12 April 2011 Ford Motor Company claims to have diverted over 4.1 million pounds (1860 tonnes) of carpet from landfill during 2010 - recycling it into sustainable materials for use in cylinder head covers.
According to the company, the use of EcoLon material - a nylon resin made from 100% recycled carpet - amounted to recycling more than 985,000 square yards (824,000 square metres) of carpet and reducing the consumption of more than 430,000 gallons (1.6 million litres) of oil.
The EcoLon material, supplied thermoplastic resin compounder and supplier, Wellman Engineering Resins, is claimed to offer an eco-friendly, high-quality alternative to typical cylinder head covers. The cylinder head covers are manufactured by Dana Holding Corporation.
"By working with Wellman and Dana, Ford has found a way to bring green applications to a new, unique location in our vehicles," said Brett Hinds, Ford manager, engine design. "This single use has made an incredible impact, and we're continuing to look for ways to expand the use."
The cylinder head covers are used on the 3.0-liter Duratec engine in Ford Fusion and Escape. They can also be found on the 5.0-liter engine, which powers Mustang and F-150.
"We didn't have to make compromises for this application," said Roy Ford, Ford engine sealing supervisor. "With a fixed raw material cost that delivers cost savings compared to oil, along with the green benefit, this application adds to the ways Ford is minimizing our impact on the environment."
The cover is claimed to be the first automotive product of its kind manufactured from post-consumer recycled nylon. To repurpose nylon, Wellman grinds used nylon carpeting into fibre and recaptures the material through a patented, proprietary process. The resulting product is a high-quality nylon resin, which Dana then uses to mould into cylinder head covers through its injection-moulding process.
Over the past several years Ford claims to have concentrated on increasing the use of nonmetal recycled and bio-based materials, including soy foam seat cushions, recycled resins for underbody systems, recycled yarns on seat covers and natural-fiber plastic for interior components.
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