sustainability Archives

BMW i Vision Circular Concept demonstrates how the ‘circular economy’ can be used for automobiles

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.

BMW brand logo modernised with visual style of today to suit digital age

Continental AMBIENC3 concept vehicle shows interior of the future

As the actual job of driving a car gets taken over by a computer in future, the interior space will become more than just a place to sit while travelling, it will be a space where the occupants, besides driving when necessary, can relax or work. These three activities are set to merge in the digital, connected and sustainable vehicles of the future.

Continental has been looking at interior spaces which it terms “Third Space”. To show what the future of vehicle interiors could be like, it has built the AMBIENC3, a concept vehicle in which everything is designed and imagined within a shared blueprint. It has stylish, light and robust surfaces for the floor, walls and ceilings, the seats, lounge and tables; natural, subtle and bright colours; warm, clearly defined lighting effects; and unobtrusive sounds.

The AMBIENC3 is full of new surface solutions made from innovative and sustainable materials. It is based on a Volkswagen T2 microvan, a vehicle of rich emotional charm that provides a meeting point for retro appeal and future direction.

“With the AMBIENC3, we are connecting a globally renowned icon of the automotive world with new, intriguing surfaces and future-focused technologies, whose attributes assist driving, working and relaxing as effectively as possible and distinguish them through colour, design and material,” said Ralf Imbery, Global Director Innovation, Transformation & Design at Continental’s surface experts. “With the AMBIENC3 we are demonstrating our expertise in terms of sustainability, design, functionality, ‘third space’ development and customer centricity. It sees us bringing together key drivers for the future of the mobile interior.”

Focus on sustainability
One highlight of the concept vehicle from Continental is a light and sound concept that creates different moods. Natural and renewable raw materials are used for the surfaces, as well as recycled and reclaimed materials – with no compromise in quality. Passengers in the AMBIENC3 can breathe clean air, thanks to low-emission, low-pollutant materials.

Light surfaces also help to lower the vehicle weight. This reduces energy consumption – and, by extension, CO₂ emissions – and therefore also increases the driving range of electric vehicles.

Natural, subtle, bright colours, plus gently flowing forms are defining elements of the AMBIENC3 interior and give it a cozy yet modern feel. The interior helps motivate passengers to work, but also encourages them to relax. Although the functions in the AMBIENC3 are always intuitive to use, there are no permanently visible controls. In fact, buttons and switches are nowhere to be seen. This is ‘Shy technology’ in use where, in OFF mode, the functions in the surfaces are invisible.

Design and function go hand in hand
Other innovative highlights of the concept vehicle include a light and sound concept that creates different moods, and heatable materials. Made using functional printing methods, these can generate heat in seconds. Other surfaces in the AMBIENC3 are distinguished by special attributes such as optimized soiling characteristics, maximum abrasion resistance and even self-healing in the event of damage.

The AMBIENC3 sets new standards in customer orientation. With solutions and surfaces that can be customized using digital printing techniques, Continental offers automakers with a host of options when it comes to tailoring vehicles to their customers’ individual requirements, upgrading interiors with new and surprising functions, and ensuring connectivity.

For example, staynu (stay new) technology makes surfaces more dirt resistant, easier to look after and more robust than ever. As the name implies, this technology helps the material to stay (and look) ‘as new’ for longer. Material equipped with this protection is used for the driver’s seat in the AMBIENC3. Stains are no longer an issue, and the material is long-lasting, low-cost and environment-friendly.

Other surfaces in the AMBIENC3 use laif technology, which delivers outstanding breathability –allowing air and water vapour to pass through – and an exceptional soft feel. An agreeable side effect of this new technology is that the breathable surfacing provides passive temperature control. Offering the look and feel of real leather, surfaces with laif technology provide an excellent alternative for which no animal needs to give up their life.

External designers create Virtual Interiors for Lexus LF-Z Electrified concept

Vaccination does not make you immune to COVID-19 infection. You can still get infected and although you may not show symptoms, you can spread the coronavirus. Do not stop taking protective measures such as wearing a facemask, washing hands frequently and social distancing.

