In the automotive aftersales industry, waste products are unavoidable and over the years, the more responsible companies have ensured that the waste products are properly disposed and do not damage the environment. Local authorities also have strict regulations to ensure that waste products like used oil do not get into the public drainage system.
One of the companies which has stepped up its efforts in this area of Environmental, Social and Governance (ESG) is BMW Group Malaysia which recently commemorated their partnership with Pentas Flora in a Memorandum of Understanding (MoU).
In 1991, Renault displayed a concept car that was the forerunner of compact MPVs with its novel management of the interior layout to comfortably accommodate a whole family. The model was called the Scenic concept, and its format would be used in a new generation of models that also used the same name.
31 years later, the French carmaker is again using the name and as before, the new model starts a new chapter in its history. Known as the Scenic Vision, the new concept car embodies the brand’s sustainable development commitments and encapsulates them in a single vehicle. Its intelligent design and manufacture incorporate methods that the Renault Group and its brands will use to achieve carbon neutrality in Europe by 2040 and worldwide by 2050.
Previous Scenic concept introduced the compact MPV format to the world in 1991.
With the Scenic Vision, Renault is proposing ‘a car for life and for living’, with a new vision for the family car. Its exterior design, measuring 4.49 metres in length, provides a preview of an all-electric model in the C-segment that will be unveiled in 2024.
The unique design is enhanced by the choice of colours, where black and white create a singular graphic universe. Shades of black on the outside, and white on the inside, offer a contrast of light and dark that reflects the design team’s wish for this concept car to be a work of art where artistic expression takes to the fore.
Fuel cell powertrain
The Scenic Vision is proposed with a fuel cell that generates electricity for a new-generation motor. The 160 kW motor derives directly from the latest Megane E-Tech Electric’s motor and uses no rare-earth elements. This helps to reduce its carbon footprint and create a responsible and sustainable ecosystem.
The 40 kWh battery pack is recyclable and will be made in France by 2024 at the Renault ElectriCity Gigafactory. It is lighter, smaller and costs less than a battery pack for a similar electric vehicle. The 15 kW fuel cell will recharge it during long drives and thus extend its range. In 2030 and beyond, once the network of hydrogen stations is large enough, it will be possible to drive up to 800 kms, with the hydrogen tank able to be refilled in 5 minutes or less.
The all-new platform used by the Scenic Vision is currently in the prototyping phase. It is purpose-designed to fit all the components – electric motor, hydrogen engine, battery, fuel cell and hydrogen tank. The engine is at the rear, so there is enough space for the 2.5-kg hydrogen tank at the front; the fuel cell is under the floor, at the back of the platform, behind the battery.
Optimal travel times
This propulsion system’s operation is simple and efficient. The car can be driven as a conventional electric vehicle, without using the fuel cell, on daily trips. When there is a requirement to travel longer distances, a route planner calculates the power the fuel cell needs to supply to keep the battery charged for longer, so that there is no need to charge it on the way.
The point of using the fuel cell on long journeys is that it’s quicker to top up the hydrogen tank than to charge the battery. This way, there is no need to charge the battery until the car reaches its destination. When the weather is cold, the hydrogen range-extender also keeps the battery at the right temperate for optimal operation and extra range.
95% recyclable
A full 95% of this concept car’s materials – including the battery – are recyclable. This new approach to design looks beyond the vehicle and includes previously unexplored ventures and technologies. The exterior materials (steel, aluminium, carbonfibre and plastics) can all be recycled at the end of their life.
Everything inside is also designed responsibly. For example, the foams, fabrics and stitching on the light beige seats are made of the same material, produced from fully recycled and recyclable plastic.
Estimates suggest that the number of electric vehicles on Europe’s roads will increase tenfold between now and 2030, from 10 million to 100 million. The Renault Group is the first carmaker to work on the full battery lifecycle, and has developed solid expertise in increasing their durability and using them for a wider variety of purposes. Once a battery is no longer fit to power a vehicle, its energy can be reused in stationary storage solutions in homes or offices, or elsewhere (in boats, refrigeration systems, machinery or airport logistics, etc).
