aim: zero emissions - Toyota

aim: zero emissions

Kaizen
“Continuous improvement. As no process can ever
be declared perfect, there is always room for improvement.”

Table of Contents
Aim: zero emissions, zero waste 4
Towards the ultimate Eco-car 7
Clean manufacturing 10
Green technologies 11
The 3 Rs: Reduce, Reuse, Recycle 18
The next horizon 21
September 2006 edition

Residential
(CO 2 )
Aim:
zero emissions, zero waste
There are over 200 million cars in use on Europe’s roads
today, providing freedom of mobility to every type of driver.
European CO2 emissions World by CO2
sector emmisions (2004) by sector*
Yet cars are also widely associated with being harmful to the
planet’s ecosystem. This can range from global warming and
Petroleum
refining (CO 2 )
Commercial/
Institutional (CO 2 )
5%
12%
Manufacturing Industries
and Construction (CO 2 )
Other
4%
16%
9%
Carbon Dioxide (CO 2 )
Particulate Matter (PM)
Nitrogen Oxides (NOx)
Volatile Organic
Compounds (VOCs)
Carbon Monoxide (CO)
24%
30%
* Source EEA (European Environment Agency) Technical Report 6/2006
VEhiClE
Emissions
greenhouse gases to smog, noise and landfill pollution. In
recent years, the automobile industry has made great progress
in reducing the environmental burden of motor vehicles.
Transportation (CO 2 )
a “greenhouse gas” that can contribute
to global warming.
found in soot from factories and car
exhaust amongst others. Can cause
respiratory diseases.
causes acid rain. Also generates ozone
that can contribute to photochemical
smog and global warming.
hydrocarbons from industrial
processes, factories and cars.
Contribute to smog.
harmful to humans, can be fatal; now
largely eliminated from car exhaust
emissions.
Electricity and Heat
Production (CO 2 )
Life cycle emissions
Carbon Dioxide
Particulate Matter
Nitrogen Oxides
Volatile Organic Compounds
Carbon Monoxide
hOw dO CARS AffECT
thE EnvironmEnt?
Manufacturing
Energy, Water,
Waste, Landfill, Emissions
End of Life
Waste, Landfill

&
How do cars affect the environment?
Vehicle manufacturing consumes raw materials and energy, while cars
produce exhaust emissions and have to be disposed of properly at the
end of their lives. Reducing the impact of each of these processes is a key
challenge for Toyota.
Motor vehicles interact with the
environment throughout their entire
lifecycle – from their initial design and the
way they are manufactured, to their use
on the road and their eventual disposal
when no longer needed.
When driving, car engines release
emissions into the air, influencing the
chemical composition of the atmosphere
we breathe and indirectly affecting
weather patterns around the globe. The
challenge is: How can these emissions
be further reduced?
A second environmental impact comes
from the fact that vehicles are made out of
metals, plastics and other manufactured
materials. Can cars be designed so
that they can be recycled more easily
and comprehensively? And automotive
factories use energy and materials to
manufacture new vehicles, and produce
waste as a by-product. How can
factories be designed to respond more
efficiently to environmental constraints?
For Toyota, minimizing these kinds of
environmental impact has long been
a top priority at every level of the
company’s organisation and activity. The
company’s environmental policy forms
part of a much wider vision of sustainable
development, one of the cornerstones of
global economic thinking for the future.
And building completely recyclable cars
with zero emissions is Toyota’s foremost
challenge for the years to come.
Both…and morE!
Much of the debate surrounding sustainable mobility, or
the development of the ultimate eco-car, places a cleaner
environment in opposition to economic and industrial
growth. The thinking goes: you can only have one or the
other, but not both. It is in Toyota’s corporate culture to work hard when
confronted with these challenges, to try and achieve both and more!

