CarRecyclingEurope

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This brochure can be found in English at:http://www.toyota-europe.com and in the other languages on the national Toyota sites

Main contact:Toyota Motor Marketing Europe Environmental Affairs OfficeAvenue du Bourget 60B - 1140 BrusselsTel. 0032 2 745 2486Fax: 0032 2 745 2067E-mail: eaco@toyota-europe.com

Contents

Introduction:Making People-friendly and Environmentally-friendly Cars

Current Status of Recycling:What happens to End-of-Life Vehicles

Recycling Activities all along the Life Cycle of Cars

Recycling as a Key Issue in Product Design - the Development Stage

Avoid Waste through Recycling - the Production Stage

The Essential Support of Dealers - the Use Stage

Striving for Sustainable End-of-LifeProcesses - the Disposal Stage

The Recycling Working GroupRecycling activities

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Making People-Friendly andEnvironmentally-Friendly CarsIn order to ensure that automobiles will continue to be a sustainable mode of transport in the

21st century, Toyota considers it important to proactively take action to reduce their environmental

impacts all along their life cycle. One of the aspects Toyota is focusing on is the recycling stage.

Recycling as One Approach

Automobile recycling is a positive contribution to the

reduction of many environmental impacts. In fact efficient

utilisation of resources by reusing discarded materials or

using them as energy sources lessens the impact on the

environment due to the depletion of natural resources and

the potential pollution related to disposal to landfill.

At Toyota, we are thinking about recycling opportunities at

every stage of life cycle of vehicles, i.e., development,

production, use, and final disposal.

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20 25%

45 55%

35 20%

Automobiles manufactured by automakers and used by

consumers until the end of their useful life are referred to as

end-of-life vehicles. At present, approximately 75% to 80% of

end-of-life vehicles in terms of weight, mostly metallic fractions,

both ferrous and non ferrous, is being recycled. However, the

remaining 20% to 25% in weight, consisting mainly of hetero-

geneous mix of materials such as resins, rubber, glass, textile,

etc., is still being discarded. From end-of-life vehicles, disman-

tling companies first remove the oil, engine, transmission, tire,

battery, catalytic converter, and other parts, which are

commonly recycled or reused. Shredding companies then sort

out the ferrous and non-ferrous metals and resin from the

remaining vehicle bodies. While the ferrous and non-ferrous

metals are recycled, the shredder residue is being disposed of

as waste in landfills.

In order to most effectively utilize the earth’s resources and

reduce the volume of disposable waste, automobile recycling

activities must include efforts to further reduce the volume of

this waste and promote its reuse and recycling to ultimately

achieve zero waste.

What Happens to End-of-Life Vehicles?

Current status of recycling

Disposal route for end-of-life vehicles

DismantlingCompanies Shredding Companies

Aut

omak

ers

Vehi

cles

Use

rs

De-

regi

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ed

vehi

cles

Dealers

Used car dealers,

etc.

Users

Export of used cars

End

-of-

life

vehi

cles

Pre

ss

Waste

8-9 million vehicles/year estimated figure for Europe

Rem

oval

Sorti

ng

Engines, tyres, transmissions, batteries, catalysts, oils and fuels, CFCs, HFCs, airbags, etc..

Ferrous, non-ferrous metals

Approximately 2 million tonnes per year of ASR(Automobile Shredder Residue) are disposed of

in landfills (estimated figure for Europe)

Shredder residue composition (weight in %)Non-ferrousmetals

Wire harnessesGlass

Paper 2Wood 3

Iron 8

Rubber7

Fabric15

Urethanefoam

16

Resins16Non

combustible

Combustible

In October 2000, the European Union adopted the End-of-Life Vehicles (ELV) directive (2000/53/EC) which seeks toprevent and limit waste and improve the re-use, recyclingand recovery of ELVs and their components. The directivealso promotes eco-design, the usage of recycled materialsand the improvement of the environmental performance ofall of the economic operators (e.g. shredders, dismantlers)involved in the vehicle life-cycle.

The ELV directive’s targets for re-use, recovery anddisposal include:• A minimum of 85% in weight of ELVs should be recov-

ered as of 2006, including a maximum of 5% energyrecovery, and, from 2015, a minimum of 95% in weight,including a maximum of 10% of energy recovery.

• Banning the use of hazardous substances, such aslead, mercury, cadmium and hexavalent chromium for new vehicles as from July 2003, excluding parts whereit is essential for use.

