Building Circular Societies

Toyoda Gosei uses resources effectively and contributes to circular societies by reducing waste volumes^*1 and water usage and designing products that are easily recyclable.

*1 We are currently attempting to reduce waste volumes for the minimization of industrial waste as set forth in the TG 2050 Environmental Challenge.

Basic Philosophy

As a polymer manufacturer specializing in rubber and plastics, we undertake to do our part for circular societies through the effective use of limited resources.

First, we take measures to prevent defects and improve yields centered on manufacturing floors. In addition, we are seeking ways to limit emissions and recycle materials with the involvement of our material and production engineering divisions, where all of our work starts, and expand resource circulation.

Another major problem relates to water, with water shortages and flooding in many parts of the world caused by climate change. We are therefore identifying risks in all countries and regions of the world where we have operations, and working to mitigate these risks by decreasing water consumption and recycling water, as well as returning cleaner wastewater to surrounding communities.

Risks and Opportunities Associated with Resource Circulation

The risks and opportunities associated with resource recycling are an important management issue, and we are addressing them company-wide as one of our key action items.

Impact items	Risks	Opportunities	Response
Depletion of resources (shortage)	Decreased revenue, production disruptions from difficulty purchasing raw materials and soaring prices	Higher revenue from recycling technology, reduced material usage Higher corporate value from development of the above technologies	Product development for lighter weight Development of raw material recycling technology Greater use of plant-derived biomaterials and recycled materials
Water risks (volume/ quality)	Production disruptions from difficulty ensuring water needed in production Poorer product quality from water quality deterioration Production disruptions from water damage	Higher revenue from reuse of water, decreased usage Higher corporate value from development of the above technologies	Development of water reuse technologies Greater use of rainwater Review of production networks, review of electric facility installation sites

Waste Reduction

Establishment of 2030 Milestones

As we move toward the circular societies envisioned in our TG 2050 Environmental Challenge, we aim to minimize emissions volumes and have set targets as 2030 milestones for the effective use of resources, including measures to limit emissions and control their source, recycling of rubber and plastic scrap, and reducing waste through careful and thorough separation.

■Scenario for Minimizing Amount of Waste (reduction image) ［Toyoda Gosei Co., Ltd.］

Satisfying the Plastic Resource Circulation Act

The Plastic Resource Circulation Act went into effect in April 2022, and with a view to our contribution to carbon neutrality, we are committed to designing and manufacturing environmentally friendly 3R + Renewable products. We have also set new 2030 targets for industrial plastic waste volume and are working for plastic resource circulation.

■Plastic Industrial Waste Volume ［Toyoda Gosei Co., Ltd.］

Development of Product Recycling Technology

Materials
Design
Manufacturing
Recovery/recycling

We develop and design easily recyclable products and materials with thought to the entire lifecycle of automobiles. We are also developing recycling technology for waste material.

■Development of Technology for End-of-Life Vehicle Parts Recycling

Key items	Measures implemented
New recycling	Composite material separation technology New recycling technology (high quality material recycling)
Use of recycled materials in vehicles	End-of-life vehicle recycling technology Development of applications for recycled materials
Product design for easy recycling	Product design for easy disassembly Materials and composition changes for easy recycling

Examples

Full-Scale Operation of Rubber Recycling Processes to Achieve FY2030 Targets

Recovery/recycling

We aim to reduce waste materials by 50% (compared with FY2012 levels) by 2030 on our way to achieving carbon neutrality in 2050. In April 2021, recycling processes for four types of weatherstrips were brought together in a dedicated building. By restoring waste rubber to a raw material state with our original technology and using it in new products, we expect to reduce waste by about 600 tons. This should also have an effect in reducing CO₂ emitted during raw material transport and the incineration of waste. In addition, we hope to contribute to reducing the environmental impacts of the industry overall, by using this recycled rubber not only inhouse but also selling it to other companies.

