Environmental Basic Policies) Toyota Global Vision

Development/ Recycling improvement design/

Reduction of materials discarded
Production/
Development and Design Establishing a Establishing a Production
low-carbon society recycling-based society Design development of Ecological Plastic Logistics
Internal reutilization
Ultimate Eco-Car Internal recycling
Significantly reduce GHG emissions Enhancing recycling of resources through 3R Intra-process reutilization

Internal recycling
Resource
FCHV Working together with Society Development and Design input Products
Alternative
fuel HV
Diesel
Plug-in
HV Promoting integrated Promoting use of Ecological Plastic for plastic parts
Resource
HV
THS Ⅱ actions on CO2 reduction
( p h o t o: S m a r t H o u s e
(Photo: Parts of the SAI where Ecological plastic is used) Recycling for profits input
Waste at cost
collaboratively controls Materials discarded
Incineration of waste
Hybrid Technology home electric appliances,
Further performance improvement through the
use of hybrid technology
cars and solar power to
use home energy more
Landfill waste
Increasing use of returnable shipping containers
effectively) Enhancing development of recycling technology
for effective reutilization of resources
Bio (Fig. Resource flow)
fuel
D-4

The Fifth
Mid / long-term movement and direction

DPNR
Synthetic
fuel Lean
Recycling
Common-rail
burn EV
Toyota Environmental
CNG DI
VVT- i
Eco-driving enlightenment
activities (Photo: Monitor of
Action Plan
The right vehicle for the right place at ESPO installed in SAI and
the right time Prius α) 2011 - 2015
Alternative Diesel Gasoline Electrical
fuel engines engines engines energy

Development of next-generation vehicles using Environmental protection and establishing a society in Establishing technology
electricity, and promoting combination of harmony with nature Receiving and continuing the aimed at recycling advancement
different power sources in ways that maximise (photo: Exterior view of a recycling plant)
the strengths of each blessings of nature Recycling from end-of-life Recycling of repair/
End-of-life Sales
vehicles replacement parts
Working together with Society

Used bumpers Pallets for

replaced during transport,
HV Batteries HV Motors repair at dealers etc.

Promoting initiatives on biodiversity Supporting activities in Japan and overseas Enhancing environmental education at
(Photo: Toyota’s approach to t h ro u g h t h e Toyo t a E n v i ro n m e n t a l TOYOTA Shirakawa-Go Eco-Institute
Luggage door trim
biodiversity brochure) Activities Grant Program
Engine
ASR ＊ undercover Luggage trim
Seat back board
Environmental management

＊ ASR ： Abbreviation of Automobile Shredder Residue. It is the residue left from shredding end-of-life vehicles.

2 3
Ve h i c l e R e c y c l i n g

Specific content of efforts

Development and Design Development and Design

Development and design with the environment in mind Easy to dismantle vehicle structure
In 1998, Toyota was the first in the auto industry to introduce ISO14001＊1 in its design and development division. Since then, it has been assessing
recyclability in advance, at the vehicle development stage. From 2005, we introduced the“Eco-VAS”＊3 comprehensive environmental assessment
system, which is based on the approach of LCA＊2 (Life Cycle Assessment), through the entire vehicle development process.
■ Wire harness ■ Wire harness layout innovation
Environmental performance Using pull tab-type ground terminals The wiring harness can be stripped out
Assembled condition When dismantled without interfering with other components.
・Fuel economy improvement
・Customer needs
・Reduction of exhaust gas, noise, and Pull-off
・Cost direction
environmental load substances
・CE＊4 concept
・Recycle
・LCA

Development
and Design
Separates at
thinner areas
Vehicle planning Design and prototyping Before the production start

Setting targets that reconcile environmental Target attainment Final confirmation of

and Logistics
Production
performance with customer needs environmental performance

■ Instrument panel removal

The positioning of the V grooves makes it easy to
■ Use of "Easy to remove the instrument panel by pulling it strongly.
dismantle mark"

Sales
Assessment using the“Eco-VAS”environmental assessment system “Disassembly facilitation
marks”are added to show
key points for disassembly
Information

End-of-life
＊1 ISO14001 : The international standard for environmental management systems tasks.
Toyota was the first in the auto industry to introduce it in 1998. disclosure to
＊2 Life Cycle Assessment (LCA) : The product’s impact on the environment is assessed in each process,
from development to disposal, as a way of selecting production methods, alternative raw materials, customers
and other options with lower environmental burdens.
＊3 Eco-VAS : Eco-Vehicle Assessment System
＊4 CE : Chief Engineer

■ Door trim peeling ■ Removal of heavy parts of batteries

Points at which the load required for peeling door from hybrid cars
trim off can be reduced by 30% were identified, Component removal times for the Prius are further
and marked with easy to dismantle mark. reduced.
New easy to dismantle mark
is a d d e d , s o t h at h eav y
components can be hoisted
with good balance.