Toyota endorses the directive’s requirements, and isactively working with its European National Marketing andSales Companies to meet the challenges the directiveraised. Given the vital role they play, Toyota is also workingin close co-operation with recycling and shredding com-panies to develop better and more efficient solutions fordealing with end-of-life vehicles.

A requirement of the directive is to make information about theabove topics accessible to perspective buyers of vehicles.

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Recycling Activities all along the Life Cycle of Cars Recycling should be addressed as a key issue

during the entire life cycle of an automobile,

from its conception to the end-of-life stage.

Accordingly, Toyota is involved in activities to

reduce waste as much as possible and recycle

whatever can be reused at the development,

production, use, and disposal stages.

In order to more effectively use non-renewable

resources, early in the development stage,

Design for Recycling techniques are also put in

place.

The Recycling Working GroupTo control and monitor environmental policy goals, andensure full legal compliance and integration of environ-mental performance throughout the business process,Toyota has established in Europe an EnvironmentalCommittee and Working Groups, one of which is dedicatedto “Recycling”.

The main objectives of this working group are in line withthe requirements of the ELV directive, and in the attain-ment of the recyclability and recoverability targets forvehicles sold in the European market.

The working group members are conducting research intoefficient dismantling technologies for end-of-life vehicles,promoting the utilisation of shredder residue and settingup a strategy for boosting the usage of recycled materialsfor some specific car components. Furthermore the Recycling Working Group gives its sup-port to the main Toyota Recycling Committee, based inJapan, on Design for Recycling.

DevelopmentDevelopment of easy-to-recycle

materials and design for easy

disassembling / dismantling

UseSet up a system for waste collection

and recycling at dealers; collection

of replaced parts for

remanufacturing

ProductionApplication of a range of recycling

technologies and improvement

of efficiencyFeed back of technical information

on recycling

Recycling Activities

Recoverability Prior AssessmentSystem

Design that takes Recycling into Consideration

Design with Due Care ofEnvironmental Impact

Resin Recycling Technology

Rubber Recycling Technology

Application of a Range ofRecycled Materials

Recycling of Waste by Dealers

Remanufactured Parts

A Practical Tool for Dismantling

Pioneer Recycling Plant Operational in Japan

Effective Utilisation of Shredder Residue

Enhancing Research through theAutomobile Recycling Technical Center

Building the Prius BatteryRecycling System

DisposalResearch into efficient dismantling

technologies for end-of-life vehicles, and utilization of

shredder residue

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3 Innovations in the sorting process

As early as 1981, Toyota launched amaterial ID marking system to helpidentify materials used in resin parts.Currently, a marking system thatconforms to international standardsis used for resin and rubber partsweighing more than 100 grams.

Example of ID marking

In the development stage Toyota has been developing easy-to-

recycle materials and taking removability into consideration.

This process takes benefit from feedback of information from all

along the recycling chain.

Recycling at the Development Stage

Recycling as a Key Issue in Product Design

Recycling as a Key Issue in Product Design

In the area of recycling, Toyota formu-lated design guidelines for vehiclerecycling based on the technologiesdeveloped for recycling plastic partsand on the results of evaluation andresearch on vehicle dismantlability.These guidelines are used for the priorassessment of recoverability duringthe development stage of each vehicle series. They describe detaileddesign standards related to the selec-tion and removability of several hundred plastic parts, as well as tosubstances of environmental concern.By continuously enhancing theseguidelines and by promoting improve-ments in the Prior AssessmentSystem, Toyota is trying to ensure thatvehicle design takes recoverabilityinto consideration. At the beginning of2001, the Recoverability Prior Assess-ment System was applied to 20 differ-ent vehicle models.

1 Innovations in materials

Resin materials to be used in auto-mobiles must possess high rigidityand high impact resistance as well assuperior recyclability — that is, theymust not deteriorate easily whenrecycled.Taking advantage of a moleculardesign technology based on a new

crystallization theory, in 1991 Toyotadeveloped and commercializedToyota Super Olefin Polymer (TSOP),a thermoplastic resin which has better recoverability than the conven-tional reinforced composite poly-propylene (PP). This TSOP is alreadybeing used in a wide range of interiorand exterior parts in new models,such as the front and rear bumper ofthe new Corolla. The moleculardesign of TSOP resin underwentmany refinements and Toyota hasbeen using this improved materialsince September 1999.