6
• Follow the traffic flow and anticipate
what is going to happen in front
of you.
• Change up to a higher gear early:
a higher gear always means a lower
engine speed and lower fuel
consumption
Responsibility
through
innovation
One of the
world’s leading
automobile manufacturers, Toyota sold some 8.1 million
vehicles* in 200 , marketing them in over 1 0 countries.
Toyota is one of the leading automotive brands in Europe,
where it has been selling cars since the early 1960s
and has invested over €6 billion since 1990. From its
headquarters in Brussels, Belgium, the company overseas
its eight European production sites, large R&D facilities
and design, logistics, training and service centres. In total,
Toyota employs some ,000 people in Europe, including
retailers.
* Toyota, Lexus, Hino & Daihatsu combined
• A constant speed can give
lower fuel consumption.
• Don’t use your car to travel short
distances
• If possible, switch off your engine if
you have to wait longer than
0 seconds
• Follow the manufacturer’s
instructions and have your car
serviced regularly
• Check your tyre pressures on a
monthly basis
• Keep your windows closed and use
the ventilation system
• Only use electrical accessories (air
conditioning, rear screen heater,
etc.) when necessary, as they
consume energy
toyota’s Eco-drivE tips
• Extra weight results in additional
energy consumption (10% for
ski boxes on the roof, up to
0% more for a cycle rack
on the roof). Remove them
after use.
• Plan your route in advance so
you do not make unnecessary
detours.
• Avoid driving in town,
where fuel consumption is
twice as high as on the
motorway.
• Use of equipment such as
cruise control, or a display
which shows current
consumption, can lead to
fuel savings of up to 10%.
In addition to a reputation for technological innovation,
superior quality and manufacturing expertise, Toyota fully
assumes its corporate responsibility for the environment
and for the communities in which it operates.
This commitment translates into a comprehensive vision
of sustainable mobility. Toyota’s extensive Research and
Development programmes examine every aspect of
vehicle design, performance, safety and the information
infrastructure that will underpin driving tomorrow. Finding
and implementing solutions that make cars less of an
environmental burden is one of the central foundations of
sustainable mobility.

CNG
Compressed
Natural Gas
Alternative
Fuel Engines
Towards the ultimate
Eco-car
Alternative
Fuel HV
Hybrid Technology
Biofuels
Synthetic Fuels
In 2020 it is estimated there will be some 1.2 billion cars on the
road, nearly twice the current number. Car makers must make the
right decisions today to ensure that this growth does not lead to
a drastic increase in exhaust emissions and the greenhouse gas
carbon dioxide (CO 2 ). Toyota’s approach to exhaust emissions
is to explore simultaneously a broad variety of solutions for
developing cleaner, greener vehicles. The reason is that different
countries and communities have different driving conditions,
available fuel, vehicle infrastructure and legislation.
Diesel
Engines
Diesel Hybrid
Vehicle
Diesel Particulate
NOx Reduction
Common Rail Direct Injection
Plug-in HV
Diesel HV THS II
DPNR
Common Rail DI
FCHV
Fuel Cell
Hybrid
Vehicle
Toyota
Hybrid System
D-4
Direct Injection
4-Stroke Petrol Engine
VVT-i
Variable Valve
Timing with Intelligence
Lean-Burn
Gasoline
Engines
Toyota is committed
to developing hybrid
systems as the core
technology for ecocars,
combining different
power sources
in ways that maximize
the strengths of each.
EV
Electric
Vehicle
Electrical
Energy

8
EURO 3
EURO 4
Toyota is investing in all these technologies in parallel.
Each forms a step forward towards the ultimate eco-car.
This ideal target would generate zero 1997emissions
from its
engine, and be totally recyclable. Kyoto But Protocol while pursuing this
ideal, it is important to meet thedrafted real needs of society1998
today and tomorrow, and therefore Toyota’s approach
Date of application
After 1/1/2000
1/1/2005
Petrol (in grammes/km)
100
80
60
40
20
&
One of the most promising technologies for reducing
emissions in conventional cars is known as hybrid
technology, since it advantageously combines the
benefits of two types of power source instead of relying
on just one. For example, a petrol engine can be
combined with an electric motor.
In certain contexts of vehicle use, other
types of low-emission engine technologies
are also proving effective, although they
are not yet as mature or versatile as petrol
and diesel-powered engines. These include
fuel cells (where hydrogen is used to generate
electricity) and compressed natural gas engines.
EU directives on
exhaust emission limits
CO NOx + HC
EURO 3 EURO 4
How can the environmental impact of a car be measured?
Provided we look at the whole lifecycle of a car, we can accurately
measure its overall impact in terms of materials, production, emissions
and end-of-life. This Life Cycle Assessment then makes it easier to
produce cleaner cars according to clear targets.
EU Directive:
sets emission targets
for new cars as of
2005 (Euro 4)
NOx
2.30 0.20 0.15
1.00 0.10 0.08
For Petrol cars
is to deploy the appropriate engine technology to
produce... the right car for the right place at the right
time.
EURO 3
EURO 4
2006
All Toyota engines meet
Euro 4 Directive for
emissions
Date of application
After 1/1/2000
CO NOx
2008/9
European, Japanese and
Korean car makers to
reduce average CO2
to 140 g/km
Diesel (in grammes/km)
NOx + HC Particulate
Matter
0.64 0.50 0.56 0.05
1/1/2005 0.50 0.25 0.30 0.025
CO
HC + NO x
PM
NO x