The steel in the vehicle’s structure is made from 95% recycled steel, while all the aluminium parts in the structure (housings, battery casing, seats) and trims (console, cockpit) are made from 100% recycled aluminium. All the carbonfibre is recycled from aviation industry scrap via a partnership with Airbus, and the hydrogen tank is made with carbonfibre produced from paper-industry waste.
Elsewhere, 70% of the interior and exterior plastics are recycled, with 100% of the textile fabrics made of recycled materials. It is also entirely leather-free, while the floor is made of 100% recycled plastics from food and industrial waste
Help for safer motoring
The Scenic Vision previews technology and systems which will provide assistance to drivers, enabling them to better avoid risky situations, and reduce stress behind the wheel. The multiple ADAS (Advanced Driver Assist Systems) and 3 on-board systems – Safety Score, Safety Coach, and Safe Guardian, are designed to provide extra safety for all, as well as a unique level of both physical and psychological comfort.
New Renault models will soon come with a ‘Safety Score’. Using data collected by sensors mounted on the vehicle, it analyses the driver’s driving style – acceleration, smoothness, inattention, speed management, and driver distractibility. It then gives personalised driving tips to each driver based on a safety score calculated at the end of each trip.
To further aid drivers, the vehicle comes fitted with an array of health monitoring systems. A heart rate sensor placed in the steering wheel and a camera serve to detect signs of driver fatigue or inattentiveness. Should a problem arise, warning signals are sent to the driver and passengers, and emergency services are alerted automatically.
The Scenic Vision has been designed with a new architecture that features an extra-large screen located where the dashboard meets the windscreen. It displays the car’s immediate environment, thanks to an array of on-board cameras located at the front of the vehicle. The system increases the driver’s field of view by 24% due to a visual widening of the windscreen and a front bonnet that ‘disappears’.
New technological solutions help rescue services at the scene of an incident. The Fireman Access and Rescue Code are two such systems already featured on production vehicles, with the former featuring a specialised access hatch to the core of the battery that means it now only takes a few minutes to extinguish a battery fire instead of up to 2 hours.
Scrapping cars at the end of their useful life has been a common practice for decades. The metal and plastic parts that can be extracted can be reused for other goods – but not necessarily cars again. BMW thinks that cars of the future should be made from nearly 100% recycled materials. This will support the idea of a ‘circular economy’, where materials are continually reused, rather than discarded at the end of a single product’s lifespan, as in the conventional linear economy.
To demonstrate how the circular economy can be applied by the auto industry, the carmaker built the i Vision Circular concept which is a compact EV that might be in use in 2040. Working with companies like BASF and the ALBA Group, materials like recycled plastics are identified as sustainable materials that go into the construction of the i Vision Circular concept.
The recycling approach applies to the all-solid-state battery pack which is also manufactured almost entirely using materials sourced from the recycling loop. It will achieve much higher energy density with significantly reduced use of the most valuable resources, especially rare earth materials.
BMW also used 3D printing for many interior components, which further helps reduce waste, the automaker noted. The process produces less scrap material, and whatever isn’t used can be fed back into the production cycle as raw material.
Circularity from design stage
“We gave thorough consideration to circularity from the outset during the design process for the BMW i Vision Circular. As a result, this Vision Vehicle is packed with innovative ideas for combining sustainability with a new, inspirational aesthetic – we call this approach ‘circular design’,” explained Adrian van Hooydonk, Head of BMW Group Design.
The number of parts on the bodywork has been reduced as much as possible. Instead of having a chrome surround with bars, for example, the iconic kidney grille has been newly interpreted as a digital surface. Even the brand logo on the front end is engraved and the vehicle badge is laser-etched to avoid using extra add-on parts.
The surfaces below the windscreen are made from secondary aluminium. An additional sensor cluster between the two kidney elements groups together technological features, enabling simple disassembly within a single removable element. The bumper area further down is manufactured from recycled plastic with a sophisticated marbled surface.
Minimum parts and ease of disassembly
Having a small number of different mono-material groups with connections that can easily be undone is crucial for good recycling. For this reason, there are no bonded connections or composite materials and, instead, intelligent types of connection, such as cords, press studs and quick-release fasteners are used. A special socket wrench can separate the component parts joined by the fastener with a single rotation.