2 Innovations in vehicle structure

In order to improve the recoverabilityof dismantled parts, Toyota is usingthe same type of thermoplastic resinfor instrument panels, air-condition-ing ducts, insulation pads, and seal-ing materials. Moreover, these partsare installed using friction weldingrather than screws or metal clips,thereby eliminating the need for dis-mantling operations during recycling.This new design has been adapted inthe Hiace (light commercial vehicle).

Recoverability PriorAssessment System

TSOP bumpers in new Corolla

Before

Instrument panel on the Hiace

After

1. Unification of reinforcement parts

2. Elimination of ducts

Outer

Inner

Design with Due Care ofEnvironmental Impact

• Battery cable terminals • Copper radiators • Copper heater cores • Undercoating • High pressure hoses for

power steering• Side-protection moulding • Wire harnesses • Seat belt G sensors• Fuel hoses

Example of parts fromwhich lead has alreadybeen eliminated

• Fuel tanks • Glass ceramic print• Meter needle balancers• Constant velocity joint grease• Wheel balancers • Electrodeposited paint

Example of parts for which lead elimination is underway

• Other engine components• Other body parts• Printed circuit boards etc.

Example of parts forwhich lead eliminationtechnology is underdevelopment

TSOP (Toyota Super Olefin Polymer)

TPU (Thermo Plastic Urethane)

TPO (Thermo Plastic Olefin)

RSPP (Recycled Soundproofing Products)

Recycled PP (Polypropylene)

Kenaf (natural fiber)

Use of material that takes recycling into consideration in the LS430

Design that TakesRecycling into Consideration

In addition to these assembly andstructure reevaluations, Toyota isworking toward producing designsthat take recoverability into consider-ation through reduction and integra-tion of parts and joints.

There is more and more pressure todecrease the volume and increasethe quality of the shredder residuegenerated from end-of-life vehicles.Therefore, Toyota has been consider-ing for some time now, at the designstage, the reduction of the amount oflead, which has been gaining atten-tion as a substance of environmentalconcern in automobile shredderresidue. In new Corolla, produced inthe UK, Toyota has succeeded indeveloping parts, which are now leadfree. For example, the wire harnesstraditionally required lead for heatresistance but Toyota has developedan alternative heat resistant materialfor the wire harness, which containsno lead. Other examples include theradiator, heater core, fuel hose, andthe fuel tank. Big efforts are alsobeing made to significantly improvethe treatment of airbags containinggas-generating materials.

1 Milestone to phase out lead

Toyota’s voluntary target was toreduce the amount of lead used innew models, excluding that in bat-teries, to 1/2 of the (1996) industryaverage by 2000; it is now further proceeding to phase it out.

2 Development of airbags withconsideration to disposal

The gas generator used in airbagshas generally been sodium azide, atoxic substance that is converted in aharmless material when the airbagexplodes. Nevertheless this gasmakes undetonated airbags disposala potential concern for the environ-ment. Toyota, working in close co-operation with parts manufacturers,has developed - and put in place -airbags that employ a substitutecompound, phasing out the use ofsodium azide.

To enable easy airbag deployment,Toyota has developed and adoptedstandard connectors, which enablesimultaneous processing of airbagsin the driver’s seat as well as in thefront passenger’s seat; these are

available on all models for theJapanese market and on some modelsfor the European one. Possibilities forstandards harmonisation within theautomobile industry globally are cur-rently under investigation.

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Toyota is strongly committed to developing technologies for effec-

tively utilising resin and rubber, which are difficult to reuse or

recycle due to difficulties in separation of composite materials and to

high quality standards requested. The recycling technologies that

have been developed are first applied to the remnant materials

generated in production processes; commonly remnants from the

manufacturing of plastic parts are recycled internally, for example

in the case of bumpers. Toyota has extended the application of these

recycling technologies to the parts collected at dealers and from

end-of-life vehicles.

Recycling at the Production Stage

Avoid Waste through RecyclingAvoid Waste through Recycling

Floor carpets used in automobilesconsist of composite materials andthus, are extremely difficult to recycle.Toyota has developed a technologyfor recycling the remnant materialsgenerated in the floor carpet production process into a resinmaterial, which is utilized as thebacking material for floor carpetsand as the raw material for mouldedparts.