4 5
Ve h i c l e R e c y c l i n g

Development and Design Production and Logistics

■ The Ecological plastic CO2

Examples of efforts other than recycling   circulation concept Promotion of effective use of resources
CO2

Development and wider use of plastics derived from plants CO2

Photonic
Production
Toyota is suppressing CO2 emissions by other methods besides recycling, to prevent global warming. synthesis
CO2
CO2

Petroleum-based plastics Reduction of discarded materials from the plants

Toyota researched how to use plastics Heat recovery Plant-based We promote resource loss reduction activities to cut waste from the plants.
made from plants in cars! materials
In particular, we are tackling yield improvement measures and waste reduction to steadily cut down the amounts of waste output by the company.
Plastics derived from plants
■ Resource Flow ■ Environment Center
・Suppress CO2 emissions to prevent global warming

Development
The Toyota Environment Center is an energy recovery plant that is

and Design
・Helping to reduce the usage of oil resources Automobile
parts
Raw materials
adjacent to the Motomachi plant. The Center generates electricity
Internal reutilization
Internal recycling
Intra-process reutilization
and steam by burning combustlble waste and functions as the
■ Record of use in cars energy source for the Motomachi plant.
Resource

and Logistics
Products ・The Center had been completely shut down due to decrepit facili-

Production
World input
Use of Ecological plastic in the“Raum”in May 2003 Use of Ecological plastic＊1 in cars first
ties and resumed its operation in April 2009 after the renewal.
Recycling for profit
Waste at cost＊1 Managing combustion drastically reduced the emissions of
Incineration of waste
Bio-PET＊2 derived from sugar cane is used World Materials discarded (Waste
Use of new Ecological plastic in the“CT200h”in Jan. 2011 Landfill waste substances of concern in the exhaust gas.
in new Ecological plastic＊3. first not processed within Toyota)
・Incinerated ash shall be recycled outside
Use of new Ecological plastic for interior surfaces of Toyota as materials for cement or

in the“SAI”in Nov. 2011
Usage has reached
% of the surface area of all
interior decor components.
mponents.
Sales
Use in components that are difficult with previous Ecological plastic
pavement , etc.
Reach the same level as petroleum-based plastics,
80
includingg component
p costs.
Used in
Reduction of water usage
Parts which require high wear resistance
mass-produced cars!! ... Seat covers, floor carpets, etc. We are constantly working on ways to use water effectively in the plants, with particularly thorough attention

End- of-life
to management in car assembly plants, which use large volumes, to reduce overall water usage

Logistics
SAI CT200h
Reduction of packaging and wrapping materials
Usage is reduced by simplification of wrapping ■ Results of activities to reduce packaging and
specifications, including slimmer bumper wrapping,   wrapping materials (FY2012)
Reduction
and wider use of returnable shipping containers. Topics Products Details (Thousand
tons/year)

Changing packaging specifications, reuse, etc. 1.6

Increasing Service
lean parts
Increasing lean specifications for wrapping 0.3
specifications
：Areas where Ecological plastic is used for wrapping,
(approximately 80% of interior decor surface area) ：Areas where new eEcological plastic is used Production Improvement of storage capacity,
etc. 0.1
parts simplification of packing specifications, etc.
〈 Use of Ecological plastic in interior parts of partially redesigned SAI〉 Sugar cane Service Expanding the use of returnable containers
Increasing 0.3
parts (Expansion to more product types)
returnable
containers Production Expanding applications of returnable containers
＊1 Ecological plastic : The general name for plastics developed by Toyota for use in vehicles, which include plants as raw material and achieve better heat 0.3
parts (Expansion to more product types)
resistance, impact resistance, and other properties than general plant-derived plastics
＊2 Bio-PET : PET that is manufactured by replacing the monoethylene glycol that is one of the raw materials of polyethylene terephthalate with biological Before improvement : After improvement : Total 2.6
raw material derived from sugar cane Corrugated cardboard Air bubble sheet (polyethylene)
＊3 New Ecological plastic : Plastic that provides far better heat resistance, durability, expansion and contraction resistance, and other properties, than other
general plastics derived from plant materials ＊1 Waste at cost : Materials discarded that are recycled for a fee

6 7
Ve h i c l e R e c y c l i n g

Break
Coffee

Sales

Bumpers replaced
Recycling at the Sale Stage for repairs at car dealers
are recycled.
Recycling in Changing Times, and Toyota’s Response

Collecting discarded bumpers from dealers and recycling

ng of plastics
 1970∼  1990∼ 2001 2002 2003 2004 2005 2006 2007  2008∼
Discarded bumpers are made which allows easy recycling when they are discarded,
so we actively collect them through Toyota dealers nationwide.