The tyres in ‘Vivid Blue Rubber’ are made from certified, sustainably cultivated natural rubber and have a slightly transparent appearance. Extra coloured, recycled rubber particles are added to the tyre compound for strengthening, creating an intriguing terrazzo effect and purposefully highlighting the reuse of materials.
The wheel rims are designed and manufactured with minimal materials use. Rim centres with maximum permeability provide brake cooling, while the more enclosed surfaces to the outer reaches of the wheels ensure the greatest possible aerodynamic efficiency. The wheels are fixed in place with a quick-release fastener at the centre of each wheel.
Only visible when looking from above, a narrow fin is integrated centrally in the rear section of the glass roof. It contains the communications and antenna technology, and provides information on the status of the vehicle (open/closed, charge level of the battery, etc.). It also integrates the high-mounted centre brake light.
Luxurious ambience with recycled materials
Inside, the i Vision Circular is also true to employing materials and production processes that are indicative of a responsible approach to the environment and its resources. But that does not mean it cannot have a luxurious ambience. For this, the interior designers carried out purposeful selection of materials. This involves using not just the right basic materials in the form of mono-materials but also clever new joining techniques for them which avoid the use of glue in order to ensure optimum suitability for dismantling and sorting at a later stage.
In order to minimise the amount of waste and offcuts, all components and materials will be manufactured to fit exactly using processes such as 3D printing. Any surplus material will be systematically fed back into the materials cycle.
The instrument panel is turned into a next-generation ‘phygital’ (a newly coined term that refers to turning digitality into a haptic experience) user interface. Here, it takes the form of a hovering, V-shaped sculpture that projects out into the cabin. At its heart is a 3D-printed, crystal body with nerve-like structures running through it, great visual depth and an enthralling lighting effect. This is where the vehicle’s “thinking” is visualised, allowing the user to see its intelligence at work.
The information area you would normally expect to find in a central information display is located above the instrument panel, at the bottom of the windscreen. This display area takes the Head-Up Display to a whole new level. All relevant information is projected onto the bottom area of the windscreen across its entire width. Driving displays for the driver can be found here together with communications functions and entertainment features for the passengers.
3D-printed steering wheel
The steering wheel forms a link between past and future at the same time as reducing the quantity of material and components. The rim has been 3D-printed from bio-based material, with the wood powder variant shown here giving the steering wheel a natural and warm feel. The unconventional, central positioning of the vertical spoke in gold-bronze adds a modern twist.
The display and operating surface below the windows visible on the outside of the car can be found on the inside too, forming a connecting element between interior and exterior. Here again, it extends back into the rear of the car and around the Hofmeister kink. Featuring the same crystal appearance as the instrument panel and ambient lighting, this element in the sidewall adds to the intriguing and mystical aura produced in the cabin.
BMW makes it clear that the i Vision Circular concept is not the basis or any future model. It has a range of next-generation EVs under development, referred to as ‘Neue Klasse’ (German for ‘New Class’) which may adopt some of the ideas from the sustainability-focused concept car.
It’s all about sustainability today, using materials and processes that do not deplete and to preserve the environment for future generations. In the auto industry, sustainability is pursued seriously in all areas and with the MINI STRIP, the British brand showcases inspirational ideas for a more sustainable method of automotive design.
A custom-made, one-off model co-created by MINI and Paul Smith, a well known fashion designers, the MINI STRIP is guided by the theme of ‘Simplicity, Transparency, Sustainability’. As the name suggests, the process began by completely stripping down a MINI Electric and reducing it to its structural essence. Only then were the elements that the designer viewed as absolutely necessary defined and implemented – with sustainability as the top priority.
Incidentally, the original Mini was also a model of simplicity, with a very basic but functional design that was space-efficient as well. Sir Alex Issigonis, the designer, made it easy to build and even thought that placing the speedometer in the centre would simplify having lefthand drive and righthand drive versions. It’s a feature which continues to this day in the modern MINI though not for the same reason.
An outside perspective
As a designer with a passion for bicycles, books and much more, Smith asked questions that provided fresh energy to explore beyond the obvious. The joint design process applied the principles of maximum reduction, to produce a minimalist, high-class design with a fresh and unconventional appeal.
