Materials can be more or less sustainable based on a number of factors, including the origin of the material – virgin, renewable or reclaimed – and the resources used and emissions produced throughout its life cycle.
Vehicles in North America typically are composed of 20 to 25 percent post-consumer recycled material by weight, primarily due to the extensive use of steel and aluminum with recycled content. Ford has concentrated its efforts on developing new uses for recycled materials in the nonmetallic portions of the vehicle, which are typically composed of virgin materials. While the amount of recycled content in each vehicle varies, we are continuously increasing the amount of recycled material used in each vehicle line.
All of Ford's European vehicles use recycled polymers and renewable parts, where these can be seen as contributing to a sustainable material supply and providing a more sustainable solution.
We use Design for Environment and other tools to analyze the properties of materials used in our products and manufacturing and to identify better choices. For example:
- At Ford's Innovation Center, a group of research scientists are focused solely on developing automotive foams, plastics and composites derived from renewable resources. In partnership with supplier Lear Corporation, they have succeeded in developing 20 percent soy content foam formulations that meet or exceed all automotive requirements, reduce petroleum dependency and reduce CO2 emissions by 5.5 kg/kg polyol produced. If mass-produced, these materials would offer the potential for cost savings and insulation from petroleum-product price swings.
- The scientists are also examining the use of natural fiber composites, which will help to reduce the weight of vehicles and improve their fuel economy. Even plastic resins can be generated from natural resources such as corn, and the scientists are looking at how to improve the feasibility of these materials so that plastic components on future Ford vehicles can be composted instead of landfilled.
- Nanotechnology also offers opportunities to improve the materials we use and reduce the weight of vehicles.
- The 2008 Escape is believed to be the first U.S. automotive application of 100 percent post-industrial fabric seating surfaces (see Sitting Pretty on Recycled Fabric case study.)
- At the 2007 North American International Auto Show, Ford introduced the Lincoln MKR concept sedan, which featured renewable mohair carpet, soy-based foam seat bases and recycled oak wood in the instrument panel.
- In May 2007, Ford became one of the first European automakers to be certified in compliance with EU Directive 2005/64/EC by demonstrating to external authorities that the Ford processes properly manage the reusability, recyclability and recoverability aspects of vehicles.
Closing Loops
Many materials are used and many wastes are produced throughout our complex value chain. Among these wastes are high-value materials. We are exploring ways to use wastes we generate as raw materials.