Towards the creation of a recycling-based society

Changing times
We have advanced the technology built ● Thorough removal of foreign material,
up by recycling bumpers, developing a   such as grit adhering to bumpers
・Advance of the car ・The 2000 EU ELV Directive＊1 ・2005 Act for promotion of Use of ・Rising resource prices, rare metal shock
recycled material with end-of-life ● Quality acquisition through detailed society ・Recycling rate 95% in 2015 Recycled Resources(Japan) Expanded action towards securing resources

Development
vehicle bumpers as the raw material.   adjustment of constituents ・Mandatory disclosure of disassembly information ・Recycling rate 95% in 2015

and Design
・Factory pollution ・Growing momentum for promoting 3R
Deflector for problems ・Enactment of the 2000 Basic Law for Establishing ・Mandatory removal of three items Advancing recycling technologies
● Start of use in deflectors engine compartment →Rising environ mental  the Recycling-based Society and the 3R Law＊2   (airbags, flon, ASR) (thermal＊3 → material＊4)
    awareness ・Demand for the promotion of recycling design

We also established technologies that New technology development towards use of recycled

and Logistics
Production
allow eco-plastics and recycled plastics plastic materials from discarded bumpers ★1970∼ ★1998∼ ★2001 ★2005 ★2007 ★2008

to be used for 20% of all plastic compo- Established

Started ASR Established Recycle
Implementation of Prepared Established
● Decision of the target components and track Toyota Metal
operations Technical Center
the Automobile scenarios for the Resource
nents in 2013. Co., Ltd. Recycling Law recycling Recirculation
  of progress World's
P12 P14 P17
technologies in Committee
highest 2020
● Removal of coating fragments etc., which reduce level
Recycling design
  impact resistance

Sales
efforts based on
Efforts for recycling design
recycling
(design for easy removal of components) technology
scenarios
Various recycling design points are extended to all new vehicles from the Raum

Reuse of used parts

s Responses

End- of-life
Handling of used parts began and extends ■ How e-commerce works More advanced
Customer recycling of resources
nationwide in 2001, using e-commerce (rare earths, rare
Used parts Used parts Used parts Wants to use
(electronic commercial transactions) to dealer A dealer B dealer C metals, etc.)
used bumpers

Toyota’
Toyota Metal Co., Ltd.
make effective use of components, (Handa City, Aichi Prefecture)
Recycle Technical Center
through wider use of used parts, supply of Shipping Repair consultation Vehicle (Toyota Metal Co., Ltd.)
instruction and request repair
remanufacturing parts, etc.
Search Compliance with
and the Automobile Recycling Law
＊1
■ Supply of rebuilt parts and new parts Inventory order Access
  (FY2012) information e-commerce
site Dealer
database
Number supplied
Part name Part
Used parts and New parts
rebuilt parts (reference) request Delivery
ASR recycle plant
Automatick (Toyota Metal Co., Ltd.)
3,775 99
transmission
Product
Remanufacturing Power (Delivery via parcel service)
parts 9,908 4,721
steering Raum Prius
Parts
Torque distributor
3,758 5,766
converter Parts distributor : Company for the distribution and sale of car repair parts
Used parts 46,135 ー and accessories, established with joint investment from
Toyota Motor Corporation and local dealers. 34 companies nationwide ＊1 EU ELV Directive : Reduce waste output from end-of-life vehicles, recover materials for environmental protection, promote reuse and recycling.
            It is legally binding.
＊2 3R (Reduce, Reuse, Recycle) : Reduce the amount of waste generated, reuse it, and then recycle it.
＊3 Thermal recycling : Rather than simply incinerating waste, use the heat and gases etc. that are generated by incineration.
＊1 Rebuilt parts : Parts that have been disassembled and cleaned, have had internal parts replaced etc., and are at the same standard as new parts ＊4 Material recycling : Process the waste produced by used products, and use it as materials or raw materials for new products.

8 9
Ve h i c l e R e c y c l i n g

End-of-life

General overview of the recycling

Dismantling company Shredder company Recycling company

Development
and Design
End-of-life vehicles Removal of parts in good condition Press Shredder Reuse as materials

and Logistics
Production
Airbag collection
CFC collection and recycling Reuse as used parts, and as ferrous and non-ferrous metals Sort into three Reuse as energy

(Copper)
Bumper Battery

Sales
Flon Airbag
Engine, transmission
Ferrous Nonferrous metals Shredder residue（ASR＊1）

End- of-life
Catalyst Power steering,  etc. Reuse as ferrous and non-ferrous metals

■ Examples of parts being recycled from end-of-life vehicles ■ Recycling/recovery route for end-of-life vehicles(Japan)
Collecting Dismantling Shredding ASR recycling
Seat (Urethane foam, fiber)→ Soundproofing materials for vehicles Body (Steel)→ companies companies companies companies
Vehicle parts, general steel products ASR material composition (Wt%)
Approx.
Window (Glass)→Tiles, etc. 3.6 million 17∼19％ ASR ASR landfill,
Trunk (Steel)→