Raw materials are a very deliberate part of the exterior design – the body was left in its unfinished state with no coloured paint applied, but instead just a thin film of transparent paint to protect against corrosion. Grinding marks from the factory have been consciously left intact on the galvanised steel panels to clearly identify the car as a functional object. This intentionally rough-hewn effect was dubbed ‘the perfect imperfection’ by Smith.
‘Unaffected expressiveness’ of the materials
Parts of the MINI black band have been 3D-printed from recycled plastic and their basic material qualities have been left exposed – like the metal panels. Visible screws in the add-on parts show how simple dismantling would be and how easily the vehicle could be reincorporated into the raw-material cycle at the end of its service life. The functional and distinctive front and rear apron inserts were also manufactured via a 3D printing process, which produced their striking texture.
The blanked-off radiator grille and its wheel covers help to reduce drag, thereby increasing its theoretical range. The grille trim and aerodynamic covers on the wheels are made from recycled Perspex, saving both weight and resources. Recycled perspex was also used for the large panoramic roof that allows curious eyes to view the largely bare structure of the bodyshell inside.
‘Simplicity and Transparency’ inside
Smith calls the MINI STRIP a ‘classic with a twist’ – both refer to unexpected details that are only revealed through the designers’ work at a second or third glance. Opening the doors reveals the signature Paul Smith stripes in a vivid composition of 5 colours; the charging flap adds a splash of neon green when opened, while the engraved drawing of an electric plug on the flap is Smith’s own work.
Inside, all trim parts have been purposefully omitted (with the exception of the dashboard, topper pad and parcel shelf), turning the bodyshell into the dominant visual feature of the cabin. It has been coloured blue at the explicit request of Smith, producing a particularly eye-catching effect. The exposed, basic material and intense blue tone give the interior an aesthetic appeal all of its own; it is bare yet feels ‘dressed’ at the same time.
Instead of the usual multi-part design, the dashboard consists of one large, semi-transparent section with a smoked-glass finish. Taking its cue from MINI design’s traditional use of circular elements, the geometry has been simplified with a graphical interpretation. However, the classic centre meter is omitted, leaving the driver’s smartphone to take centrestage instead. It is placed where the centre display would normally be, connects automatically to the car and becomes the media control centre. The only physical controls in the interior are located lower in the centre stack, where the toggle switches for the power windows and the start/stop function can be found.
Innovative materials
Alongside the minimalist design inside the MINI STRIP, the use of recycled, environment-friendly materials also underpins the car’s sustainability credentials. The interior is free of both leather and chrome, with the seats upholstered in a knitted fabric. The completely mono-material design for the seat coverings means they are fully recyclable – including the piping – allowing material circularity to be maintained.
The floormats are made from recycled rubber with their terrazzo-like pattern a by-product of the recycling and manufacturing process, positively showcasing the multi-coloured constituent elements enjoying a second life as part of this material.
Minimalist and functional
The steering wheel, which is also a focal point of the interior, has been reduced to the most essential functions. Its rim has been wrapped in handlebar tape in true road bike style. Three aluminium spokes connect the rim to the steering wheel’s impact absorber, whose mesh covering makes it possible to see the airbag behind.
As on the outside of the car, there are visible screws showing how easy it would be to dismantle the steering wheel at a later date and reuse the aluminium. The door panels are made from the same mesh material that covers the airbag, enabling the door structure to be clearly seen behind the mesh panels, which are held within a frame. The transparency of the knitted mesh changes according to the angle of view, adding a further dimension to the interior’s appearance.
The pull handles in the door shoulders are made from wound climbing rope and, together with the matching seat belts, liven up the interior with their bright orange finish. Like the pull handles, the door openers in milled aluminium are housed in the cork door shoulders and provide a high-class finishing touch for the door area.
As the eye wanders further up the door, it arrives at the exposed airbag unit in the roof pillar. This has the same effect as the visible cable routing in the interior – deliberately drawing attention to functions that are normally concealed during manufacture.
The MINI STRIP translates MINI’s ‘Creative Use of Space’ philosophy into a radical and fundamental redesign of a MINI – especially in the interior. As such, it can provide a catalyst for more sustainable use of resources in automotive design.