how environmental
is your car?
To achieve lower emissions and greener vehicles on the
way toward the ultimate eco-car, it is essential to measure
progress. Toyota has therefore developed its Ecological
Eco-VAS
at work
When a new Toyota vehicle is
planned, the Chief Engineer sets
quantitative targets for reducing its
environmental impact. Assessment covers a wide range
of items. It starts with materials – including the elimination
of substances of concern such as lead or chrome
– components and production methods. It continues
by examining fuel efficiency and emissions during the
vehicle’s use. And it factors in the amount of materials that
can be recovered on disposal, as well as overall reduction
of emissions throughout the vehicle’s life cycle.
All findings from these assessments are kept in a computer
database that can be accessed to compare and contrast
progress in reaching Eco-VAS targets, and confirm the
environmental conformity of a new vehicle based on the
concept of total Life Cycle Assessment (LCA).
Vehicle planning
Eco-VAS at work
Designing and
prototype building
Vehicle Assessment System, or Eco-VAS. This is a
comprehensive approach to assessing a vehicle’s whole
life cycle – from production, through use to disposal – in
terms of its impact on the environment, starting at the
early stages of development, before the vehicle is actually
built. Toyota began using Eco-VAS in 200 , bringing the
system to a high level of implementation in 200 .
By enabling development teams to evaluate the
environmental impact of a new vehicle ahead of its actual
production, it will be easier for Toyota to ensure constant
step by step improvements on the road to the ultimate
eco-car.
Production
Target setting Target-achievement
Target-achievement status check
Evaluation-results feedback
status con�rmation
9

The production of vehicles, engines and transmissions in
factories inevitably has an impact on the environment. To
ensure that car manufacturing can make more with less,
Toyota developed its world-famous Toyota Production
System (TPS) several decades ago. Over the years, TPS
has also evolved to include new environmental targets.
It is now applied in Toyota’s production facilities all over
Europe.
toyota’s production system...
• eliminates waste
• reduces energy usage
• minimises use of raw materials
• delivers standardised quality
by...
• applying best practice in
all processes (“Yokoten”)
• continuous improvement
(“Kaizen”)
• going to the source to find the
facts (“Genchi Genbutsu”)
• just-in-time production, by
‘pulling’ products through the
production line
• active involvement from
all team members
10
Greener
manufacturing
in the Toyota Prius
Clean
manufacturing
Constant efforts to improve standards
throughout the workplace have radically
reduced the environmental impact of
production at our plants.
Since 2001:
• Total energy usage per car has
been reduced by 37% across all of
Toyota’s European manufacturing
plants.
• Water usage has been reduced in
Europe by 34%.
• Packaging waste has been reduced
through the full use of returnable or
recyclable packaging.
• Volatile organic compound
emissions per square metre of
painted surface have been reduced
by 21%.
Aim: zero emissions
through TPS
For example: Toyota’s vehicle plants in both the U.K. and France, have achieved the
ambitious target of delivering zero waste to landfill.* Applying TPS principles, staff
carefully examined how production waste was created, and invented appropriate
solutions to reduce, reuse or recycle all the ‘waste’ materials generated. This has resulted
in a 73% reduction of waste going to landfill since 2001.
The manufacturing process for the new Prius model has been organized to reduce the amount of energy needed
for building the car. CO 2 emissions during the manufacturing process are cut by 31% compared to the previous
Prius production plant. Special Eco-plastic made from plants to provide floor mats is used. This further reduces CO 2
emissions during manufacturing. The batteries are smaller and more efficient, resulting in 33% less CO 2 emissions
during manufacturing when compared to the previous generation Prius.
the toyota prius is 90% recycable!
* Zero waste to landfill: less than 3% of 1997 amount of waste disposal to landfill