MINI STRIP – showing a sustainable approach to automotive design and manufacturing

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.

MINI Vision Urbanaut concept

Making fuel sustainable and low carbon for future vehicles with combustion engines

Almost every day, there’s news about the electrification in the auto industry, if not the introduction of a new electric vehicle (EV). The industry, especially in Europe, has fast-tracked plans to move existing model fleets from using internal combustion engines to either hybrid or fully electric powertrains. Some companies even plan to stop selling vehicles with combustion engines before the end of this decade.

But there are also some companies that will look for a balance in the rush to electrification, focussing more on overall carbon neutrality (which can address climate change) for their entire operations, rather than just the products alone. Akio Toyoda, President of Toyota Motor Corporation, is one of those who feels that the rush to switch to zero emission vehicles is too excessive, demands massive investments and will damage the industry in some ways.

Whole world won’t ‘electrify’ at the same time
While governments are forcing the corporate hands of the carmakers to make the changes and cut emissions from vehicles, there will still be models with combustion engines on sale for a while. We don’t know yet how fast the infrastructure to support EVs can be developed and grow because, in some places, it doesn’t even exist yet. In Malaysia, for example, the number of recharging stations already set up is really just ‘a handful’ and an absence of a coherent policy to encourage sales and use of EVs has yet to be formulated.

While motorists in regions like Europe are steadily switching to electric vehicles, there are many millions elsewhere in the world who will continue to use vehicles running on fluid fuels for many more years.

So while some carmakers may feel that they can get by (in future) selling just EVs, there will be some who will still be developing models with combustion engines for the rest of this decade at least. Engineers can still push emissions down further to meet stricter regulations and a new generation of fuels will also help in this respect.

Renewable low-carbon fuels
These are renewable low-carbon fuels and following on from R33 Blue Diesel which has been around since 2018, Bosch, Shell, and Volkswagen have now come up with low-carbon petrol. Their new fuel, called Blue Gasoline, similarly contains up to 33% renewables, ensuring a well-to-wheel reduction in carbon emissions of at least 20% per kilometre driven. This means a fleet of 1,000 VW Golf Mk.8 1.5 TSIs alone could save more than 230 metric tons of CO₂ per year, assuming an annual mileage of 10,000 kms each.

Shell will offset the remaining carbon emissions from the use of Blue Gasoline through certified offset arrangements. The initial plan is to make the fuel available at regular filling stations over the course of the year, starting in Germany.

“On the road to climate-friendly mobility, we must ensure we don’t leave any technical opportunities untapped, starting with electromobility and ending with renewable fuels. Every bit of CO₂ we save can help us achieve our climate targets,” said Dr. Uwe Gackstatter, President of the Bosch Powertrain Solutions division.

“Blue Gasoline is another building block in the effective reduction of CO₂ emissions from the vehicle fleet. Blue Gasoline’s high storage stability makes the fuel particularly suitable for use in plug-in hybrid vehicles. In the future, the expansion of the charging infrastructure and larger batteries will mean that these vehicles predominantly run on electrical power, and thus that fuel may remain in the fuel tank for longer periods of time,” explained Sebastian Willmann, Head of Internal Combustion Engine Development at Volkswagen

Highest standards set for fuel quality and sustainability
Blue Gasoline fuel complies with the EN 228/E10 standard and even exceeds it in key parameters such as storage stability and boiling behaviour. High-quality additives also keep the engine extremely clean and protect it against corrosion. This means not only that the fuel can be distributed via the existing filling station network, but also that it can be used in all new and existing vehicles for which Super 95 E10 petrol has been approved.

The proportion of up to 33% renewables is made up of biomass-based naphtha or ethanol certified by the International Sustainability and Carbon Certification (ISCC) system. One source of such naphtha is what is known as tall oil, a by-product in the production of pulp for paper. But naphtha can also be obtained from other residual and waste materials.