Motor vehicles can last a long time but at some point, they will be scrapped and depending on what processes are available, the various parts that were assembled together to form the vehicle will be removed and can be recycled, typically, plastic and metal items as well as batteries and tyres.
With Re:Style 2020, Hyundai Motor Company (in the UK) announces the launch of a creative approach to sustainable fashion by upcycling discarded materials from the automotive manufacturing and scrapping process into marketable products in collaboration with leading artists in eco-friendly design.
Other materials can also be recycled Re:Style 2020 stems from the recognition that although most of the materials, such as iron and non-ferrous metals, are currently recycled as part of the vehicle scrapping process, there are still some materials such as leather, glass and airbags that end up in landfill. For Re:Style 2020 as well as its past iteration in 2019, the company collected various leftover materials with the help of diverse partners and sent them to the collaborating designers.
Building on the success of its predecessor in 2019, the Re:Style 2020 capsule fashion collection has been created in partnership with renowned trendy fashion brands Alighieri, E.L.V. DENIM, Public School, pushBUTTON, Richard Quinn and Rosie Assoulin.
Sales on Selfridges online store
In view of the current global pandemic, the collection has been presented online this week via Hyundai’s social media channels, as well as those of Britain’s Selfridges and the participating brands. Featuring a variety of products such as jewelry, jumpsuits, working vests, bags and various other clothing made with discarded materials from the automobile production and scrapping process, the event will kick-start sales on the Selfridges online store.
L.V. Denim’s Jumpsuit from upcycled denim and leather scraps from the car manufacturing process (left), and Public School’s Fuji Technical Vest (right) created out of discarded seatbelt webbings and airbag materials.
pushBUTTON’s Work Vest (left) with pockets using airbag materials that keeps the airbag’s original details, and Rosie Assoulin’s Tote Bag made of seatbelt webbings, carpet fabrics and foam repurposed from discarded automotive materials.
“At Hyundai Motor, we understand that ethical consumption and caring for the environment are increasingly important considerations of our customers in the post COVID-19 world. Through Re:Style 2020 we want to offer another way Hyundai Motor can help customers enjoy the sustainable lifestyle they aspire to,” said Wonhong Cho, Executive Vice-President and Global Chief Marketing Officer of Hyundai Motor Company.
“By demonstrating that discarded resources can be reimagined into valuable products, Hyundai Motor encourages more industries to see waste as a recreative opportunity and to work collaboratively toward an environmentally accountable and economically efficient future.”
Under its Strategy 2025, Hyundai Motor aims to spearhead a global leadership in zero-emissions and clean mobility by becoming the world’s third-largest automaker of eco-friendly vehicles by 2025.
The lead-acid batteries in motor vehicles have been around for many decades and because they are made from elements that can be recycled, there is an established ‘business’ in collecting and recycling batteries. Even the guy who collects old newspapers will take them as the lead, plastics and even the sulphuric acid can also be recycled.
Lead-acid batteries are therefore considered as ‘closed-loop’ products which means that when their ‘first life’ is over, they can be recycled into other products. It is estimated that globally, 98% of such batteries are being recycled.
With the advent of hybrid and electric vehicles since the late 1990s, more powerful battery packs have appeared. These are needed to store electricity in large amounts and to power the electric motors. These have not continued with the lead-acid approach which would make the battery packs very heavy as they would have to be very big to store sufficient electricity.
Instead, the battery packs for battery-powered electric and hybrid vehicles use nickel-cadmium (NiCd), nickel–metal hydride (Ni-Mh), and more recently, lithium-ion or lithium-ion polymer. The technology is constantly advancing, and the battery packs are getting more compact while their storage capacity keeps growing, making possible longer travel ranges.
Battery pack used in an Accord Hybrid.
End-of-life disposal
The manufacturers have been mindful of the fact that the battery packs have an end-of-life and unlike lead-acid batteries, their disposal is not so straightforward. Various solutions have been explored to keep them in service and Honda Motor Europe, together with SNAM (Societe Nouvelle d’Affinage des Metaux), is investigating the possibility of using batteries in a ’second life’ for the storage of renewable energy in industrial applications.
