Recycling: How JLR is Embedding Circularity in its EVs

From Land Rover Defenders to Jaguar F-Type Coupes, JLR is embedding circular economy principles into the heart of its EV strategy. 

A study from the European Automobile Manufacturers’ Association suggests this shift could cut waste by as much as 70%. 

Across its UK and European operations, JLR is investing £100m (US$133m) into refurbishing, reusing and recycling equipment – decisions that align not just with sustainability targets, but with the technical demands of electrification.

EVs built on reused tools

JLR’s circular economy initiative extends across tens of thousands of tools and pieces of equipment, from screwdrivers to whole production lines. 

These are being evaluated for continued use based on: 

• Compliance standards
• The availability of spare parts
• The cost of refurbishing and service
• Potential scrap value 
• Sale revenues.

Instead of buying new equipment for EV lines, JLR is reusing more than 50,000 square metres of kit – roughly the size of seven football pitches. 

Equipment from Castle Bromwich, which ceased production in 2024, and the Electric Propulsion Manufacturing Centre (EPMC) in Wolverhampton, as well as facilities in Graz, Austria, is now being redistributed to sites in the UK and Nitra, Slovakia.

Hundreds of second-life robots are already being installed in Solihull, Halewood and the EPMC in Wolverhampton, where they are set to build JLR’s next generation of EVs and battery packs. 

In terms of material recovery, 18,600 tonnes of scrapped metal from Castle Bromwich and Graz have gone to a supplier for recycling – saving 1,258kg of CO₂e emissions per tonne compared with using new steel.

With the launch of the Range Rover Electric (RRE) on the horizon, JLR is preparing its industrial base for the shift. 

“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.”

JLR’s repairable and recyclable EVs

In parallel with factory changes, JLR is redesigning its vehicles and components for circularity. 

Its ‘REALITY’ project focuses on disassembly and the recovery of materials, promoting reuse at the end of a vehicle’s life. 

The Circularity Lab at Gaydon is central to these efforts, connecting internal teams with external partners to scale circular solutions.

To track assets through their lifecycle, JLR is developing a digital management system that logs everything from acquisition to sale, scrapping and reuse. 

This will include an internal marketplace of tools and parts to support future EV production lines. 

“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.”

On-site teams have also developed new skills in maintenance, safety and technical refurbishing – enabling production-grade recalibration without outsourcing.

Climate consciousness beyond the factory

JLR’s commitment to a circular approach extends into the vehicles themselves. 

Working with Dow and Adient, the company is recycling polyurethane seat foam from end-of-life vehicles into new seats, cutting CO₂ emissions by more than 44kg per seat. 

At the same time, JLR continues a closed-loop aluminium recycling programme to limit its reliance on virgin materials.

The company aims to reach net zero carbon emissions by 2039 and meet interim targets under the SBTi by 2030. 

All UK manufacturing is already powered by 100% renewable electricity and global operations are moving in the same direction. 

Sustainable sourcing is now standard, including recycled aluminium and non-leather options such as Eucalyptus textile and Kvadrat wool blends.

In support of environmental and humanitarian causes, JLR has launched its first-ever Defender Awards, backed by a £1m (US$1.3m) fund. 

The initiative recognises grassroots organisations in conservation and social support, with seven winners each receiving a £100,000 (US$133,000) bursary, a Defender vehicle and expert mentoring. 

Categories include:

• Defenders of the Wild – protecting endangered or vulnerable species
   
• Defenders of Humanity – supporting at-risk and underserved communities
   
• Defenders of the Land – conserving vital ecosystems
   
• Defenders of the Sea – safeguarding ocean habitats.

In the background, digital tools like digital twins and traceability systems are helping cut waste and optimise flows. 

Automation and virtual testing also reduce the need for physical prototypes. 

JLR’s collaboration with partners such as Dow and Adient, as well as wider alignment across Tata Group, supports innovation in polymer use and recovery of materials from end-of-life vehicles.

JLR is embedding circularity into every stage of the EV lifecycle, showing that environmental responsibility and electric innovation can go hand in hand.

Explore the latest edition of EV Magazine and be part of the conversation at our global conference series, Sustainability LIVE.

Discover all our upcoming events and secure your tickets today.

EV Magazine is a BizClik brand