Green Technologies
Petrol and diesel engines are highly efficient, but they come at a price. They emit CO 2
and other gases and particles that pollute the atmosphere and might influence longer-
term climate patterns. Toyota is therefore committed to developing technologies that
reduce emissions to much lower levels. Since petrol and diesel engines will probably
continue to form the major source of automotive power in the years to come, a major
effort is being made to reduce the environmental impact of these technologies.
For example, Toyota has re-examined the whole structure
of the internal combustion engine to identify specific ways
in which petrol and diesel engines can burn less fuel more
efficiently, and so emit less CO 2 and other unwanted
gases.
This has led to the development of integrated intelligent
technologies that use advanced solutions inside engines
to improve the management of fuel and driving operations.
One of these is Variable Valve Timing-intelligent
(VVT-i), which uses less fuel than comparable petrol
engines and emits less carbon dioxide, nitrogen oxides
and hydrocarbons.
Another is Toyota’s Common Rail Diesel technology
(known as D-4D), which injects a precise amount of fuel
directly into the combustion chamber to deliver more
efficient combustion and better fuel economy. These both
help reduce CO 2 levels in exhaust emissions.
Toyota has also made significant advances in developing engines that are powered by alternative energy
sources. One of the most promising approaches is to combine two different power sources in a single system
to exploit the performance potential of both. This is known as hybrid technology, and forms one of the most
promising development paths on Toyota’s eco-car roadmap.
11

Do diesel engines pollute more than petrol engines?
Diesel engines use less fuel and overall produce less CO 2 than petrol
engines. However, they produce more particulate matter and nitrogen
oxides than petrol engines. Advanced technologies can improve the
efficiency and cleanliness of both petrol and diesel engines.
Advancing
with diesel
Mile for mile, diesel engines are more efficient as a power
source than petrol engines. But this efficiency comes at a
price. Diesel exhaust contains higher quantities of Particulate
Matter (mostly consisting of un-burnt carbon compounds), as well
as nitrogen oxide. Over the years, Toyota has developed a
number of engine technologies that lower diesel’s impact.
Common Rail Diesel technology (D- D), for example, reduces
CO 2 emissions. Special catalysts have been developed to reduce
particulate matter and nitrogen oxides. Toyota’s D- D
and exhaust gas recirculation technology help reduce the
presence of hydrocarbons, carbon monoxide and particulate
matter in vehicle exhaust.
In 200 , Toyota revolutionised the diesel engine by combining
these different technologies into a single new integrated solution
called Toyota Diesel Clean Advanced
Technology (Toyota D-CAT). This
advanced concept dramatically
reduces particulate matter and
nitrogen oxides resulting in the
world’s cleanest diesel engine
technology! In 200 , Toyota D-CAT
was featured in a brand-new 2.2litre
high-power (1 DIN hp) diesel
engine, built in Poland. Toyota’s
new 2.0-litre D- D 12 diesel engine
is available with a diesel particulate
filter, reducing particulate
emissions even further.
Toyota’s challenge is to ensure that
diesel engines’ emissions performance
will eventually be equivalent to
petrol engines.
12
&
The D-4D 2.2-litre, Toyota D-CAT engine integrates special technologies
to produce very low NOx and particle emissions
EGR Valve
Exhaust Port Injector
Variable Nozzle Turbocharger
Air fuel ratio sensor
Oxidation Catalyst
EGR Cooler
Piezoelectric common-rail injection
DPNR Catalyst
High Power Diesel Engine
• 2.2-litre, in-line 4-cylinders
Pressure Difference Sensor
NOx storage reduction catalyst
Gas Temperature Sensors