Low-carbon fuels at Bosch company stations
In the Blue Gasoline project, the three partners jointly defined the fuel specification to be achieved, taking into account engine requirements and sustainability. They put the product they developed through intensive testing on engine test benches and in trial vehicles – with consistently positive results. Bosch has begun supplying Blue Gasoline at its company filling stations for the past month, with other stations scheduled during for rest of 2021.

The supply of conventional Super 95 E10 petrol will then be gradually phased out. Since the end of 2018, R33 Blue Diesel has been the only diesel fuel that Bosch company filling stations offer for company cars and internal delivery vehicles. R33 Blue Diesel is also becoming available at more and more regular filling stations in Germany. At present, it is offered at 8 filling stations belonging to different brands nationwide, with more set to follow.

Not a substitute for electromobility
For Bosch, renewable low-carbon and carbon-neutral fuels will not replace electromobility but complement it. In principle, the use of these fuels makes sense in all modes of transport, but especially in those for which there is as yet no clear and economical path to electrification. In addition to ships and aircraft, this applies primarily to heavy goods vehicles and existing vehicles, but also to the millions of vehicles with internal combustion engines or hybrid powertrains that are on the world’s roads today or will be built in the coming decades.

To promote rapid market uptake for these fuels, the focus is on renewable biomass and synthetic fuel components that can be blended into regular fuel in high proportions in line with existing fuel standards.

BMW X5 PHEV uses world’s first FSC-certified tyre

Pirelli is the first company in the world to produce a range of FSC-certified (Forest Stewardship Council) tyres which represent a new horizon for increasingly sustainable tyre production. The tyres are made from rayon and FSC-certified natural rubber which comes from FSC-certified plantations.

What is FSC?
FSC forest management certification confirms that plantations are managed in a way that preserves biological diversity and benefits the lives of local people and workers, while ensuring it sustains economic viability. In Malaysia, 684,913 hectares of plantations are FSC-certified (as of January 2021).

The complex FSC chain of custody certification process verifies that FSC-certified material has been identified and separated from non-certified material as it makes its way along the supply chain, from the plantations to the tyre manufacturer.

*Malaysia has 684,913 hectares of plantations FSC-certified to preserves biological diversity and benefits the lives of local people and workers.*

First fitment on BMW X5 PHEV
The world’s first FSC-certified tyre is the Pirelli P Zero and the first vehicle in the world to have it as Original Equipment is the BMW X5, specifically the xDrive45e Plug-in-Hybrid. It is sized 275/35 R22 for the front wheels and 315/30 R22 for the rear wheels.

The use of this tyre complements the ‘green’ philosophy of the PHEV. The BMW Group has also conducted a full-cycle CO₂ certification for the X5 xDrive45e from raw material procurement, the supply chain, manufacturing and the use phase, all the way to recycling.

“As a premium manufacturer, we aspire to lead the way in sustainability and take responsibility,” said Andreas Wendt, member of the Board of Management of BMW AG responsible for Purchasing and Supplier Network. “We have been committed to improving cultivation of natural rubber and increasing transparency in the supplier network since 2015. The use of tyres made of certified natural rubber is a pioneering achievement for our industry. In this way, we are helping preserve biodiversity and forests to counteract climate change.”

Low rolling resistance and quieter
The new tyre, produced only at Pirelli’s factory in the USA, is designed to specifically target environmental sustainability along with low rolling resistance as well as lower noise levels.

The FSC certification for the natural rubber used to make the new P ZERO tyre for BMW’s X5 Plug-in-Hybrid procured from certified plantations is the latest step on the path that Pirelli has been on for many years towards the sustainable management of the natural rubber supply chain. This is achieved through a roadmap of activities based on the training and sharing of good practices in the countries of origin of the material, in line with the principles and values contained in the Pirelli Sustainable Natural Rubber Policy, which was issued in 2017.

To know more about the X5 PHEV or other BMW models in Malaysia, visit www.bmw.com.my.

‘The Boss’ gets electrified with the new BMW X5 xDrive45e M Sport

The National Vaccination Program in Malaysia is free of charge.