Sectional view of a floor carpet

Backing

uses a recycled material( )

Plasticization Devulcanization

Recycled rubber

Continuous devulcanizationequipment

Made into product (weather stripping) Blended with new material

Shredding Scrap material from processes (weather stripping)

• New waste rubber recycling technology

• Example of manufacturing of engine covers from recycled PET bottles, in Japan

Rubber RecyclingTechnology

Waste rubber generated in the production processes can also berecycled into regenerated rubber forautomobile parts.Together with Toyota Gosei Co., Ltd.,Toyota developed the world’s firstwaste rubber recycling technology in1997. Full-scale application of thistechnology started in 1998. Atpresent, approximately 200 tons peryear of waste rubber is being recy-cled for Toyota vehicle production inJapan as weather stripping to water-proof vehicle doors and trunks.

Applications of VariousRecycled Material

Type Original Item Recycled Part

Thermoplastic resin TSOP (Toyota Super Bumper Fuel tank protectorOlefin Polimer) bumper Luggage trim Fuel pump protector

Seat backboard Seat under-coverLamp cover Back door trim coverEngine under-cover Luggage compartment trimBumper step Deckside trim

Interior trim, garnish Timing belt cover Fan shroud

Thermosetting resin FRP parts Sunroof housing Cylinder head cover(Fiber Reinforced Plastic)

Resin composite material Carpet Carpet backing Carpet reinforcement parts

Seat fabric Floor silencer

Instrument panel covering Dash silencer

Molded roof lining Luggage trim

Rubber Weather stripping Hose protector Weather stripping

Automobile Shredder Urethane foam & fiber RSPP (Recycled Sound-Proofing Products)

Residue (ASR) Copper wiring Reinforcing materials for aluminium casting

Glass Reinforcing materials for tiles

Other PET bottles Sound absorbing materials

Technologies for material recycling developed by Toyota

Discarded PET Bottles PET Bottle Recycling PET ➞

Repelletized MaterialCompounding PET ➞ Compounded Material

Engine cover Injection moulding

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Bumper production at the Toyota plant in Valenciennes (France)

Resin RecyclingTechnology

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In terms of product development,Toyota is actively pursuing an envi-ronmentally friendly policy, throughthe expansion of its genuine remanu-factured parts range. These productsreuse many components, therebyeliminating the requirement for newraw materials and saving the energyneeded to turn these materials intothe finished product. It is expectedthat over the next three years, Toyotawill introduce between 10 and 15 newremanufactured product ranges, allof which will be available from allToyota dealers in Europe.

Different kinds of waste are produced during car maintenance at

the workshops, some of which is recyclable. Toyota requested

the support of dealers for enhancing the recycling of consum-

ables and spare parts through an increased efficiency of collec-

tion and the setting up of contacts with recycling companies.

Furthermore Toyota is promoting sales of remanufactured parts.

Recycling at the Use Stage

The Essential Support of Dealers

The Essential Support of Dealers

Recycling of Waste by Dealers

Remanufactured Parts

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In 2002 Toyota has launched, to allEuropean markets, remanufactured airconditioning compressors and powersteering racks and are currently work-ing on remanufactured engines, short-blocks and cylinder heads, with thelaunch of these planed for beginningof 2003.In addition, Toyota in Europe has coor-dinated the development and imple-mentation of a more efficient partsreturn system, with used parts beingreturned through the main Europeanparts distribution center, instead ofdirect from dealers to supplier. In thelong term this will ensure that morecores are returned correctly and thesystem managed more professionally.

The following parts, tested andapproved in accordance with Toyotastandards, are available:• remanufactured starter• remanufactured alternator• remanufactured clutch kit• remanufactured automatic

transmission• remanufactured air conditioning

compressors• remanufactured power steering

racks

In several European markets, NMSCs

are already operating nation-wide

systems for the management of deal-

ers waste through agreements with

selected partners. These partners are

responsible for the management of

dealer service area waste, from col-

lection to sorting and treatment.

For example, in the UK Toyota and

Lexus dealers work together with

approved waste management com-

panies such as Cleanaway. They

ensure that all hazardous and gener-

al waste materials removed from the

dealerships are disposed of properly

and recycled or recovered, whenever

feasible and economically viable.

A bumper recycling project is also in

place in Germany. Toyota dealers

remove from old bumpers metal,

parts and stripes; bumpers are then

collected and transferred, via regional

hubs or depots, to a grinding facility

for recyling.

