How Circularity is Transforming JLR's Manufacturing Sites

Jaguar Land Rover (JLR) is investing £100m (US$133m) in reuse, refurbishment, repurposing and recycling across its manufacturing operations. 

The strategy aligns with recent findings from the European Automobile Manufacturers’ Association, which shows that a circular vehicle model can cut waste by up to 70%. 

The company’s shift supports its ambition to reshape how automotive manufacturing is managed and delivered, particularly as it transitions to electric vehicles (EVs).

Embedding circularity: reuse over replacement

Rather than investing in new machinery and tools, JLR is putting over 50,000 square metres – equivalent to the area of seven football pitches – of production equipment back into service. 

This ranges from complete production lines to basic hand tools. 

Every item is assessed on a case-by-case basis, with decisions made based on compliance with standards, spare parts availability, cost of servicing, resale value and whether the equipment should be scrapped.

Tools and machinery from Castle Bromwich, a plant that stopped production last year, and from two Electric Propulsion Manufacturing Centres (EPMC) in the UK and Austria, are being transferred to sites in the UK and Slovakia.

Hundreds of second-life industrial robots are also now being installed at JLR’s sites in Solihull, Halewood and EPMC. 

These will support the company’s next wave of production for EVs and battery packs. 

In parallel, more than 18,000 tonnes of metal waste from Castle Bromwich and Graz have been sent to suppliers for recycling. This avoids the need for newly produced steel and cuts CO₂e emissions by 1,258kg per tonne.

In line with the upcoming launch of JLR’s Range Rover Electric (RRE), the company’s manufacturing teams are focused on readying facilities for next-generation vehicles.

“Rigorous testing procedures in extreme and unpredictable conditions like those experienced in Arjeplog are crucial to RRE's real‑world reliability and resilience,” says Thomas Müller, Executive Director and Product Engineering at JLR. 

“It will help to ensure RRE’s range remains intelligently optimised while also ensuring charging speeds are maintained when a top‑up is required.”

Manufactured for longevity

JLR’s vehicles and parts are increasingly being designed and manufactured with circularity in mind. That means ensuring components can be repaired, reused or recycled at the end of their life. 

The company’s ‘REALITY’ project plays a central role in this shift, focusing on how vehicles are disassembled and how materials are recovered.

The Circularity Lab in Gaydon leads this effort, bringing together JLR teams and external partners to scale up workable solutions. 

Its goal is to embed circular economy practices into daily manufacturing processes.

To measure progress against this goal, JLR is also developing a digital asset management system in-house. This new platform will follow each vehicle programme asset through its lifecycle, from procurement to reuse, resale or scrapping. 

It will include a catalogue of items available for internal purchase, making reuse more efficient and accessible across JLR sites.

“As we are entering a critical phase in our electrification journey, JLR has at heart, and aims to act as a responsible user of resources by enhancing product utility and longevity and maximising recycling and repurposing,” comments Andrea Debbane, Chief Sustainability Officer at JLR. 

“It’s not only the right thing to do, but it also improves profitability and increases supply chain resilience. Through these initiatives, JLR advocates that sustainable choices are not always more expensive, they can help reduce costs and even become opportunities for the growth and development of our colleagues.”

Circular collaboration and material innovation

The company’s circularity also extends to its material sourcing and production partnerships. 

For example, JLR has teamed up with Dow and Adient to establish a closed-loop process for polyurethane seat foam. 

This means foam from end-of-life vehicles is made into new seats, a process that delivers a saving of over 44kg of CO₂ per seat and more sustainable supply chain practices.

JLR also recycles aluminium within its production system, which reduces dependence on virgin materials and lowers its overall environmental impact. 

The company uses digital twins and material traceability tools to monitor and optimise resources across production. Automated systems and virtual testing reduce the need for physical prototypes, helping cut both waste and development time.

Each of these initiatives support JLR’s wider sustainability objectives. The company has committed to net zero carbon emissions by 2039, with interim targets through the Science Based Targets initiative (SBTi) for reductions by 2030. 

All its UK manufacturing locations already use 100% renewable electricity, with global operations aiming to follow suit.

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