hybrid
hybrid
Technology
Electric
No single engine technology
or fuel can deliver an optimal
solution to the emissions
problem. All have their shortcomings.
Petrol engines emit less nitrogen oxides than diesel
engines, and produce insignificant levels of particulate
matter. Diesel engines, on the other hand,
are more fuel efficient and therefore produce less
carbon dioxide than petrol engines. Among non-petroleum
power sources, electric vehicles, for example,
are clean, but cannot deliver satisfying overall
drive performance, acceptable driving range, and have
to be recharged.
But what if it were possible to combine different types
of power sources and make them work together to enhance
their respective benefits and reduce their obvious
shortcomings?
This leap forward has been made through the creation
of Toyota’s hybrid technology, now one of the company’s
core vehicle technologies.
If you drive 25,000 km a year in a Prius,
you will save over 1 tonne more
CO2 when compared to a
similarly-sized diesel car.
+
+
+
+
Diesel
or
or
Alternatives
Fuels
Petrol
or
Fuel Cell
Hybrid technology can be applied effectively to improve
the efficiencies of a variety of power trains irrespective
of the type of fuel used (gasoline, diesel, alternative fuels
or fuel cell vehicles).
Hybrids not only deliver lower emissions and reduced
fuel consumption, but they are completely silent when
operating electrically and deliver impressive driving performance.
The revolutionary breakthrough achieved by hybrid
technology is the intelligent management of the energy
flows from two different power sources so that each dimension
of driving – acceleration, open road, braking
and stop-and-go – is performed in an optimal way.
This highly innovative solution consists of a petrol engine
designed to minimize fuel consumption, combined
with a zero-emission electric motor matched to a nickel
metal hydride electric battery pack to provide additional
power. Both of these power sources work together
under the supervision of a sophisticated power
management controller to deliver maximum overall
driving efficiency.
One tree (1) absorbs around 14kg (2) of CO2
each year. So you'd be doing the annual
workload of a forest with 71 trees.
(1) Measured using Japanese cedar
(2) CO 2 equivalent
1

1
toyota &
hyBrid:
• Launched the world’s first mass-produced hybrid
car (Toyota Prius) in 199 .
• Is the world’s leading manufacturer of hybrid
vehicles and has the largest hybrid model line-up.
• Intends to double the number of models in its
hybrid line-up by the early 2010s.
• Over 00,000 hybrid vehicles sold worldwide
(July 2006).
• Over 0,000 hybrid vehicles sold in
Europe (July 2006).
• Target of reaching annual hybrid sales
of 1 million units by the early 2010s.
ordinary driving
Full-throttle
acceleration
deceleration/braking stop-and-go
Runs with electric motor
and engine in most fuel-efficient
configuration
Engine Engine Engine
Engine
Engine power +
electric motor power
Engine Engine Engine
lectric motor Battery BatteryElectric
Battery Electric motor motor Electric motor Battery Electric motor Battery Battery Electric Battery Electric motor motor Electric motor
High fuel-efficiency driving
Battery
Electricity is generated,
and partly recharges the battery
Battery Battery Battery
The Toyota Prius has already captured 90%
of the world market for hybrid technology,
having been on the market since 1997.
The Prius was voted the 2005 European
Car of the Year – a strong endorsement for
environmentally beneficial hybrid technology.
Energy recovered
and stored
Prius:
an eco-pioneer
Engine stops automatically,
and can run on electricity alone
Battery Electric motor Battery BatteryElectric Battery Electric motor motor Electric motor
Zero fuel consumption

hybrid
Synergy drive
Hybrid Synergy Drive® (HSD) is the concept behind
the new generation of hybrid vehicles from the Toyota
brand, including the Toyota Prius, the world’s bestselling
hybrid vehicle. HSD combines driving pleasure
and performance with fuel economy, low emissions
and silent driving. The word “synergy” extends to the
higher synergy between the petrol engine and electric
motor to power the vehicle. The electric motor is now
more powerful, allowing a higher ratio of electrical/
petrol usage. The results are more performance with
greatly improved efficiency.
the benefits of
hybrid synergy drive
in the prius
• Excellent driving performance:
acceleration similar to a mainstream
D-segment (1) diesel engine.
• Low fuel consumption:
. litres/100 km – equivalent
to a B-segment (1) diesel car.
• Lower emissions:
CO 2 emissions of 10 g/km in the
combined cycle (2) , down from
120 g/km for the previous generation.
• silent driving:
HSD can run on the electric motor only,
offering a completely silent
driving experience.
(1) B-segment cars are compact cars like the Toyota Yaris.
D-segment cars are larger, more powerful cars such
as the Toyota Avensis.
(2) City and highway driving.
1.5-litre Petrol engine
Uses special technology to
extract more energy from petrol
combustion.
Regenerative braking system
Uses electric motor
as generator to convert
braking energy into electricity.
Inverter
Converts DC from battery to
AC for driving the motor.
Battery
Charged by the engine via the
generator when cruising, and
by electric motor when
braking. Never needs to be
plugged in.
Electric motor
Permanent-magnet
technology to produce 50kW
output.
Power Split Device
Splits power between engine,
motor, generator and wheels.
1

