Technology Development and Production Activities for Building a Recycling-Oriented Society

The Toyota Boshoku group incorporates the use of raw materials and other materials that can be recycled and considers product design and development with a view to the creation of a recycling-oriented society. We also work to reduce waste and water consumption in the production stage.

Development and design

Toyota Boshoku has been pouring its efforts into shifting from petroleum-derived materials to plant-derived materials that can recycle CO2 with the aim of creating a recycling-oriented society.

Toyota Boshoku has worked on the development of materials with a focus on the application of plant derivatives in industrial products since the latter half of the 1990s. The primary material has been kenaf, in which we have gradually been expanding the use of kenaf following its use as a base material in door trim for the Toyota Celsior in 2000. dditionally, Toyota Boshoku has developed numerous products made with plant material, including the development of completely plant-derived components that combine kenaf with polylactic acid, as well as bio-urethane, which uses castor oil as a plant material aside from kenaf. Door trim and air cleaner cases, an engine-related component, are among the core products that adopt plant-derived material.

Image of CO2 recycling

Production and logistics

Recycling activities

The Toyota Boshoku group worked to raise yields and took other measures to reduce waste at the source as well as promoted recycling initiatives to transform waste into valuable items in the market. We also pushed ahead with efforts to reduce the amount of waste generated and other recycling activities.

As a result, the Toyota Boshoku group achieved its target of 24,176t with a result of 21,435t. With regard to the basic unit for waste, the group achieved a result of 1.0t / 100 million yen compared with its target of 1.2t / 100 million yen.

Toyota Boshoku has achieved direct zero waste every year since fiscal 2007.

Reducing the amount of packing and packaging materials

Toyota Boshoku works to reduce the amount of packaging materials used with the aim of enabling more environmentally friendly packaging while keeping intact the quality of the product.

In fiscal 2015, we succeeded in reducing packaging material by 198t per year by making five different improvements. Of these, we confirmed that improvements made to packaging conducted for replacement bumpers by eliminating one kind of packaging material, leading to a reduction in packaging consumption, did not cause any adverse impact on the product quality when delivered to automakers.

As a result, Toyota Boshoku achieved its reduction target of 2,054t with a result of 2,008t.

Reuse of water resources

The Toyota Boshoku group continued implementing initiatives that place value on water in fiscal 2015, with a particular focus on sites with processes that consume a lot of water. Efforts included reuse of rainwater, reclaimed water, cooling water and wastewater purified with a Reverse Osmosis (RO) system.

As a result, the Toyota Boshoku group achieved a result of 1,895 thousand m3 compared with its target of 2,050 thousand m3 for water consumption.

Amount of water used(Toyota Boshoku group)

TOPICSMonitoring the quality of wastewater following treatment by using living creatures

The Toyota Boshoku Sanage Plant and TB Kawashima monitor water quality following wastewater treatment using machinery on a steady basis to confirm that there are no issues with effluent discharged into the river system. Additionally, the companies conduct monitoring of factory effluent following wastewater treatment by using killifish and crucian carp. In addition to using living creatures to manage the quality of factory effluent, it enables us to convey in simple terms the effects of wastewater treatment to local children when they visit the factory for tours after showing them the wastewater treatment process in a laboratory setting.

Factory tour at Toyota Boshoku Sanage Plant
Monitoring by using crucian carp(TB Kawashima)