■Development of Technology for End-of-Life Vehicle Parts Recycling

Reduction of Waste Materials in the Production Stage

Manufacturing
Recovery/recycling

To reduce waste in the production stage, we are combating waste at its source and recycling. To minimize waste in the TG 2050 Environmental Challenge, we launched a waste reduction project in 2018 by our plants and production engineering, materials technology, and product design divisions, in which we combat waste at its source and recycle. We also conduct mottainai inspections to identify items for reduction with genchi-genbutsu (go and see) and other reduction activities at each business location. Good examples of reduction are shared among domestic and international Group companies as the entire Group tries to reduce waste.

■Amounts of Waste Generated and Disposed of (results for FY2021) ［Toyoda Gosei Co., Ltd.］

Examples

Waste reduction from design of airbag pads that can be easily taken apart^*2

Previously, the pad and metal were riveted and caulked. As a result, when there was a problem the product could not be taken apart and it all had to be disposed of as waste, including good components. By switching to a fixation method that allows for easy dismantling while maintaining quality, and for separation of each material component (plastic pad, cloth, metal), waste was reduced by about 8.5 tons as a result of recycling and converting waste into valuables. We will continue reducing waste with similar approaches.

*2 The ability to easily dismantle various parts

Development of products that use material remnants

We are developing products using rubber remnants and recycled materials, and have developed a floor mat that reduces fatigue during work in factories. We have also developed ecobags and other products using airbag remnants, and have begun selling them under the “Re-S” brand name.

Reduction of Packaging in the Distribution Stage

Recovery/recycling

The packing material used in product transport is being reduced to prevent products from being soiled by increasing the number of times reusable containers are used in the field and maintaining cleanliness. We are also reducing packing material by putting lids on reusable containers and other changes, considering the balance between maintaining product quality and reducing the use of packing materials.

■Amount of Waste ［Toyoda Gosei Co., Ltd.］

■Waste Volume per Sales Unit (index)^*3 ［Overseas Group companies］

*3 A figure obtained taking the base year as 100

Reducing Water RisksManufacturing

We have set and are working toward 2030 milestones to achieve the targets in the TG 2050 Environmental Challenge. For this we are assessing risks in both water usage and water quality in Japan and international locations, and making improvements at high-risk locations. Even in places where risks are low, we are trying to reduce water intake amounts for the effective use of resources.

In FY2021, we cut water use through improvements to reduce leakage and by promoting recycling. We are also planning upgrades to wastewater treatment facilities for cleaner waste water.

■2030 Reducing Water Risks Milestone［Global］

	Item	2030 target
High risk area	Water quality	Measures completed at four locations
High risk area	Water intake	Measures completed at seven locations
Low risk area	Water intake per sales unit	11% decrease vs. FY2019

■Water Intake per Sales Unit (index)^*4 ［Toyoda Gosei Co., Ltd.］

*4 A figure obtained taking the base year as 100

Re-S Eco-Brand Recovery/recycling

As one part of our efforts to reduce waste, we have expanded to products that use remnants generated in the production of automotive parts such as airbags and steering wheels, under the Re-S brand.

Our Re-S brand is widely marketed to the general public, including consumers, and is being promoted through regular pop-up stores at nearby commercial facilities and through our own online store.

In addition, we are actively collaborating with companies in different industries, which we hope will lead to the accumulation of B to C business know-how.

In FY2021, we promoted and launched a project for collaborative products with Doala, the mascot of the Chunichi Dragons professional baseball team, Yamanami Kobo, a facility for people with disabilities, and students of Kinjo Gakuin University.

“Re-S” was coined from the prefix “re-,” as in “reborn” and “recycle,” that is the start of environmentally-friendly activities, and also includes the meaning of sustainability (S).
https://res00.base.shop/

Re-S online shop

Representative product

Airbags & seatbelts

Collaborative product with Kinjo Gakuin University

Examples

Wastewater treatment facility at Morimachi Plant upgraded

The wastewater treatment facility for production processes at the Morimachi Plant, which had been in use for more than 30 years, was upgraded in FY2018. With the adoption of more advanced processing (membrane bioreactor) and a constant monitoring system, a cleaner and more stable water quality than before is achieved in wastewater. Future use as coolant water is under investigation.

Reduced water usage with the use of rainwater

Toyoda Gosei Group company Hoshin Gosei Co., Ltd. reduced water usage about 3% by recirculating water in production processes, installing green curtains, and using rainwater to water plants in employee rest spaces.