Toyota in Europe has been acti-vely participating in promoting thedevelopment of comprehensive deal-er waste management systems. Inthis scope, some mandatory cate-gories for collection, such as batter-ies, tires, waste oil, oil filters, brakefluid, paint and solvents, have beenidentified. In Germany, over 230,000oil filters and 25,000 car batterieswere collected in 2001 and sent forrecovery. While in France, some50,000 oil filters and almost 3,000 bat-teries were collected and processed.

In early 2001, Toyota published theEnvironmental Guidelines for NationalMarketing and Sales Companies(NMSCs).The Environmental Guidelines set outspecific requirements that relate torecycling activities at dealer serviceareas. All dealers must implement awaste management system, takinginto account all local regulations andcompliance conditions. Through this,

Independent technician fitting genuine exhaust Example of remanufactured parts now available on the European market

Independent body technician in body shop

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During the dismantling process,engines, tires and other vital parts arefirst removed from end-of-life vehi-cles. The body is then crushed by ashredder and ferrous and non-ferrousmetals are recovered. The remainingshredder residue, containing piecesof resin, rubber, glass and otheritems, was thought to be virtuallyimpossible to recycle and disposedof as waste in landfills. In 1993,

Toyota, together with Toyota MetalCo., Ltd., began to develop techno-logy for effective utilization of shred-der residue and then constructed the world’s first mass-production recycling plant, with a capacity ofrecycling about 15,000 end-of-lifevehicles per month, which went intooperation in August 1998. This centreprovides research results for Toyotadesign divisions and provides infor-mation worldwide to help disman-tling, shredding and recycling com-panies improve recycling methods.

Toyota independently developedtechnologies for dry separation, sort-ing and recycling. By means of thesetechnologies, the minute pieces ofrubber, glass etc. in the shredderresidue can be recycled into excel-lent, new material.

1 Development of RSPP

Urethane foam and fabric, the majorconstituents of shredder residue, aresorted out and recycled into RSPP(Recycled Sound Proofing Products),a soundproofing material now beingreused in several vehicle parts.Compared to conventional products,this new soundproofing material hasample air pockets that maintain agood balance between its soundinsulating and sound absorbing characteristics for exceptional sound-proofing performance.

Current recycling rates vary from country to country due to

differences in the recycled/recovered materials markets, labour

costs, landfill costs, and the levels of quality and professionalism in

collection and dismantling, at treatment facilities and in technology.

This explains the necessity for matching the early stages of Design

for Recycling with current economical sustainable practices.

Toyota is both cooperating with other auto manufacturers and

growing in-house expertise in that direction.

of new vehicle put on the market. In order to meet this requirement,Toyota joined a Consortium of morethan 20 manufacturers, which pre-pares dismantling information in anelectronic format - the InternationalDismantling Information System(IDIS). This information is regularlyupdated and distributed to the autho-rised dismantling network in Europe. More information on the IDIS systemcan be found on the web site athttp://www.idis2.com.

A Practical Tool for Dismantling

Pioneer Recycling PlantOperational in Japan

Striving for Sustainable End-of-Life Processes

Striving for Sustainable End-of-Life Processes

Recycling at the Disposal Stage

• Examples of parts being recycled from end-of-life vehicles •Seat (urethane foam, fiber) ➞ Soundproofing materials for vehicles

Window (glass) ➞ Tiles, etc.

Hood (steel) ➞ Car parts, general steel products

Engine (steel, aluminum) ➞Engines and aluminum products

Wire harness (copper) ➞ Copper products, engines (cast aluminum reinforcements)Engine oil (oil) ➞ Alternative fuel for boilers and incineratorsRadiator (copper, aluminum) ➞ Gun metal ingots, aluminum products

Coolant (alcohol) ➞ Alternative fuel for boilers and incinerators

Bumper (resin) ➞ Bumpers, interior parts, toolboxes, etc.

Battery (lead) ➞ Batteries

Transmission (steel, aluminum) ➞ General steel products, aluminum products

Tire (rubber) ➞ Raw material, alternative fuel for cement

Suspension (steel, aluminum) ➞ General steel products, aluminum products

Wheel (steel, aluminum) ➞ Car parts, general steel products, aluminum products

Gear oil (oil) ➞ Alternative fuel for boilers and incinerators

Catalytic converter (rare metals) ➞Catalytic converters

Door (steel) ➞ Car parts, general steel products

Tire (rubber) ➞ Raw material, alternative fuel for cement

Bumper (resin) ➞

Bumpers, interior parts

Trunk (steel) ➞ Car parts, general products

Body (steel) ➞ Car parts, general steel products

Effective Utilization ofShredder Residue

The Recycling Plant (Toyota Metal Co., Ltd.)

