Toyota’s Circular Factory has strengthened its EV dismantling capability through site-based, IMI-certified training from ELEVATE. As more electric end-of-life vehicles enter the recycling stream, the training shows why practical high-voltage competence, safe battery removal and clear processes are becoming essential for ATFs preparing for future circular economy demands.

As electric ELVs begin entering the recycling stream in greater numbers, safe, practical EV training is becoming essential for ATFs and circular economy operators. ELEVATE explains how it supported Toyota’s Circular Factory at Burnaston with site-based, IMI-certified training designed to build confidence, improve efficiency and prepare teams for the next phase of vehicle recycling.
At Toyota’s Circular Factory (TCF), end-of-life vehicles have become a strategic resource. This is, of course, the ultimate goal for the automotive industry, where waste and environmental impact are eliminated, and profitability and environmental protection are the only by-products of production. It’s impressive to see how close Toyota is to achieving this idealistic model – supported by materials from ATFs, and not at a test site, but in a fully operational facility right here in the UK.
Vice President, Circular Economy and Energy Business at Toyota Motor Europe, Leon Van Der Merwe, spoke at ATF Professional’s conference in June and was candid about the volume of ELV materials they need from ATFs to keep production going at Burnaston. As an example, he said Toyota needs plastic feedstock from 250,000 dismantled vehicles to produce one million cars per year in Europe. Toyota needs to buy in approximately 80% of recycled material, so while ATFs can be reassured there is a strong market for the materials they’re processing from ELVs, the number of cars making up that end-of-life stock will increasingly include EVs and everyone needs to be up to speed for safe and efficient handling.
While the majority of EVs will end up being processed by independent ATFs, with more eELVs starting to filter through to the TCF, Manager Craig Marston needed to find suitable training to level up their capabilities.
Toyota turned to EV specialists ELEVATE for this high-level training. Craig had this to say about the training they received and its impact:
“We were impressed with ELEVATE’s flexible training options – lead consultant and trainer Ken Byng is professional and really knows his field. Taking my team through every step of the process, and importantly, doing that practically – by coming to site and using our equipment to disconnect and remove batteries, it meant the TCF team were immediately familiar with the tools and processes, rather than having to apply that knowledge after a remote training session. Ken is also now on hand for any questions we have through consulting.
Not only can we now confidently complete electric vehicle dismantling in a safe manner, knowing we’ve followed the correct procedures, we are also IMI-certified. As the first TCF globally, we aim to apply the best practices we can in every aspect of the business, and we are learning all the time. We will share our experience (Yokoten) with the industry and, of course, with more TCFs around the globe to ensure they can work as efficiently as possible.”
If you haven’t heard the term before, ‘Yokoten’ is a Japanese term meaning ‘horizontal deployment’, the practice of sharing successful solutions, concepts and best practices laterally across departments or facilities, rather than from top-level management. No doubt one of the key reasons the company’s second TCF in Poland has had such a positive start.
Ken Byng, MD of ELEVATE, carried out Toyota’s training with new Business Development Lead, George Rumble, who was struck by this critical moment in the industry’s growth. George had this to say:
“Toyota’s impressive facility at Burnaston demonstrates their commitment to circularity and progress to meeting new European ELV requirements for recycled materials. It was great to train the team to enhance safety and improve efficiency for removing high-voltage batteries.
Since joining ELEVATE, I’ve noticed many businesses need to invest and upskill to get ahead of the curve. With the volume of eELVs returning from the market set to spike, and the growing demand from vehicle manufacturers for recycled content, there’s huge opportunity for industry players that can process EVs safely and compliantly.
That’s where we are proud to offer ELEVATE’s EV expertise through the only IMI-accredited EV training that has been designed specifically for ATFs. Our bespoke training options mean we can support operations effectively, whether we’re working with a small family-run ATF or a global organisation like Toyota.”
The handling and processing of eELVs will rapidly need to be part of ATFs normal business activities, rather than being seen as a rare inconvenience. Toyota’s Circular Factory is providing the industry with many valuable insights as it evolves, the latest of which is embracing the future of eELVs. Simply put, EV training is an essential tool to future-proof your business and the automotive industry as a whole.
If you need support in safely handling EVs and would like an informal chat about your existing arrangements, do get in touch. ELEVATE is happy to talk you through the equipment, tooling, and training requirements and help you prepare for your future needs.
Further Reading on ATF Professional
- Toyota Circular Factory: Where the End of Vehicle Life Is the Beginning of New Opportunities
- Copart Leading the Way in EV Safety & Skills
- ELVES Advances Safe End-of-Life Electric Vehicle Processing with Sligo and Athlone EV Dismantling Training Sessions
- Best Practices for Handling Lithium-Ion Batteries