BMW Group Financial Services Malaysia gives support to reforestation efforts in Borneo

The BMW Group has sustainability goals to reduce carbon emissions globally and affiliates throughout the world work in their own ways to support those goals. In Malaysia, BMW Group Financial Services Malaysia has announced a commitment to reforestation efforts in Borneo. These efforts are with a local social enterprise, Animal Projects and Environmental Education (APE Malaysia).

*A logging area that will be reforested.*

Helping mitigate climate change
Commenting on the commitment, Tobias Eismann, MD of BMW Group Financial Services Malaysia, said: “We recognise that climate protection is a shared responsibility. By playing our part in supporting planned reforestation efforts in the country, we look forward to helping mitigate climate change.”

He said BMW Group Financial Services Malaysia will be directly contributing to APE Malaysia’s Restore Our Amazing Rainforest (ROAR) programme which aims to create and reconnect important forest corridors that have been degraded by deforestation. “As a company, we are focusing more and more into tangible initiatives to support sustainability, beginning internally with our own initiatives to go digital in efforts to reduce paper consumption,” he added.

Contributions from financing contracts
The initiative will see contributions of RM100, made on behalf of BMW and MINI customers, for every funded contract (for financing purchases) of the following models – the BMW 330e M Sport, BMW 530e M Sport, BMW 740Le xDrive, BMW X5 xDrive45e M Sport, as well as the MINI Cooper SE Countryman ALL4. All funded contracts from May 1 to July 31, 2021 for the models mentioned are eligible for this initiative.

Every RM100 will contribute to 5 new trees planted at the Lower Kinabatangan Wildlife Sanctuary. Customers whose contracts contributed to the initiative will receive a photo, as well as an e-certificate with the GPS coordinates of their trees from APE Malaysia. The ROAR programme also serves to restore habitat for endangered animals which includes the orangutan and Borneo Pygmy Elephant, as well as to counteract carbon footprint.

Earlier this year, BMW Group Financial Services Malaysia also successfully raised over RM20,500 via BMW Engage for the upcoming phase of the BMW Safety 360° subsidy programme. The third phase of this programme will see over 300 more child carseat subsidies made available for parents in the local B40 community. The subsidy programme has delivered over 500 child carseats since its inception in late 2019.

https://www.piston.my/2021/02/10/bmw-group-financial-services-malaysia-contributes-over-rm200000-to-bmw-safety-360-subsidy-programme/

Mercedes-Benz battery pack production facility in Thailand begins operations

With increasing emphasis on electrification of vehicles in the industry, demand for battery packs has also been accelerating. It is crucial that higher volumes be achieved in order to get economies of scale and push production costs down. Different manufacturers have different strategies to address this demand and for Mercedes-Benz, the approach taken is to establish a global battery production network.

Daimler is investing more than one billion euros in this global battery production network which will consist of 9 factories at 7 locations on 3 continents. Four factories have already started operations, with the most recent one being in Thailand.

100 million euros invested
The Thai production facility in the Bangkok region is a joint effort with local partners Thonburi Automotive Assembly Plant (TAAP) and Thonburi Energy Storage Systems (TESM). Mercedes-Benz AG has invested a total of more than 100 million euros in the battery production and a plant expansion of the existing vehicle production plant. In doing so, the partners are responding to the high demand for electric mobility and, in particular, for plug-in hybrid vehicles in Thailand. At the same time, they are driving the shift towards sustainable mobility as well as a carbon neutral and resource-efficient production.

The production facilities for plug-in hybrid battery packs are highly standardised and flexible. As a result, they can be adapted to local market conditions in a short time. “We have been successfully producing Mercedes-Benz vehicles for the local market at our Thai plant for more than 40 years. With the start of production of our battery factory in Bangkok, we are taking another important step in the expansion of our global battery production network at Mercedes-Benz Cars with nine factories worldwide. The local production of batteries enables us to make the best possible use of the potential for e-mobility in Thailand. As in the case of vehicle manufacturing, we have optimized all processes in terms of efficiency, flexibility and sustainability in the battery factory. We show how sustainable products can be produced sustainably,” said Jorg Burzer, Member of the Board of Management of Mercedes-Benz AG, Production and Supply Chain Management.