ELV Shredder Plant (End of Life Vehicle)

ASR Recycling Plant (Automobile Shredder Residue)

Primary shredderMain shredder

Pneumatic sorting

Magnetic sorter

Shredded ferrous metal Non-ferrousmetal

Melt-bricking system

Resin/rubber

Copper

Urethane foam/fabric

Aluminium

Glass

ASR

Pneu-matic

Sorting

Trommel

Crushing

Non-ferrousmetal separator

Ferrous metal

Pneumaticsorting Specific

gravity separator

RSPP

Dashboard silencer

Use of RSPP inLexus 430

Dashboard silencerRSPP

Dismantling the end-of-life vehicle is the first step of the treatmentprocess, and the accuracy and quali-

ty of this process determines thepossibility of re-utilisation and recy-cling of parts and components.As part of the European end-of-life,auto manufacturers must provide dismantling information for each type

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4 Alternative fuels

The sorted resins form the bulk of shred-der residue in terms of weight, anduniform pieces size. They have a highheating value on par with that of coal.This gives them the potential to beused as substitutes for coal andkerosene. Toyota, with Sanei IndustryCo., Ltd., set out to research the pos-sibility of using sorted resins as analternative fuel, and succeeded incommercialization. This fuel has beenin actual use in Japan since April 1999.

Shredder residue

5 Melt-bricking technology

greatly reduces landfill

waste volume

From 1996, controls were imposed onASR (Automobile Shredder Residue)landfills in Japan, and the regulationson permissible leaching levels ofharmful metals were made more rigor-ous. In addition, in 1999, the Europeanlandfill directive laid down strictacceptance criteria for hazardous andnon-hazardous waste in landfill. Toconform to these new regulations,Toyota developed a melt-brickingtechnology that uses a high-speedscrew to knead and heat the ASR,reducing both its volume (1/5 of pre-vious levels) and the amount of leadleaching. As a first step, this enabledToyota to meet the new regulations forcontrolled landfill sites in Japan.

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Shredder Residue Utilization

End-of-life vehicle shredder residue(previously disposed of in landfills)

Wood 3

Paper 2

Non-ferrous metals

Wire harnesses

Shredder residue composition (weight in %)

GlassIron

8

Rubber

Noncombustible

Combustible

Fabric

Urethane foam

Resins33

World’s first (dry) sorting and recycling technology

Pulverization/granulation

Trommel

Magnetic sorting

Non-ferrousmetal sorting

Pneumatic sorting

Vibration sorting

Vibration sorting

Application technologies

Glass

Iron

Copper

Urethane foam & fabric

Reinforcement for tilesMaterials for landscaping pavement

Iron

Copper (Reinforcement for castaluminium parts)New soundproofing material that has agood balance between sound insulatingand sound absorbing characteristics

Combustion technology Melt-bricking technology High value-added application technologies

Quality-controlled resins are usedas alternative fuel (substitute for

kerosene) in incinerators

Processing technology that includes controlling lead leaching and reducing the

volume of lead in ASR by 1/5.

Technologies, such as polymer moulding, bywhich the greater part of ASR is recycled

greatly improve vehicle recovery rates.

The year 2000 witnessed some majordevelopments with regard to recy-cling. A new law was enacted inJapan, the goal of which was topromote a recycling-based societywhile in Europe a directive wasissued to ensure the collection ofend-of-life vehicles, their treatmentunder environmentally sound condi-tions and their reuse and recovery. At that time a Toyota recycling plantwas already in operation but Toyotadecided to further advance recyclingtechnologies from his accumulatedbase and established, inside ToyotaMetal Co., Ltd., the AutomobileRecycle Technical Center.

Enhancing Rresearchthrough the Automobile

Recycling Technical Center

Automobile Recycle Technical Center (Handa City, Aichi Prefecture), Japan

• Positioning of the Automobile Recycle Technical Center

Development and design of easy-to-recycle vehiclesDevelopment and propagation of vehicle recycling technologies

Development of easy-to-recycle parts and materialsDevelopment and propagation of parts and materials recycling technologies

Proposal on easy-to-recycle vehicle designs

Parts and materials manufacturers etc.

Automobile Recycle Technical Center

Research on easy-to-dismantle vehicle structuresResearch on appropriate and effective dismantling technologies, etc.