End-of-life vehicles
Hood (Steel)→Vehicle parts, general steel products Vehicle parts, general products Dealers
units/year etc. Wire harness Nonferrous metal

Press
Glass Non-combustible
Engine (Steel, aluminum)→Engines, aluminum products
Bumper (Resin)→Interior parts Vehicle
40∼60％ Paper
Used car
End user
Wiring harness (Copper)→ 4
Tire (Rubber)→ recycling/ 2 5
Copper products, engines (cast aluminum reinforcement) dealers
Raw materials, recovery rate : 7 Resin
alternative fuel for cement, etc. Service over 99%＊2
Engine oil (Oil)→ 33
Alternative fuel for boilers and incinerators centers 20∼45％
Door (Steel)→ Iron 8

Recycling
Vehicle parts, general steel products

Removal

Sorting
Radiator (Copper, aluminum)→
Gunmetal ingots, aluminum products Exports of Combustible
Catalytic converter (Rare metal)→
Catalytic converters used cars Rubber
Coolant (Alcohol)→ 7
Alternative fuel for boilers and incinerators Urethane
Gear oil (Oil)→Alternative fuel for boilers and incinerator Fabric foam
Bumper (Resin)→Interior parts, tool boxes, etc. Engines, transmissions, catalysts, tires, Ferrous, Soundproofing products, Wood 15
Suspension (Steel, aluminum)→General steel products, aluminum products 16
3
batteries, oils, fuels, flons, airbags, etc. nonferrous metal copper, slag, electricity, etc.
Battery (Lead)→Batteries
Wheel (Steel, aluminum)→Vehicle parts, general steel products, aluminum products
Transmission (Steel, aluminum)→
General steel products, aluminum products Tire (Rubber)→Raw materials, alternative fuel for cement, etc.
＊1 ASR : Abbreviation of Automobile Shredder Residue.
＊2 Recycling efficacy rate : Weight sent for recycling / total weight of end-of-life vehicles

10 11
Ve h i c l e R e c y c l i n g

End-of-life

＊1
Use of resin as a heat source
Recycling of automobile shredder residue (ASR ) for electric steel furnaces Joint technical development
with Aichi Steel Corporation

from end-of-life vehicles Electric steel furnaces use heat sources

in Jan. 2005

and carbon additives when then melt

ferrous scrap to turn it into steel.
In 1993, Toyota started working jointly with Toyota Metal Co., Ltd. Iron scrap
Substitution
to develop ASR recycling technology. We built a unique recycling for heat sources
By adding an appropriate amount of the and carbon
plant and started operating it in August 1998, recycling on a mass additives
resin sorted out from ASR, it has become
production basis (approximately 15,000 cars per month).
possible to achieve a heating efficiency
usable as a heat source and also to use
Toyota Metal Co., Ltd. the resin as an alternative to the recar- Dissolution

Development
and Design
burizer.
Development and use of ASR sorting technology
Resin within ASR Electric steel furnace
To use automobile shredder residue, leaving no residues, it is necessary to return it to the basic materials of products. The Automobile Recycling Law calls for
That requires separation of constituents to raise their purity, so we developed special separation technologies for the ASR recycling rate to be raised to 70% This technology enables effec-

and Logistics
ASR recycling plants, using wind and magnetism, to make shredder residue reusable. by 2015, but Toyota already reached that tive use of light materials of

Production
target in 2007. low calorific value, such as
ELV Shredder Plant ASR Recycling Plant mixed resin, which were previ-
（End of Life Vehicle） （Automobile Shredder Residue）
ously difficult to recycle. Steel and components for vehicles

Trommel
World’ s first
mass production

Sales
process of shredding
Crushing and ASR recycling
Primary shredder
Main shredder Use as substitute fuel Recycle of glass
Pneumatic Aluminum T h e resi n t h at is t h e l a rgest We have developed technologies to recycle vehicle
sorting
ingredient of ASR, by weight, is glass, making the most of its high-purity property.

End- of-life
used as alternative fuel.
Non-ferrous
sorting
Glass
Joint research with Sanei Corporation
Urethane foam/ and in use since April 1999
Pneumatic sorting Ferrous metal fibers
ASR
(Shredder dust) Pneumatic High-strength, precise tiles
sorting
Magnetic sorter
Rotating sieve

Glass
Copper

Resin/rubber Resin within ASR Landscape paving

Shredded ferrous Nonferrous
metal Melt-solidification
metal
Technical development about landfill

Iron scrap (Toyota plants) Electric furnace heat source ●Toyota has established a technology to mix and ●The amount of lead elution is reduced to 1/5 of
Press  heat ASR, reducing it to 1/5 of the volume.  the previous level, reducing the environmental
 load on landfill sites.
＊ ASR ： Abbreviation of Automobile Shredder Residue.