SNAM is a battery recycling company and is increasing its role in partnership with the carmaker to advance the sustainable usability of its end-of-life battery packs. The pan-European arrangement will see SNAM collect and recycle batteries from Honda’s increasing number of hybrid and electric vehicles and either potentially prepare them for ‘second-life’ renewable energy storage uses or extract valuable materials for recycling if they are not suitable for that purpose.
End-of-life battery packs can be divided in two types – those that can be reconditioned and continue to function as energy storage units or broken apart and their materials recycled (below).
Honda and SNAM have worked together since 2013 to ensure the traceability of end-of-life batterie packs and dispose of them in accordance with European Union environmental standards. The expansion of this agreement will see SNAM collect lithium-ion and NiMH batteries from Honda’s dealer network and Authorised Treatment Facilities in 22 countries, before analysing how suitable they are for recycling and processing them accordingly.
Second life applications
“As demand for Honda’s expanding range of hybrid and electric cars continues to grow, so does the requirement to manage batteries in the most environmentally-friendly way possible. Recent market developments may allow us to make use of these batteries in a second life application for powering businesses or by using recent improved recycling techniques to recover useful raw materials which can be used as feedstock into the production of new batteries,” said Tom Gardner, Senior Vice-President at Honda Motor Europe.
Safe and low carbon transport is utilised for the collection of used batterie packs. On arrival, SNAM assesses which battery packs are valid for inclusion in a new energy storage device. These are then repurposed and made available by SNAM for domestic and industrial applications.
One application for recycled battery packs.
When battery cells are damaged and unsuitable for ‘second life’ applications, materials such as cobalt and lithium can be extracted using hydrometallurgy techniques involving the use of aqueous chemistry. These can be reused in the production of new batteries, colour pigments or as useful additives for mortar. Other commonly used materials including copper, metal and plastics are recycled and offered to the market for use in the production of a variety of applications.
Use of recycled materials in car parts has gone on for a long time as carmakers have tried to contribute to sustainable manufacturing processes. However, cost has also to be considered and with new technologies, recycling processes have been cost-effective enough to use.
Many disused items are recycled – from old jeans to coffee beans to coffee bean skins – and PET (commonly abbreviated from Polyethylene tErephThalate) bottles are popular for such use. In fact, the fashion industry produces jewelry, clothes and bags from PET bottles.
Audi is also using recycled material for its new fourth generation A3 for the first time as it continues to follow the corporate strategy of sustainability. The A3’s seat upholstery is made from secondary raw materials are being and up to 89% of the textile used comes from recycled PET bottles.
From old to new
In Germany, there are machines which accept PET bottles from the public, for which they get 0.25 euro (around RM1.20) per bottle. The bottles are then compressed for truck transport in order to save space. Once they have arrived at the recycling plant, they are sorted by colour, size and quality. Foreign matter such as the caps are separated.
A mill then crushes the bottles into flakes, which are washed, dried and melted down. Nozzles shape continuous plastic strands out of the mass. Once they have dried, a machine chops them into small pieces. This results in granulate, otherwise known as recyclate, and this undergoes extrusion to create threads. Wound onto coils, these are used in the final stage to manufacture materials.
In Audi’s case, they are transformed into yarn for the seat fabrics. The company says that in terms of look and feel, the quality standards are the same as conventional textile upholstery.
More than 100 PET bottles in a single A3
Up to 45 PET bottles with a capacity of 1.5 litres are used per seating system. On top of this, an additional 62 PET bottles are recycled for the carpet in the new A3. Other components in the interior are also increasingly made of secondary raw materials, eg insulating materials and absorbers, the side panel trims of the luggage compartment, the loading floor and the mats.
At present, the seat upholstery is not yet made completely of recyclable material. “The lower layer of woven material, which is connected to the upper material with adhesive, is what poses the challenge. We are working on replacing this with recyclable polyester,” says Ute Gronheim, who is in charge of material development in the textiles division at Audi. “It is our goal to make the seat upholstery completely from unmixed material so that it can be recycled again. We are no longer very far away from this.”
The latest 4th generation Audi A3
In the long term, all seat upholstery across all model series will be made of recycled material. The goal is clear: the percentage of recycled material in the Audi fleet is to rise considerably in the coming years.
