Visteon Drives Plan to Recycle Post-Consumer Plastic Bumpers
12 November 1998
Visteon Drives Industry-First Plan to Recycle Post-Consumer Plastic BumpersDEARBORN, Mich., Nov. 11 -- Visteon Automotive Systems has raised the bar on green with an award-winning environmental program. In a significant industry first, Visteon plans to reuse plastic vehicle bumpers collected from salvage yards to help make new bumpers for a variety of Ford Motor Company cars and trucks beginning next year. The program, which has won the Society of Plastics Engineers 1998 environmental award, insures that tons of plastic formerly destined for landfills will be successfully recycled. As a precursor to salvage yard recycling, Visteon's Utica and Milan facilities are implementing leading-edge recycling programs to reuse all of their painted plastic bumper scrap to make new bumpers. The Utica plant now recycles approximately 30,000 pounds of Thermoplastic Olefin (TPO) per week -- about 15 percent recycled content in every bumper produced. Visteon's Milan Plant will begin using about 30,000 pounds of recycled TPO per week in December. The automotive industry uses about 300 million pounds of TPO annually, according to industry reports. Visteon is the first supplier to implement a recycling program that uses painted TPO scrap to produce new bumper fascias. The Utica and Milan plants are using a closed-loop, post-industrial material system in partnership with American Commodities Inc. (ACI), a Flint, Michigan recycling company. Post-industrial TPO scrap is sent to ACI for recovery and reuse back into new vehicle bumpers. But as Visteon pushes to expand its usage of recycled TPO, it will prove out material from salvage yard bumpers to fill its material demands. "Visteon is committed to being an environmental leader in the automotive industry," said Rohintan K. Deputy, director, Advanced Technology Office, Visteon. "Our customers want to incorporate environmentally-friendly components and systems into their vehicles, and we are intent upon providing them. We are aggressively pursuing technologies that will contribute to a cleaner environment. We believe this is our responsibility to our customers, our communities, our suppliers and our employees." Visteon's planned use of post-consumer TPO will set an automotive standard in North America. Post-consumer TPO has gone through a cycle of manufacturing, consumer use and ultimate disposal. Post-industrial recycled TPO has been tested extensively by Visteon engineers to insure that it maintains bumper durability, performance and appearance. In fact, tests revealed that while the use of recycled TPO was economically feasible, there was virtually no performance difference between bumpers made from virgin material and those made with some recycled TPO content. "Our goal is to recycle all of the plastic that Visteon uses," said Daniela Olejnik, an advanced manufacturing engineer for Visteon. "We tested the recycled TPO for a year and met all product performance requirements for this material. We proved that post-industrial recycled TPO performs exactly like virgin material -- and helps us protect the environment and save money." The Utica and Milan plants are manufacturing bumpers with recycled content for the Ford Taurus wagon and for the Lincoln Town Car, Lincoln Continental, Lincoln Navigator and Mercury Sable. Visteon's future demand for additional recycled TPO has spurred ACI to establish a network of 400 collection centers across the country to pull bumpers from vehicles delivered to salvage yards. In order to verify bumper material content, only bumpers from specific year, make and model vehicles are being pulled. American Commodities has developed a proprietary process for removing paint from the used bumpers -- a major recycling breakthrough. Prior to the development of this process, most bumpers could not be recycled because the industry did not have an efficient, cost-effective way to remove paint and dirt from their surfaces. "Post-industrial recycled TPO is so resilient and cost efficient, we actually have approval to use 100 percent regrind in our operations," said Anthony Brooks, a materials engineer with Visteon. A number of other Visteon facilities have been recognized for their environmental initiatives and leadership. Visteon's Sheldon Road plant in Plymouth Township, Michigan, Charleville-Muzipres plant in northern France, and Enfield plant near London, for example, are using plastic recycled from soda bottles and tops to manufacture components that have 25 percent recycled content. Visteon's carpet to car parts process of recycling large quantities of used commercial carpet into vehicle engine air cleaner housings won the Grand Award and Environmental Award from the Society of Plastics Engineers. Visteon expects all of its global manufacturing facilities will be ISO 14001 compliant by the end of 1998. Visteon, an enterprise of Ford Motor Company, has 82,000 employees located in 21 countries. Visteon has 82 plants, including 32 joint ventures, and 37 sales offices, engineering and technical centers. Visteon's corporate headquarters is located in Dearborn, Michigan.