12 13
Ve h i c l e R e c y c l i n g

End-of-life

Research and development of recycling technologies R&D on resource recycling

End-of-life vehicle recycling research Development of appropriate and Research into technologies for
Toyo t a h a s to d a te co n d u c te d e x te n si v e re s e a rc h to efficient recycling technologies disassembling parts that use rare earths
enhance the dismantlability of end-of-life vehicles and the We are researching and developing technologies for We are researching efficient dismantling technologies
recyclability of parts. To further advance dismantling and the recycling and appropriate treatment of parts for the magnets used in devices such as hybrid vehicle
recycling technologies and commercialize and incorporate disassembled from end-of-life vehicles, including drive motors which use neodymium and dysprosium＊2.
them in vehicle designs based on the technologies and methods for their appropriate and efficient disassem-
expertise gained from this research, Toyota established the bly and reuse.
Automobile Recycle Technical Center within Toyota Metal

Development
and Design
Co., Ltd. in 2001.
Automobile Recycle Technical Center
Research into technologies for
disassembling parts that use noble metals
We are researching technologies for the efficient dis- Motor removal Motor disassembly
Positioning of the Automobile Recycle Technical Center

and Logistics
assembly of electronic circuit boards and sensors

Production
etc., which are viewed as urban mine resources＊1,
and technologies for the removal of components Research into efficient removal and
Toyota Motor Corporation Dismantling and shredding industries, etc. recovery technologies
containing noble metals.
We are researching dismantling technologies that are
World's
■Engine ECU
Disclosure of efficient when used with widely used heavy dismantling

Proposing easy to
recycle vehicle designs
Sales
highest
Proposing efficient level
information on dismantling equipment, and easy to dismantle vehicle structures.
dismantling technologies
technologies, etc.

Technical development

End- of-life
for recycling rare metal and
rare earth resources
Before scrapping After scrapping

■O2sensor
Automobile Recycle
Technical Center
・Research into vehicle structures that are easy
to recycle
・Research into efficient scrapping technologies Heavy scrapping
equipment
・Development of appropriate and efficient
recycling technologies

Before scrapping After scrapping

Technical development Disclosure of
for recycling rare metal and information on dismantling
rare earth resources technologies, etc.

Removing a wire harness＊3 with

heavy scrapping equipment
Component and material manufacturers, etc. Tool and instrument manufacturers, etc.

＊1 Urban mines : The valuable rare metals contained in vehicles, electrical appliances, etc. that are discarded as garbage in urban areas are seen mine resources.
＊2 Neodymium and dysprosium : Rare earths used in the production of powerful permanent magnets
＊3 Wire harness : The bundled electric wires that supply electricity within the vehicle.

14 15
Ve h i c l e R e c y c l i n g

End-of-life

Resin recycling research

Resource recycling of Hybrid vehicle motors Hybrid vehicle batteries
We are considering the possibility of reusing resin
Nd Li
vehicle parts recovered from end-of-life vehicles, as a rare metal and rare earth Neodymium Lithium

way of promoting the wider recycling of resin.

E.g.) Bumper material from end- of-life vehicles→ In recent years, vehicles have come to use numerous motors and circuit boards.
Ni
Nickel
Reused in resin body components Compared to previous vehicles, hybrid vehicles, in particular, have increasing numbers
＊1 ＊2
Cu Dy
We are also working on R&D towards future realiza- of components, such as batteries and motors that use rare metals and rare earths . Copper Dysprosium

tion of bumper to bumper recycling.

Toyota is working on rare metals to provide its customers

with stable supply of good vehicles

Development
and Design
Procurement risks ■ Leading producing countries of non-ferrous metal resources(2009)
Source: Annual report on the environment in Japan 2010

●The potential extraction period is short

Rare earth Lithium
●Production is concentrated in a few countries. Other
Brazil 1% 0%
●Procurement is easily affected by economic Other

and Logistics
India 2%

Production
 and political changes. 22%
Chile
41%
●Prices are extremely volatile. China China
Vehicle resin parts 97% 13%
Australia
This is one of the factors that can have 24%

a major impact on the production and

Copper Nickel
Research into technology for the removal and sale of cars in the future
Russia

Sales
recovery of batteries from hybrid vehicles Countermeasures Chile 19%
Other 34% Other Indonesia
50% 55%
End-of-life hybrid vehicle battery units basically remain Manuals for the disassembly and removal ●Reduce the quantities used of materials subject 13%
to procurement risks. Peru 8% Canada
at high voltage and, if they are damaged during the of hybrid vehicle batteries are also available U.S.A 8% 13%
●Stabilize procurement by opening up new routes.
removal process, they can cause sparks, fire, and fluid on the Toyota Motor Corporation official site

End- of-life
●Recycle resources from“urban mines”
. ＊1 Rare metal : Metals difficult to obtain. Lithium, cobalt, nickel, etc.
leakage accidents, so safe removal is required. (http://www.toyota.co.jp/). ＊2 Rare earth : Rare-earth 17 metals of similar chemical properties, included in the rare metals