The battery packs are used for plug-in hybrid variants for the current Mercedes-Benz C-Class, E-Class, S-Class as well as for the Mercedes-Benz GLC and GLC Coupe. The high variety of product variants of the local market require very flexible and efficient production and facility concepts. Central assembly stations were set up in the same way as in the battery factory in Germany and were further developed for site-specific requirements. In this way, all battery types can be manufactured in the new line for all current and future plug-in hybrids.

*Mercedes-Benz C300e – one of the models which will use Thai-made battery packs*

Decision to locate in Thailand
The decision for a local battery production in Thailand supports Mercedes-Benz’s overall sustainability goals under the heading ‘Ambition2039’ as well. The aim is a carbon neutral new car fleet until 2039. By 2030, at least every second vehicle sold should have an electric drive – this includes full-electric vehicles and Plug-In hybrids.

On the way to sustainable mobility, apart from products production plays a central role: All European Mercedes-Benz plants are to produce completely carbon neutral from 2022. The battery factory in Bangkok will meet this requirement by using large solar systems on the roofs of the production buildings. Excess solar power, for example, is temporarily stored in so-called 2nd-life battery storage systems from recycled electric vehicle batteries. The plant works closely with the Mercedes-Benz Energy GmbH. The stationary storage systems, which can compensate for local energy fluctuations and contribute significantly to grid stabilization, enable economical and resource-saving reuse for disused batteries of electric and hybrid vehicles. This is an important contribution to the economic efficiency and environmental balance of electric vehicles.

Besides Mercedes-Benz, the BMW Group has also chosen Thailand to produce battery packs. Its facility is a joint investment with the DRAXLMAIER Group worth 500 million baht (about RM69 million).

Mercedes-Benz is the world’s most valuable luxury car brand of 2019

Your future Ford will have parts made from coffee bean skins!

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.

1999 Ford Focus — *First generation of Ford Focus had sound insulation materials made from old jeans.*

Ford uses 1.2 billion plastic bottles for auto parts each year

Hyundai Motor Group begins selling first model with solar roof charging system

The Hyundai Motor Group has launched its first car with a solar roof charging system. It is one of three types of solar roof charging systems the carmaker is developing. This technology will provide vehicles with additional electrical power that can increase fuel efficiency and driving range in hybrids.

The system debuts on the New Sonata Hybrid which is the first mid-sized hybrid sedan in the Korean market with fuel consumption officially rated at over 20 kms/litre. To date, other models in the same segment have achieved 18 kms/litre at best.

The new model also equipped with the world’s first Active Shift Control technology as well as a Smartstream G2.0 GDi HEV engine and 6-speed hybrid transmission. Hyundai’s new model also supports a ‘Digital Key’ function via a dedicated smartphone app.

“Solar roof technology is a good example of how Hyundai Motor is moving towards becoming a clean mobility provider. The technology allows our customers to actively tackle emissions issue,” said Heui Won Yang, Senior Vice-President and head of Body Tech Unit of Hyundai Motor Group.

Adding an extra 1,300 kms annually
The solar roof charging system includes a structure of silicon solar panels that are mounted on the car’s roof. Being able to charge even while driving, the solar roof system can charge 30% to 60% of the battery per day. With 6 hours of daily charging (which can take place while the vehicle is parked), it is expected to increase vehicle travel distance by an extra 1,300 kms annually.

The system is composed of a solar panel and a controller. Electricity is produced when solar energy activates the solar panel’s surface, which converts this energy by using photons of light from the sun. This creates the electron-hole pairs in silicon cells, which generate solar electricity. The electricity from this process is converted to the standard voltage by the controller, then stored in the battery.

Hyundai Motor took not only efficiency but also design into account while developing the charging system. While the solar roof system currently plays a supporting role, it opens up perspectives for vehicles that no longer need fossil fuel to operate, ie pure electric vehicles.

The New Sonata Hybrid has just gone on sale in Korea and will also be available in North America. However, the company says it has no plans to offer it in other markets in the immediate future.

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