Recycled Carpet in Your Ford? You’ll Never Guess Where
APR
11

Clever usage of recycled materials is becoming the norm this century, and the Ford “Reduce, reuse and recycle” commitment is part of the company’s broader global sustainability strategy for reducing its environmental footprint. What happened when the two concepts once again collided at Ford?  Perhaps the oddest-sounding partnership of all: carpet and cylinder head covers.

The efforts by Ford to use renewable materials in its vehicles resulted in the introduction of EcoLon®, a nylon made from 100 percent recycled carpet. The EcoLon material from Wellman Engineering Resins offers an eco-friendly, high-quality alternative to typical cylinder head covers. The cylinder head covers are manufactured by Dana Holding Corporation, and are used on the 3.0-liter Duratec engine in the Ford Fusion and Escape and on the 5.0-liter engine in the Mustang and F-150.

“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 cover is the first automotive product of its kind manufactured from post-consumer recycled nylon. To repurpose nylon, Wellman grinds used nylon carpeting into fiber and recaptures the material through a patented, proprietary process. The resulting product is a high-quality nylon resin, which Dana then uses to mold into cylinder head covers through its injection-molding process.

In 2010, using EcoLon material saved more than 4.1 million pounds of carpet from landfills, the equivalent of nearly 154 football fields. It also amounted to recycling more than 985,000 yards of carpet and reducing the consumption of more than 430,000 gallons of oil.

“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.”

Over the past several years Ford has 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.

And perhaps the one most likely to work as a conversation-starter at the next party you attend, recycled blue jeans for sound-dampening material.

Related Tags
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Green
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1 COMMENTS ON THIS ARTICLE
So do good questions just go unaswered on this site? That's not any fun - hello - anybody there ? there's a very big part about being SOCIAL and that's actually communicating with customers - FORD HELLO ??? From your happy '01 Ford Cobra Owner + polymer expert.
2 year(s) ago via
Jacob Bradley @ William Reeder Its the visible cover on top of the engine. It is mostly cosmetic but it also muffles some sound coming out of the engine.
3 year(s) ago via
eric i beleive they used recycled materials to reduce the amount of oil based products which no other auto company is doing. im not an eco freak but ive known ford was doing things like this since 04. i say its great. it doesnt reduce quality. after all why is ford in the top 5 every year inthe j.d power quality survey..the only domestic company at that..and also Henry Ford was a big eco person and a genious. one of his main things was that he always tried to make things more efeciant. also Ford has won the EPA award more than any other company also the only auto company to win it twice in arow. Great job FORD
3 year(s) ago via
Sean Kruger My big question is the N,6 that this is using, is it recyclable after it cracks from the heat or is their so many industrial chemicals in it that it will outlast our sun? And if you are trying to save the planet why do you use the material that is least used in carpet and not try to use the N6,6 PPE and PET that as of now has no major use other than fuel?
3 year(s) ago via Facebook
William Reeder Question: Are we talking about the part over the heads that keeps oil from flinging all over the place, or about the cosmetic (?) shield that hides much of the engine? By the way, is there any function besides cosmetic for that engine cover thing?
3 year(s) ago via
kurt Good job ford, Most light duty engine valve covers are made of plastic (for the people that don't know about cars). Ford's new engines have more power then any engine built in the past, twice the fuel economy and 200,000 miles is nothing nowdays. I remember less then 20 years ago you would barly make it to a 100k. Again, Great Job Ford!!!
3 year(s) ago via
Joseph Rifkin I agree with mustang man....you guys really need to go pre-1987 back when you had the 460 motors with the C6 trannies...two great examples of bullet proof components!
3 year(s) ago via Facebook
Doug Beck Hey, when are you going to start importing V8 6 speed3 pedal manual transmission Falcons to the United States?
3 year(s) ago via Facebook
Jason Confer bradely, people never read, they just start running their mouth because they think they know it all. everyone as their own opinions, if they dont like ford, then they need to stay off the ford posts, thats just common sense. they only come on here to try and sound smart and to make an argument, but they need to atleast be smart enough to read into what they are arguing about..
3 year(s) ago via Facebook
Bradley Thayer Grief people....read. These are the head covers, not the heads. The engine isn't plastic.
3 year(s) ago via Facebook
jonathan muñoz ford is the best
3 year(s) ago via
Terry Loux Yuk puke!!!
3 year(s) ago via Facebook
Eric Wisneski Why does it matter where it comes from? It doesn't do anything because its just trimming. All it does is make the car look better!
3 year(s) ago via
Mark Payne recycled carpet = hobos beard shavings aiight?
3 year(s) ago via Facebook
Melody Sablan Just look of "chevrolet fail" on youtube... then you'll be glad you have a Ford. THen again, if you buy a focus, a relatively cheap car for ppl who want to say they bought a new car but don't want to spend decent money for it - you get what you pay for. I was rearended by a new Toyota Camry and I was in my '03 Ford Explorer - her entire front end crumpled up - I had NO damage. The only reason the adjuster could tell I was even involved in the accident was because they found her blue paint on my tow hitch. GO FORD!!
3 year(s) ago via Facebook
Melody Sablan Did you used recycled paint under the hood? lol. It's like the same color blue as the trucks in the 70's... really, couldn't have paid a few more dollars to make it the same color as the truck?
3 year(s) ago via Facebook
Monty Greer What are you making transmissions out of? Tinfoil? Paper?
3 year(s) ago via Facebook
cole You can find information about the Fiesta line up at http://www.ford.com/cars/fiesta/. Cole Quinnell Editorial Director theFordStory
3 year(s) ago via
Joseph Longo Jacob how is ur 2011 chevy truck with the rear end locking
3 year(s) ago via Facebook
Jacob Herman I knew fords were made from garbage but i would have never thought they would try to advertise this as a feture.
3 year(s) ago via Facebook
Dunn & Associates, Inc. Green only works if the bottom line is affected in the positive. Great job Ford on attempting to use a material again. Not every green inititive is worthwhile so finding one that works is fantastic.
3 year(s) ago via Facebook
Cannie Annie wish the lovely carpet and front seats that I had in my Mk2 Fiesta would've fitted in my Mk5 as the carpet is cheap, impossible to hoover felt, and my driver's seat is so uncomfortable! But we've been through so much together and I wouldn't part with her unless she naturally came to the end of her life!
3 year(s) ago via Facebook
Peter Supernak hello, does the person who posts for FoMoCo know a thing or two about the new fiesta range....?
3 year(s) ago via Facebook
Sean Kruger Great so my doors and bumpers are plastic, and my engine is nylon (cloth) what else can you cheap out on? This isn't about being "green" its about your bottom line!!!
3 year(s) ago via Facebook
John Stretch Ayers Scotch Guard
3 year(s) ago via Facebook
Neil Bagley More developments should be made like this, not only does it save help save the planet we all life on. but its common sence to recyle what we can
3 year(s) ago via Facebook
Joseph Rifkin Yeah..."recycled material"...aka garbage
3 year(s) ago via Facebook
Lee Henderson So my new 5.0s valve covers are recycled carpet...whatever works I guess...
3 year(s) ago via Facebook
Bruce Harold See Recycle all the Way!! When are we going to see the FORD logo back at Indy and F1?
3 year(s) ago via Facebook
Chris Brown Sounds cheap. Keep it metal
3 year(s) ago via Facebook
Abdul Izhar yay!me first!
3 year(s) ago via Facebook
This discussion is missing your voice.

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