Therefore, we are collaborating with the Japan ELV＊1

Recycler’s Association to run training sessions nation-
wide on the safe and appropriate removal of hybrid B re a k
Coffee Periodic table of the elements
vehicle batteries.
(Group) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
(Period)
1 2

1 H He
Hydrogen Helium
3 4 5 6 7 8 9 10

2 Li Be B C N O F Ne
Lithium Beryllium Boron Carbon Nitrogen Oxygen Fluorine Neon
11 12 13 14 15 16 17 18

3 Na Mg Al Si P S Cl Ar
Sodium Magnesium Aluminum Silicon Phosphorus Sulfur Chlorine Argon
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

4 K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr
Potassium Calcium Scandium Titanium Vanadium Chromium Manganese Iron Cobalt Nickel Copper Zinc Gallium Germanium Arsenic Selenium Bromine Krypton
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

5 Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe
Rubidium Strontium Yttrium Zirconium Niobium Molybdenum Technetium Ruthenium Rhodium Palladium Silver Cadmium Indium Tin Antimony Tellurium Iodine Xenon
55 56 57∼71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86

6 Cs Ba Lanthanide
Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn
Cesium Barium Series Hafnium Tantalum Tungsten Rhenium Osmium Iridium Platinum Gold Mercury Thallium Lead Bismuth Polonium Astatine Radon
87 88 89∼103

7 Fr Rg Actinide
Francium Radium Series
Workshop for disassembly
and removal of 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71
hybrid vehicle batteries Rare metal
Lanthanide
Series
La Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu
Lanthanum Cerium Praseodymium Neodymium Promethium Samarium Europium Gadolinium Terbium Dysprosium Holmium Erbium Thulium Ytterbium Lutetium Rare earth

＊1 ELV : End-of-life

16 17
Ve h i c l e R e c y c l i n g

Wo
r
first ld
!
End-of-life

Recycling of nickel＊1 included in batteries

Resource recycling of rare metal and rare earth
In October 2010, Toyota started the world’s Hybrid vehicle
purchase
We have built a collection network, unique to Toyota, for the first“battery to battery”recycling operation, in
collection of used batteries, and the Toyota HV＊1 Call Center partnership with other related companies. It Removal of
End-of-life hybrid vehicle batteries
receives collection requests nationwide. This system is able extracts nickel from used nickel-metal hydride hybrid vehicle

to recover over 90% of used batteries (record for FY2010). batteries and recycles it as raw material for
batteries. Total recycling of rare metals has
Hybrid vehicle Dismantling
Customers
This system also increases consolidation on the returning deliv- moved into the final validation phase＊2. production companies Discarded battery reception
Collection and transportation
ery trucks of Toyota service parts, reduce CO2 emissions. In instructions

future, we plan to build a global recycling system, covering Until now Toyota HV
Toyota
Call Center
North America, Europe, and elsewhere. Recycled as scrap for raw

Development
and Design
material of stainless steel.
PEVE
system Toyota
（Primearth EV Chemical
Energy） Engineering
Production of Reduction,
Stainless hybrid vehicle batteries crushing and sorting

Rare earth Sumitomo Metal

Outline of the Whole Collection Network Development of advanced sorting recycler Mining Co., Ltd.
and extraction technologies

and Logistics
Production
Materials from
battery recycling
Ni and Co refining
In future Battery raw material
manufacturing
Dismantling companies Dealers
Transition to complete recycling. Removal NEW

of nickel, cobalt＊3,
③Transportation ③Transportation and rare earths
 (consolidated with  (reverse logistics of service Nickel Rare earth
hydroxide compounds
 catalysts)  parts delivery)

Sales
③ Dismantler : ③ Distributor : Nickel Rare earth
Cathode material Anode material
Aggregate Consolidation with Part supply and
Toyotsu Recycle recovered catalysts return service
Distributors
Corporation

End- of-life
Part supply transportation Toyota Chemical Sumitomo Metal Primearth EV Toyota Motor
① Collection request

② Recovery request

company Engineering Co., Ltd. Mining Co., Ltd. Energy Co., Ltd. Corporation

Hybrid vehicle battery recycling process

Reduction process, Refining and Production of hybrid Hybrid vehicle
④Transportation crushing and sorting processing vehicle batteries production
 (reverse logistics of service
 parts delivery)

Toyota Chemical
④ Reverse logistics of
Engineering Co., Ltd. supply deliveries
⑤Reduction process

Toyota HV call center

(24 hours a day) Sumitomo Metal Mining
Co., Ltd.

