Facilities-Related Emissions

We report on a variety of facilities-related emissions in the Environment data section. In this section, however, we put particular emphasis on reducing our emissions of volatile organic compound (VOCs), because they are a significant aspect of Ford's manufacturing operations due to the large number of paint shops we operate. For more information on greenhouse gas emissions from facilities, please see Operational Energy Use and Greenhouse Gas Emissions.

Since 2000, Ford's North American operations have cut volatile organic compound emissions associated with the painting process (by far our largest source of VOC emissions) by 25 percent. In 2008, these operations emitted 24 grams of VOCs per square meter of surface coated. Because the control equipment used to reduce VOC emissions consumes significant amounts of energy, we have worked to identify innovative approaches to painting operations that meet cost, quality and production goals while allowing us to reduce energy use significantly and maintain environmental compliance.

As one element of this approach, Ford developed an innovative "fumes-to-fuel" system in partnership with Detroit Edison. Initially tested at the Dearborn Truck Plant, the system concentrates fumes containing VOC emissions from solvent-based paint and uses them as fuel to generate electricity. The Dearborn Truck Plant system fed the concentrated fumes into a fuel cell.

In March 2007, a beta-test version of the fumes-to-fuel system was installed as a pilot project at Ford's Michigan Truck Plant. This system used a specially designed Stirling Cycle Engine that was more cost-effective than a fuel cell. The engine produced about 50 kilowatts of electricity to help power the facility. The only byproducts of the system, which cut electrical use by one-third to one-half, were small amounts of water vapor, CO2 and nitrogen oxides (NOx). The Stirling Engine also produces heat during combustion, which may serve as another useful source of energy in the future.

In 2008, we began full-scale implementation of a fumes-to-fuel system at our Oakville, Ontario, plant. This version is initially using a 120 kilowatt internal-combustion engine; it will migrate to a 300 kilowatt fuel cell in 2009. Once the system is complete, it is expected to reduce CO2 emissions from the plant by 88 percent and eliminate nitrogen oxide (NOx) emissions as compared to traditional technology. At full production, the Oakville fumes-to-fuel system will generate approximately 1,500 kilowatt-hours of energy per day.

We are also reducing VOCs by eliminating painting entirely on some plastic parts, using "mold-in-color" plastic technology. Mold-in-color plastics are injection molded with high-gloss metallic color already incorporated. By eliminating the need to paint some molded plastic parts, this technology has the potential to significantly reduce paint-related VOC emissions. Mold-in-color also reduces costs and improves quality. In its first implementation, it saved $10 per vehicle, because there was no need to prime or paint the plastic parts after they were molded. The mold-in-color technology meets or exceeds all quality and performance requirements. For example, it performs significantly better than traditional painted parts in chipping and scratching. Because the color goes all the way through the part, chips and scratches do not show. This technology was introduced on the 2008 F-250 and Super Duty wheel lip moldings. We are working on other applications, including both exterior and interior plastic parts.

We are also reducing VOC emissions with an innovative paint process called "three wet." This process reduces VOC emissions by 10 percent and has other environmental, financial and quality benefits. For more information on "three wet," please see the Operational Energy Use and Greenhouse Gas Emissions section.

We are further reducing the VOC emissions associated with our paint shops by using new paint processes and materials. We recently introduced a new paint "purge" process at the Kentucky Truck Plant that significantly reduces VOC emissions. Purging is the process of cleaning out the lines and nozzles of automatic paint spray applicators between color changes or after downtime. This process uses a new purge material that is VOC-free, eliminating tons of VOC emissions to the air as well as solid and hazardous wastes. In addition to the environmental benefits, this process has resulted in significant cost savings without compromising paint quality.