16
lexus
hybrid
drive
The Lexus brand first introduced
hybrid power
trains with the RX 400h
in May 2005. Since
then, Lexus has gained
more ground with its European
hybrid strategy,
both by launching the GS 450h in May 2006 and
presenting the company’s forthcoming flagship,
the LS 600h, in May 2007.
Hybrid technology is attracting customers to the
Lexus brand who are looking for a realistic alternative
to mainstream technology. In addition to the
quietness, smoothness and refinement of hybrid
power trains, Lexus customers appreciate the
powerful and linear acceleration combined with
segment-leading environmental performance. To
reflect the importance of its hybrid strategy, Lexus
has adopted a new brand name that will more
clearly identify its advanced hybrid technology
and philosophy: Lexus Hybrid Drive.
Alternatives
to fossil fuels
The great advantage of alternative energy sources is
that they can drastically cut emissions for cars being
driven. However, since many of the technologies
involved are not yet fully mature, and are still too
costly to be implemented into a broad range of
cars, the majority of them require further research
and development before they come to market.
Toyota has led the way in developing a number of these alternative technologies as cleaner solutions for
sustainable mobility, and has already proven that innovative solutions can be commercialised for specific uses.

inside an Fchv
CO2 output from oil well to car wheel
Petrol vehicle
Diesel vehicle
Petrol Hybrid
Toyota FCHV
(target)
Hydrogen
(Gasoline vehicle = 1)
0 0.2 0.4 0.6 0.8 1.0
Well-to-Tank CO2
Tank-to-Wheel CO2
In the Japanese 10-15 test cycle, Toyota in-house testing
FCHV: Hydrogen fuel
Well-to-Tank CO2 = CO2 emitted from the oil well until the fuel arrives at the fuel station
Tank-to-Wheel CO2 = CO2 emitted by a vehicle during use, including refueling
4
3
Water
Air
2
1
1. Fuel cell stack
2. Battery
3. Control unit
4. Motor
hydrogen fuel cells – as pure as water
One of the most promising technologies developed
to use alternative energy is ‘fuel cell’. A fuel
cell works by combining two common elements -
hydrogen and oxygen - to generate electricity that
powers an electric motor. The by-products of this
reaction are only water vapour and heat, making
this technology the ultimate zero emission solution
for vehicle use, even though the actual production
process for hydrogen is not emission-free. Toyota
has been conducting research into fuel cells since
1992. It believes fuel cell driven vehicles will become
a mainstay of mobility in the future.
Vehicles equipped with fuel cells and using Toyota’s
hybrid system configuration are 2 - times more
efficient than petrol-powered cars in terms of fuel
tank-to-wheel efficiency.
In 2002, Toyota was the first automobile manufacturer
to commercialise Fuel Cell Hybrid Vehicles
(FCHVs) in Japan and the U.S. They are equipped
with the Toyota FC Stack, a completely in-house
developed fuel cell. The full commercialisation of
fuel cell vehicles, however, will require the establishment
of a hydrogen supply network similar to that
for petrol and diesel fuel - a large-scale and costly
undertaking. But while the market of fuel cell powered
vehicles is limited for the immediate future, their
potential remains proven and clear.
Toyota has been researching a number of other
sources of cleaner fuel for some time now, in its
quest for the ultimate eco-car.
For example, Toyota has researched Compressed
Natural Gas (CNG) for over two decades, with
limited-scale commercialisation. Compared to
conventional diesel and petrol vehicles, natural
gas powered vehicles emit very small amounts of
Particulate Matter, and much less carbon dioxide.
However, CNG requires very large storage tanks
for the fuel, and tends to deliver less energy than
conventional fossil fuels, limiting its long-term applications
to very specific driving contexts such as
bus or taxi transport in city centres. Gas-to-Liquid
(GTL) – a synthetic diesel fuel produced from CNG
- is another promising energy alternative, as it uses
existing diesel fuel infrastructures. It provides the
benefit of further emissions reduction and the better
fuel economy of the latest clean diesel engines
– such as Toyota D-CAT and Toyota’s Diesel Particulate
Filter.
Toyota also supports the use of alternative fuels including
bio-fuels for cars to help reduce fossil fuel
consumption and to prevent climate change.
Gsi - GEar shiFt indicator
Fuel consumption in vehicles can also be reduced by making more efficient use of existing
technology.The “Gear Shift Indicator” is a good example. It’s a technology that aims to encourage
fuel efficient driving behaviour. It does this by indicating the optimum point to change gear for
eco-driving. By doing so, awareness of fuel efficient driving is increased. Depending on the
circumstances, fuel consumption can be reduced by over %.
1