＊1 HV : Abbreviation of Hybrid Vehicle Materials from Nickel battery raw

Hybrid vehicle battery Hybrid vehicle
battery recycling materials
Product
NEW

Rare earth compounds

＊1 Nickel : Rare metal

＊2 Validation phase : Studying the problems of a newly-developed product or technology, etc. by using it in real situations, as preparation for practical use
＊3 Cobalt : Rare metal

18 19
Ve h i c l e R e c y c l i n g

End-of-life

Resource recycling of rare metal and rare earth Resource recycling of copper, aluminum,
rare metal, and non-ferrous metal
Rare earth resource recycling ■ Toyota's Goal of Magnets Vehicle-to-Vehicle Recycling
Compared to nickel metal hydride batteries, lithium batteries use less metal
＊1
Neodymium and dysprosium , which are rare resources to produce the same battery capacity.
earths, are essential for the magnets used in Toyota is developing technologies to recycle rare metals, non-ferrous metals
devices such as hybrid vehicle drive motors. and other elements of lithium batteries in the same way as from nickel metal
Scrapping hydride batteries. Lithium battery
New car Dismantling
s Responses

Development of motors with less

rare earths wherever possible.

Development
and Design
Toyota’

Development of systems for

Recycle loop of carbide product waste (tungsten)

S
vehicle-to-vehicle recycling of magnets

S
N
New car

N
manufacturing Extracting magnets ● With the cooperation of Sumitomo Electric Indus-
tries, Ltd. and Toyota Motor Corporation, the
Toyota

and Logistics
world’s first and forefront system for recycling

Production
(Scrap sorting)
S S
tungsten (rare metal) from carbide product waste
in domestic reflow has been established.
N N

Copper resource recycling Recycling of ● 100% recovery and recycling of tungsten from
Magnets
Resources
carbide product waste has been achieved. Chips, etc. Rotating tools,
HVs and electric vehicles use copper in their motor cables

Sales
etc.
and battery electrodes, as well as in the wiring harnesses. Rare earth ● This activity is being extended
  in Toyota Group (16 companies).

Group company of Group company of

End- of-life
Sumitomo Electric Industries,Ltd. Sumitomo Electric Industries,Ltd.
●Development of sorting technologies (Carbide product manufacturing) (Material recycling)
Motor wires ●Parts evaluation tests
●Development of manufacturing methods
 and other fields are R&D topics.
Copper

Carbide Carbide Tungsten powder

chips drills
Wire harnesses

＊1 Neodymium/dysprosium : Rare earths used in the production of powerful permanent magnets.

20 21
Ve h i c l e R e c y c l i n g

Compliance with the domestic act for Compliance with overseas

promotion of use of recycled resources recycling laws

The Automobile Recycling Law, which came into effect in January 2005, mandates an appropriate division of Compliance with overseas automobile recycling laws
roles between automakers and other involved parties, to promote the recycling and appropriate processing of
All EU member states have enacted automobile recycling laws based on EU ELV Directive of 2000, and as of
end-of-life vehicles.
January 2007 automakers started to take back end-of-life vehicles (ELVs) in most member states. In cooperation
In line with the Act for Promotion of Use of Recycled Resources, Toyota collects CFCs, airbags, and ASR from
with TME and distributors in various member states, Toyota has completed construction of a network ELV collection
end-of-life vehicles and actively uses them for recycling and other applications.
of the 28 EU member states, and is proceeding with the necessary action in the remaining four member states in
accordance with government authorization of dismantlers.
Outline of the Law for recycling of end-of-life vehicles (Automobile Recycling Law) In other countries around the world, Toyota is diligently pursuing similar responses, working closely
(in effect since January 1st, 2005)
with its distributors to ascertain local regulatory trends and studying local infrastructure in each country.
■ System for collection and recycling under the Automobile Recycling Law
Targets: 4-wheel passenger vehicles(including mini-vehicles) and 4-wheel commercial vehicles(standard, small, mini-trucks and buses)
■ Legislation status ■ EU member states
Japan automobile recycling promotion center(JARP) New vehicle owner, etc.
〈Three designated companies〉 Status Country/Region Legend
Claim
Used car EU, EFTA※, Japan,
Enacted

under the road vehicles act

Fund management corporation Return of vehicle Taiwan, Korea, Turkey
Automakers and importers (self implementation or outsourced)

Recycling fee weight tax

De-registration system
Payment Final owner Under study
Russia, India, China, Finland
Information management center Mexico, Vietnam
Sweden
End-of-life
vehicle ※ EFTA：4 member states of Switzerland, Norway, Iceland, and Liechtenstein Estonia
Designated recycling support organization Latvia
Ireland Denmark
Collection company
Lithuania
(dealer, vehicle maintenance company, etc.) Netherlands UK
Belgium Poland
End-of-life Luxembourg Germany
Outsourced/ Fluorocarbon Collection of flon, vehicle
Czech Rep. Slovakia
payment destruction etc.
company France
Hungary
Outsourced/ Flon collecting company
Japan Auto Austria
payment Fee payment Slovenia Romania
Recycling Portugal Italy
Partnership End-of-life Bulgaria
Outsourced/ Airbag Collection of vehicle Spain Croatia
(JARP)
payment recycling airbags
company Used parts, etc. Greece
Dismantling company

