It was also the first overseas Toyota plant to use waterborne paints and is the first UK car plant to achieve zero waste to landfill.
At Toyota Manufacturing UK, since the start of our operations in 1992, we have continued to seek ways to reduce the environmental impact of our operations. The following statistics indicate our Burnaston plant performance in each of these environmental KPIs since 1993. Each year we continue to set targets to improve our results.
Since 2003 we have seen significant reduction in the amount of CO2 produced per vehicle and engine from our plants in Burnaston, Derbyshire (vehicle manufacturing) and Deeside, North Wales (engine manufacturing).
In 2001, our UK manufacturing plants produced 8.5kg of waste per vehicle which was send to landfill, equal to 1,818 tonnes per year. As part of our Environmental Action Plan a five year ‘dream’ goal was set to reduce this amount to zero.
Our goal was to reduce, reuse or recycle all waste. In 2003 zero waste to landfill was achieved, two years ahead of schedule, making Toyota Manufacturing UK the first UK car manufacturer to meet this environmental target.
In 2004, Business in the Community (BITC) awarded TMUK a ‘Big Tick’ Award for Excellence for Environmental Leadership in recognition meeting this challenging waste reduction target.
Our Burnaston plant saves 100,000 cubic metres of water from going to waste, with a specially designed purification system. This recycles water discharged from the paint shop, which is then used in the plant’s boilers to generate steam for use on-site. The water is so clean that it has even increased the efficiency of the boilers. The innovation was acknowledged in 2007 with an eco-efficiency award from Business in the Community.
Painting cars accounts for over half of the energy that we use at our Burnaston plant in the UK. With this in mind, we decided to increase our energy efficiency by expanding the range of air temperature and humidity at which paint could be applied effectively. Our resulting 'predictive' control system led to a 40% drop in steam used in the paint shop and a related 40% reduction in CO2 emissions. The move led to three accolades, including the Business Commitment to the Environment (BCE) award.
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