The 3 Rs:
Reduce, Reuse, Recycle
For car makers, truly sustainable mobility also
means manufacturing vehicles and processing
them at the end of their lifetime in ways that ensure
maximum energy efficiency and minimum waste.
The 2015 target is to have 85% of the vehicle
weight being reused or recycled and 10% energy
recovery, leaving the remaining 5% for disposal.
End-of-life
vehicles
18
&
End-of-life vehicles (ELVs) contain
materials ranging from steel and
rubber to plastic and solvents. Some of these
contain Substances of Concern (SoCs) which
would contaminate the soil and the groundwater
reserves if an ELV is simply thrown away.
Toyota’s Eco-VAS (Vehicle Assessment System)
sets targets and consistently tracks measures
for limiting SoCs and reducing other forms of
environmental burden. And further improvements
will follow in the future.
toyota makes vehicle recycling easier:
1. Designing cars for easier recovery.
2. Manufacturing cars with recovery in mind.
3. Recovery of used parts and components that are
replaced during the life of a vehicle.
4. Minimising the remaining waste of an ELV.
How does recycling reduce CO 2 emissions?
Making new cars involves the use of many materials, from metals and
synthetic products to cardboard, which all have to be first produced
industrially. By recycling materials where and when appropriate, the
amount of energy used can be reduced, along with factory emissions.

The recycling
Process
The European End-of-
Life Vehicle Directive
(Environmental Directive
2000/ /EC) was adopted
by the European Parliament
and Council on September 18, 2000, to improve
the recycling and recovery of ELVs, and
to increase the environmental performance of all
economic players in the processing chain. Since
then, all EU Member States have enacted laws
to implement this Directive.
designing for recycling
In order to simplify the dismantling process, Toyota
designed a new ‘Easy to Dismantle Mark’.
This mark is added to vehicle parts clearly indicating
certain points that assist in initial dismantling,
such as the positions at which large resin
parts can be easily separated and the locations
at which holes can be drilled for removing fuel.
Cars contain plastics that are hard to recycle.
Toyota has therefore developed a special recyclable
plastic called Toyota Super Olefin Polymer,
or TSOP, that can be used to make car bumpers
and other parts which can then be recycled
many times over.
IDIS, a practical tool
to dismantle cars
Pioneer Recycling
Plant in Japan
Using shredder
residue effectively
Automobile Recycling
Technical Centre
Toyota Prius battery
recycling system
Eco-VAS ‘design
with care’
DISPOSAL
Replacement
remanufactured
parts
Build recoverability
into design
LOPM
DEVELOPMENT PRODUCTION
RECYCLING
RECYCLING
CAR
CAR
USE
Dealer waste
collection system
Design for recycling
Rubber recycling
and reuse
Application of
recycled materials
Greening spare parts
Batteries, tyres, and oil filters all need to be replaced
during a vehicle’s lifetime. Toyota has
therefore set up a waste collection system that
retrieves used parts from European dealers and
sends them back for recovery. In addition, Toyota’s
remanufactured parts offering now includes
air conditioning compressors, power steering
racks, cylinder heads, starters, automatic transmissions,
alternators, engines and clutch kits.
substances of concern
Lead, together with Mercury, Cadmium and
Hexavalent Chromium, are heavy metals that
cause long-term damage to the environment if
buried unprocessed in landfills. In line with the
year 2000 European Union directive on End-of-
Life Vehicles which limits the use of these Substances
of Concern (SoCs) in materials and vehicle
components starting in 200 , Toyota now
uses a number of zero-lead car parts and anticorrosion
coatings, mercury-free lighting and
switches, and asbestos-free friction materials
and engine gaskets. It also avoids SoCs in various
kinds of paints and in solvents.
Resin recycling
and reuse
19