Ford Motor Company has long been making car parts from discarded materials that can be recycled. In one example, old jeans were used as sound insulation material for the first generation of the Focus. Besides plastic bottles, recycled resins are used for various other parts, supporting the company’s sustainability agenda.
Now, working with McDonald’s in the USA, coffee beans will also be used in vehicle parts such as headlamp housings. Every year, gigantic quantities of coffee chaff – the dried skin of the bean – naturally comes off during the roasting process. Together, Ford and McDonald’s can use a significant portion of that material rather than just throw it away.
The companies found that chaff can be converted into a durable material to reinforce certain vehicle parts. By heating the chaff to high temperatures under low oxygen, mixing it with plastic and other additives and turning it into pellets, the material can be formed into various shapes. . This is the first time Ford has used coffee bean skins to convert into selected vehicle parts.
The chaff composite meets the quality specifications for parts like headlamp housings and other interior and under-bonnet components. The resulting components can be about 20% lighter and require up to 25% less energy during the molding process. Heat properties of the chaff component are significantly better than the currently used material, according to Ford.
McDonald’s is expected to send a significant portion of its coffee chaff in North America to Ford to be incorporated into vehicle parts. This will help Ford as it progresses toward a goal of using recycled and renewable plastics in vehicles globally, with an increasing range of sustainable materials.
“McDonald’s commitment to innovation was impressive to us and matched our own forward-thinking vision and action for sustainability,” said Debbie Mielewski, Ford senior technical leader, sustainability and emerging materials research team. “This has been a priority for Ford for over 20 years, and this is an example of jump starting the closed-loop economy, where different industries work together and exchange materials that otherwise would be side or waste products.”
Planning to buy a Ford vehicle in Malaysia? Visit www.sdacford,com.my for the location of the nearest showroom.
First generation of Ford Focus had sound insulation materials made from old jeans.
Drinking water is good for you and many take water bottles with them in their car or bag when they go out. However, where the empty bottle ends up is not always certain. Those who care for the environment will make sure they dispose of the plastic bottle in the right place, like a rubbish bin if not a recycling centre. Many though will just throw it by the roadside without a thought and if not collected, it will remain there for the next 450 – 1,000 years, depending on the type of plastic used.
In coastal areas, the bottle may wash into a drain and then into the sea where it joins other rubbish – and more plastic bottles – that float around. Sea creatures are at risk and in areas such as the Pacific gyre, there is a floating mass of plastic bigger than the size of Mexico in the Pacific Ocean!
Carmakers undertake recycling activities
It’s a big challenge getting mankind to stop such pollution so car companies like Ford are helping by using recycled plastic bottles for auto parts. Ford’s use of recycled plastics dates back to the 1990s. In the past decade, aerodynamics has driven the need for underbody shields, and the use of plastics in vehicle parts is used globally and has grown exponentially. Ford uses about 1.2 billion recycled plastic bottles per year – about 300 bottles per vehicle on average.
Underbody shields made of recycled plastics from empty bottles are installed in Ford vehicles
One area where the plastic bottles are used is the underbody shield of the car. “The underbody shield is a large part, and for a part that big, if we use solid plastic it would likely weigh 3 times as much,” said Thomas Sweder, a design engineer at Ford Motor Company. “We look for the best materials to work with to make our parts, and in this case, we are also creating many environmental benefits.”
Ideal material
Due to its light weight, recycled plastic is ideal for the manufacture of underbody shields, engine under shield, and front and rear wheel arch liners that can help improve vehicle aerodynamics, which impacts fuel efficiency.
An underbody shield
Here’s how it works: when plastic bottles are thrown into a recycling bin, they are collected with thousands of others, and shredded into small pieces. That’s typically sold to suppliers who turn it into a fibre, by melting the bottle and extruding it. Those fibres are mixed together with other various types of fibre in a textile process and used to make a sheet of material – which is then used to make the automotive parts.
“Ford is among the leaders when it comes to using materials such as this, and we do it because it makes sense technically and economically as much as it makes sense for the environment,” Sweder said. “This material is very well suited for the parts we’re making with it and is extremely functional.”
Ford trucks enable you to explore and camp in our jungles but remember to leave nothing behind when you come out. Help to preserve the environment you enjoyed so the next generation can also enjoy it.
