Jaguar's XE saloon supports Novelis' Close loop recycling process

This, the aluminium intensive XE, is arguably the most important car that Jaguar has launched in its 92-year history. There have been more iconic, notably the E-Type, but it's fair to say Jaguar's future hinges on this new mid-size saloon poised to take on the might of German rivals like the BMW 3-series, Audi A4 and Mercedes-Benz C-class.

Jaguar's management has taken the bold move to offer a car brimming with technological innovation. It is rare these days to launch a completely new car, but Jaguar has had the confidence to do just that: aluminium intensive body structure, a new engine range, new suspension, even the transmissions have been given a thorough overhaul and update. Parent company, TATA, has invested £1.5billion in the project creating 1700 new jobs and erecting a new 160,000m2 production facility at its Lode Lane site that will see a vehicle appear every 78 seconds at maximum production capacity. And at 85,000m2 the aluminium body shop is the largest in Europe with 613 robots and unique 'Trunnions' developed with the Expert Group to hold bodyshells in place while riveted.

At just 251kg, JLR believes the bodyshell is the lightest in its class and it features a number of material advances over other aluminium vehicles from Jaguar Land Rover.

Foremost is the first application of RC5754 aluminium alloy developed with Novelis as Dr Mark White, chief technical specialist lightweight vehicle structures explained:

"We will be generating a lot of processed scrap in higher volumes with this car and we will be getting end of life vehicles starting to come back in 5-10 years time so we decided to take the pioneering step towards full closed loop recycling including aftermarket scrap. RC5754 is the first of a highly recycled alloy used in automotive application and we will go on to develop more."

Novelis supply the sheet metal for the bodywork including 6000 series which has allowed Jaguar to reduce material thickness from 1.5mm to 1.1mm resulting in a 27% weight reduction with no loss in strength or durability. AC300T61 is used in the front crash structure with Sapa, Hydro and Constellium providing extrusions, Magna the shock tower castings whilst Meridian supplies the magnesium cross car beam and front end carrier.

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