20
the end is a new beginning
Toyota has created a dedicated Automobile Recycling
Technical Centre in Japan to experiment
with new techniques for dismantling vehicles for
recovery. This has resulted in the construction
of an operational Automobile Shredder Residue
Recycling Plant which in 2001 achieved Toyota’s
voluntary goal of developing the technology for
a commercial system to achieve a high recovery
rate for component materials.
Once Europe’s end-of-life cars have been shredded
to extract usable materials, they still leave
2 million tonnes of residue behind. Traditionally
this has been buried in landfill or incinerated. But
the European ELV and Landfill Directives now in
force limit the use of this solution.
Plastic recycled from
polypropylene is used in
four separate parts.
Recycled plastic for the
bumper, instrument panel
and other coverings.
In Japan, Toyota has
developed ways of using
certain foam products
found in vehicle
residue to create recycled
soundproofing
products. Thanks to
the high-quality characteristics
of automotive glass, powdered glass
from shredder residue is recycled into tiles for
use in landscaping pavement.
Shredder residue that cannot be recycled can
nevertheless be melted down into extremely
small packs for landfill, reducing once more the
environmental impact of vehicles on future generations.
Toyota Avensis
and the 3 Rs
Two parts use plastic
recycled from
production waste.
Renewable materials
(recycled cotton and wool)
for sound absorption and
insulation.

The next horizon
Cars have benefited society for over a century. During this time, car makers have
explored a variety of technologies, and fine-tuned the internal combustion engine into
the high-performance machine we know today. For Toyota, the automobile’s future will
be dedicated to improving relations between cars, people and the environment.
Toyota has promised to
achieve sustainable mobility.
And our company is
well recognised for its
innovative products
and technologies.
Toyota is developing
these advanced
technologies in order
to protect the
environment, and
ensure its continued
growth. Our company
recognises the link between
mobility, a sustainable
environment and economic
growth, and believes that
the growth of our business depends on
the success of sustainable mobility.
Through the concepts it builds today for
tomorrow’s society, Toyota is seeking to
expand the scope of personal mobility while
ensuring minimal environmental impact. For
example, Toyota has developed the i-swing,
a personal, light-weight mobility vehicle that
creates a seamless transformation between
vehicle and human movement. The batterypowered
i-swing minimizes occupied space
and energy consumption with its ultra compact
size, operating in two-wheel mode when
moving among people in the city and switching
21

22
to three-wheel mode on the road with other vehicles. The driver of the
i-swing can remain in permanent contact with their vehicle through a mobile
phone or a PC, bringing personal mobility to another level.
Beyond its product range, Toyota recognises the importance of good
corporate citizenship and is taking concrete steps to positively impact
European society.
In 2002, our company established a fund – the Toyota Fund for Europe – to
enhance its good corporate citizenship through social contribution activities
in Europe. The strategic focus of this Fund is linked to our core corporate
sustainability challenges: environment, road safety and technical education.
Toyota’s advanced technologies already provide a proven new platform
for building an even wider range of cleaner and more
fuel-efficient engines, while offering an
enticing driving experience.
And other technologies such
as fuel cells promise longterm
alternatives for specific
applications.
With its effective production
methods, leading technology
and constant attention to
customer requirements, Toyota
is developing many solutions to
the global challenge of sustainable
mobility.
RAiSinG
EnViROnmEnTAl
AwAREnESS
ThROUGh ThE
TOYOTA FunD
FOR EuROPE:
Green pack
Since 2000, Toyota has
supported the Regional
Environmental Center for Central
and Eastern Europe in the
development and production of
the Green Pack – a unique multimedia
environmental education
kit designed to be used by
schools.
schools for sustainable
development
In 200 , Toyota Europe launched
the Schools for Sustainable
Development programme in
partnership with the NGOs
Groundwork UK and the
Environmental Partnership
(CE Europe). The project aims
to promote local community
environmental actions by giving
schools the opportunity to
make improvements in their
neighbourhoods.
Eco-schools
This project, rolled out in
Western Europe, is aimed at
promoting innovation in schools´
environmental problem solving,
through the awarding of grants
projects on sustainable mobility.

Genchi Genbutsu
“Going to the source to find the facts to make correct decisions,
build consensus and achieve goals.”

Toyota Motor Europe
Corporate Affairs
Avenue du Bourget 60 - 1140 Brussels, Belgium
Tel. +32 2 745 21 11 / Fax +32 2 745 20 68
e-mail: pr@toyota-europe.com
www.toyota.eu
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