Usable parts market/

Malta

Usable metal market

Payment Cyprus
Disassembled
vehicle
〈Collection management companies by team〉
Contract Metals, etc.
Shredding company ＊1 The EU ELV Directive : A directive adopted in the EU in 2000. It is legally binding.
〈TH team〉8 companies ＊2 TME (Toyota Motor Europe) : the management company in overall control of Toyota’s European operations
Outsourced/
payment (Toyotsu Recycle Corporation) Outsourced/ ASR
Toyota, Honda, Daihatsu, Hino, payment collection
VW, Audi, Peugeot, BMW Metal, electricity,
etc.
〈ART※〉 ASR recycling company, etc.

Residue
Registration required License required Certification required
Flow of materials Flow of expenses Landfill
※ ART：Automobile shredder Residue recycling promotion Team

■ Transition in Toyota's vehicle recycling/recovery rate and ASR recycling/recovery rate

99% 99%
100
Toyota's recycling/recovery rate
90 96% 97% 97% 97%
94% 94% (vehicle conversion value)
93% 93%
Toyota’
s ASR recycling/recovery rate
80 85%
80% 81%
70 76%
Legal standard for FY2015 : 70%
60 66%

50 57%
’
05 ’
06 ’
07 ’
08 ’
09 ’
10 ’
11 ’
12 (FY)

22 23
Ve h i c l e R e c y c l i n g

＊1
Result of Toyota Group’
s Efforts

Ye a r Milestone Details

1970 Toyota Metal Co., Ltd. established to meet future demand for ・First automaker to establish a recycling company
responsible disposal of end-of-life vehicles ・Approx. 6.5 million vehicles recycled between 1972 and 2012

1973 Toyota Chemical Engineering Co., Ltd. established to process and ・Established by Toyota Tsusho Corporation; 30,000 kL of waste oil
recycle cutting oil from Toyota production plants processed and recycled between 2008 and 2011

1985 Toyotsu Recycle Corporation established to recover and recycle ・Established by Toyota Tsusho Corporation; approximately
precious metals from exhaust gas catalysts 16 million catalysts recycled between 1985 and 2012

1992 Toyota Environment Committee established ・Chaired by TMC president

1996 Bumper recycling across Japan commences ・Approximately 10 million recycled between 1996 and 2012

1998 Automobile Shredder Residue (ASR＊2) recycling plant established ・Established at Toyota Metal Co., Ltd.
・World's first dedicated ASR plant
・ASR recycled into soundproofing materials for 22 million vehicles
between 1998 to 2012

End-of-life hybrid vehicle NiMH battery collection and recycling ・Approximately 30,000 collected between 1998 and 2012
commences

2001 Automobile Recycle Technical Center established ・Established at Toyota Metal Co. Ltd.; first automaker to establish
an independent recycling research institute

Ecoline Corporation, a used parts sales network operator, ・Established by Toyota Tsusho Corporation; approximately 200,000
established used parts handled annually

Parts e-commerce system introduced for Toyota parts distributors ・Approx. 600,000 used parts sold between 2001 and 2012
throughout Japan

2003 Toyota Recycling Vision formulated ・Sets targets for 2015

"Raum" model launched ・Incorporates Toyota's proprietary "Design for Recycling" (DfR) features

Bio-plastics used in parts for the first time ・World-first

2005 Aluminum recycling business established at Toyota production ・Expanded to 13 plants worldwide; approximately 2.5 million tons
plants recycled between 2005 and 2012

2007 95% vehicle recycling rate achieved

2009 Recycling guidance commences in countries where hybrid vehicles ・Aiming for development of NiMH battery collection systems
are sold outside Japan

2010 Battery-to-battery recycling of hybrid vehicle NiMH batteries ・World-first

commences

Tungsten recycling system launched ・World-first; approximately 75 tons recycled between 2010 and
August 2013

2011 99% vehicle recycling rate achieved

2012 Magnet-to-magnet hybrid vehicle motor magnet recycling system ・World-first

launched

2013 System for reusing NiMH batteries in stationary rechargeable ・World-first

batteries launched

Redesigned "Sai" dedicated hybrid sedan launched ・Achieved 20 percent usage of Ecological Plastic and recycled resin
materials

Toyota wins JEMAI Rare Metal Recycling Award ・First automaker to win the award

Toyota wins Prime Minister's Prize in the 3Rs Awards ・First automaker to win the award

＊1 Toyota Motor Corporation, Toyota Tsusho Corporation, and their affiliates

＊2 ASR : Abbreviation of Automobile Shredder Residue. It is the dust left from shredding end-of-life vehicles.

24