Toyota Motor Corporation

Tool and instrument manufacturers etc.

Development and commercialization of effective tools and equipment

• Cooperative relationship with Toyota Motor Corporation

Dismantling, shreddingindustries, etc.

Recoverability evaluation and analysis

Extraction of fluids and CFC

Airbag processing method

Removal of substances of environmental concern

Parts recycling research

Research on dismantlability

Automobile RecycleTechnical Center

Vehicle design division

Technical development division

Development and design of easy-to-recycle vehicles

Development of technologies for recycling end-of-life vehicles

The Technical Center began opera-tion in April 2001, to accelerate thepace of research related to recycling,the Technical Center will work onsubjects such as “easy-to-dismantlevehicle structures” and “appropriateand effective dismantling technolo-

gies,” which affect all divisions.Research results will be fed back todesign divisions within the company,and dismantling information will bedisclosed to dismantling companies,thereby helping to promote recy-cling.

Study of removability of exterior components

Study of removability of fluids

Study of removability of chassis-related parts

Information disclosure on dismantling technologies

Toyota MotorCorporation

2 Recycling of wire harnesses

Toyota independently developed ahigh-precision sorter to separate wireharnesses. After the plastic shieldsand connectors are removed, theremaining copper (of purity 97% orabove) is recycled. In Japan, theseparated copper is currently beingused at foundries as reinforcing mate-rial in aluminium castings.

A high-precision sorter is used to separate wire harnesses. The plastic shields and connectors are

removed, and the remaining copper is recycled

Aluminium engine cylinder heads using thesorted copper as reinforcing material

3 Glass as raw material forthe ceramic industry

Utilizing the high-quality characteris-tics of automotive glass, powderedglass from shredder residue is recy-cled into tiles with remarkable densityand strength, and also used as mate-rials for landscaping pavement.

Sorted glass

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Final disposal of batteries is consid-ered to be a key issue in the life cycleof electric vehicles. To make Prius,Toyota’s mass-produced hybrid vehi-cle, the ecological car market leaderin terms of battery disposal, the issuehas successfully been solved byToyota.

About Prius Batteries

The Toyota Prius Hybrid System bat-tery is a high voltage (~280V) NiMH(Nickel Metal Hydride) battery, weigh-ing approximately 40 kg. The batterycontains 38 modules, each sealed

and comprising six cells. To minimisethe risk of mishandling, NationalMarketing and Sales Companies(NMSCs) ensure direct collection byspecialised companies.In all countries where Prius is sold,roadside assistance and emergencyservices are informed on how to han-dle Prius batteries in the case of avehicle breakdown or accident.

Battery recycling in practice

Even before the European debut ofPrius, Toyota established in Europe adedicated NiMH battery recyclingnetwork. All those involved in thesystem - from customers, localauthorities, emergency services,

dealers, to independent workshops

and garages - have been informed

that Toyota Prius dealers are the

central collection points for batteries.

After collection, Prius batteries are

transferred to a certified Toyota recy-

cling company. Current certified

companies include: SNAM and Citron

in France; Accurec in Germany;

Batrec in Switzerland; Saft in

Sweden. Other treatment companies

can be approved by TMC upon

request. A “Prius HV Battery

Dismantling Manual” was developed

and distributed to Prius Dealers,

focusing on precautions to be

observed when dismantling a dam-

aged vehicle.

Building the Prius BatteryRecycling System

Prius battery

• Prius battery recycling system

Prius customer

Accident or abandonedPrius (from emergency

service provides, insurance companies,

local authorities)

Independent serviceworkshop

Who

le V

ehic

le

Proceed Priusfor batteryremoval toPrius dealer Prius

Dealer

Toyota Dealer

WasteManagement

Company

ELV Dismantlers

Final TreatmentCompany

Pick up onregular basistogether withother waste

Disassemblebattery pack ifnecessary

Remove batterye/o disassemblebattery pack intomodules

Remove battery from vehicle

Transport Priusfrom Toyotadealer to Prius dealer

This pamphlet was made from 100% recycled paper. No chlorine was used for bleaching and no surface processing or special coating was applied.

Published by: TOYOTA MOTOR MARKETING EUROPEEnvironmental Affairs Co-ordination OfficeTel: 0032 2 745 24 86Fax: 0032 2 745 20 67E-mail: eaco@toyota-europe.com

Published: October 2002 (based on the Japanese version issued November 2001)