Resource Recycling Efforts

Resource Recycling Efforts

TOYO TIRE considers our mission to contribute to the shift from a society that consumes resources to one that recycles as the social responsibility of a manufacturer that conducts business globally.
As the scale of our production activities expands, the amount of raw materials we use also increases. Therefore, we strive to secure a stable and sustainable supply of raw materials indispensable for business growth, such as natural rubber, the main raw material in the procurement stage, in terms of both quality and volume. We are also moving forward with efforts to develop new materials and to improve product design and production processes to make more efficient use of materials.
The Toyo Tire Group is making constant efforts to increase material usage efficiency. For example, TOYO TIRE NORTH AMERICA MANUFACTURING INC. (U.S.) has introduced new equipment that will contribute to resource consumption reduction in the production process. Use of this equipment will improve the functionality of the materials; thereby, reducing consumption of the raw materials and the processing time. And Toyo Soflan Co., Ltd., for example, reuses 100%* of defective units and discards (cut pieces from the molding process) from its resin product manufacturing process by feeding them back to the process.
*Excluding products using special materials

TOYO AUTOMOTIVE PARTS (USA), INC., on the other hand, is expanding the scope of items for reuse that would be otherwise disposed of. In FY2019, they designated 16 items for reuse. They also chose the Resource Conservation and Recovery Act (RCRA) of the U.S. as a topic for environmental learning, a segment covered in their weekly meetings, in order to raise the environmental awareness of their employees.
As for when products are used, efforts are being made to extend the service lives of products, which includes manufacturing products with outstanding durability and producing reused tires (retreaded tires) from used tires.
All of the Group’s business sites completed risk assessments stipulated by the Industrial Safety and Health Act. In addition to responding to the added chemical substances, we are also introducing reduction risks.

Examples of resource recycling efforts
  • Moving away from incinerating waste and switching to thermal recycling
  • Replaced wooden pallets with more durable plastic pallets
  • Examining alternatives for regulated substances
  • Efforts related to chemical substance risk assessments based on independent initiatives, wear dust, and used tires

Management of Specific Chemical Substances

Toyo Tire Corporation manages raw materials (chemical substances) that it needs for business continuity in accordance with the laws/regulations in each country as well as the chemical substance management guidelines provided by customers.
In Japan, from conventional, Regarding the specific chemical substances that are necessary to continue our business activities, we carry out strict management on the use, storage, and disposal of these substances, based on the “Law Concerning Reporting, etc. of Releases to the Environment of Specific Chemical Substances and Promoting Improvements in Their Management.” In accordance with the PRTR system, when a designated chemical substance is released or transferred, we are aware of the amount and report it to the national government.
Whenever the EU regulations concerning Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), Global Automotive Declarable Substance List (GADSL), or customers’ lists of chemical substances management are revised, we adjust our operations accordingly.
Furthermore, we comply with the Ordinance on Prevention of Hazards Due to Specified Chemical Substances, the Ordinance on Prevention of Organic Solvent Poisoning, and related laws and ordinances based on the Industrial Safety and Health Act, and ensure that emission control measures using local exhaust ventilators, appointment of a work supervisor, measurement of the working environment, and medical checkups are conducted properly.

Main Materials used

(1000t)

2017 2018 2019
Total weight of main materials 334.4 332.8 314.0
Renewable 179.0 190.7 187.6
Non-renewable 155.4 142.1 126.4
Percentage of recycled input materials used to rubber material 1.2% 1.2% 1.2%

Waste

Non-hazardous waste (industrial and general waste)

(1000t)

2017 2018 2019
Total weight of Non-hazardous waste 34.8 32.5 30.4
Recycled amount of non-hazardous waste 18.9 16.1 12.2
Reused amount of non-hazardous waste 0.90 0.85 0.06
  • * In 2019, our Sendai Plant converted its thermal energy source to natural gas, which resulted in a decrease in the amount of products reused within the company as a fuel.

(t)

2017 2018 2019
Total weight of Hazardous waste 149.9 129.3 114.4
  • *How the waste disposal method has been determined;
  • Non-hazardous waste (industrial and general waste): Information provided by the waste disposal contractor
  • Hazardous waste (special control industrial waste) *in Japan: Information provided by the waste disposal contractor
Reference: In-house management goals and results
  • Goals: Achieve a waste recycling rate of 100% by December 31, 2018
  • Boundary: TOYO TIRE Corp. (Headquarters, Sendai Plant, Kuwana Plant (tire/ Automotive Parts), Hyogo Manufacturing Complex, Tire Technical Center, Automotive Parts Technical Center, Corporate Technology Center, Tire Proving Ground), Fukushima Rubber Co., Ltd., Toyo Soflan Co., Ltd., Ayabe Toyo Rubber Co., Ltd., Orient Machinery Co., Ltd. (Headquarters, Sendai branch)
  • Management unit: Direct recycling amount*/ Total weight of waste×100
  • 2*Amount outsourced for recycling to a direct waste disposal company (Excludes direct landfill, in-house simple incineration, and outsourced simple incineration.)
  • FY2019 results: Waste recycling rate of 100%

Transport of hazardous waste (PRTR-designated chemical substances)

2017 2018 2019
Handled 4348.4 3930.1 2978.0
Emitted 228.8 179.2 164.7
Transferred 81.6 83.0 88.8
  • *How the waste disposal method has been determined;
    Transport of hazardous waste (PRTR-designated chemical substances) *in Japan: Disposed of directly by the organization
TOPIC
TOYO TIRE RUS LLC:Celebrated Eco-Day with an Environment NPO
Goal 12

Amid the growing interest in the importance of resource recycling, TOYO TIRE RUS LLC (TTRU) of Russia observed "Eco-Day in TTRU" in December 2019 at the suggestion of its employees.
An expert was invited from a local NPO that promotes recycling, Sobirator (Собиратор), to speak about how we can form a daily habit of using resources with care and the new garbage separation rules in Moscow, where their office is located. This environment NPO donates proceeds earned by recycling disused articles to foundations working for the eradication of poverty. Their employees brought articles that they no longer need on the day for the NPO to take back for their activities.
This Russian subsidiary will continue working to raise their employees’ environmental awareness through recycling activities, while at the same time working to resolve social issues for the achievement of TOYO TIRE’s SDGs.

  • Eco-Day in TTRU
  • Eco-Day in TTRU

TOYO TIRES Brand, also known for High Quality Recycled (Retreaded) Tires

Collecting and recycling used tires is an important issue in the tire industry for recycling resources. As one solution, we are working to spread the use of retreaded tires.
Retreaded tires involve replacing the tread (the part of a tire that comes into contact with the road surface) on worn tires to make them serviceable again. Since retreading reuses all the remaining part of the tire, it naturally saves resources and even emits less CO2 than in manufacturing new tires*.
We produce and supply highly durable, high quality tires, and we have received high praise from users regarding retreaded products.
We contribute to the promotion of resource recycling in the transportation industry by spreading the use of high-quality retreaded tires.

  • *Retreaded tires produce 41% less CO2 in comparison to new tires during production. (Source: Japan Retreader’s Association)

Total Production Shipments of Recycled (Retreaded) Tires *TOYO Brand

Total Production Shipments of Recycled (Retreaded) Tires *TOYO Brand

(1,000 units/year)

2017 2018 2019
Production output 124.9 131.0 130.0

Retreaded tire production flow

There are two methods of retreading: In Remold method, new tread rubber is applied to tire casting. It is then placed in a mold and vulcanized to form tread. In Pre-cure method, previously prepared tread strip is applied to tire casing and vulcanized in a vulcanizer.
Our group has established high technology in both construction methods and produce with both.