Ford plant turns fumes into energy
Ford has unveiled a new paint-shop operation
which reduces volatile organic compounds (VOCs) emissions while recycling fumes and paint waste. This paint shop of the
future is the product of three solutions coming together. First, Ford and its suppliers have developed a paint formula
that produces less VOC emissions while also reducing the amount of paint required to cover a vehicle. Additionally, any
overspray is collected and formed into a noise insulating material for production vehicles. This innovative recycling
helps eliminate the non-toxic sludge that typically makes its way into landfills. Secondly, Ford has developed a new
three-wet paint process that eliminates the prime-coat application and its related processes and waste. Finally, this
new concept in paint shop operations includes a Fumes-to-Fuel technology that collections paint fumes and uses them to
produce electricity. Ford claims this patented technology can provide power for a typical suburban block. Check out the
press release after the jump.
Using innovative technological solutions, Ford Motor Company today unveiled a clean, efficient and quality-driven
paint shop of the future, which reduces volatile organic compounds (VOCs) emissions by 10 percent and CO2 by 20
percent.
Cost savings are estimated between $7 and $11 per vehicle.
Traditionally, automotive paint operations have represented the industrys biggest manufacturing-related environmental
challenge. Industry-wide, 70 million pounds of paint fumes annually are collected and destroyed by expensive pollution
abatement systems around the world before they are emitted into the air.
And 24 million pounds of paint overspray are captured in spray booths, treated and consolidated into nonhazardous
sludge that eventually finds its way to landfills.
Painting vehicles is arguably the auto industrys biggest challenge, said Mary Ellen Rosenberger, manager, Paint
Strategy, Ford Motor Company. Ford has found the solution. Its environmentally sound. Its cost-efficient. And it
produces beautifully painted vehicles with long-term durability.
Fords Paint Shop of the Future consists of three major technological solutions: an advanced chemical paint
formulation, an innovative three-wet application process and patented waste management technology that converts paint
fumes into electricity and recycles paint sludge into car parts.
The new paint shop will be piloted at Ohio Assembly Plant early next year.
Advanced Chemical Formulation
Ford and its suppliers have developed a patented high-solids, solvent-borne paint formulation that produces fewer VOC
emissions than do current water-borne and solvent-borne paints. The new formulation contains more color pigment and,
therefore, requires less paint to cover a vehicle. Furthermore, it contains new polymers and other additives that
prevent running and sagging.
According to Ford internal quality data, solvent-borne paint provides better long-term resistance to chips and
scratches than does water-borne paint.
Three Coats of Wet Paint
A patented three-wet paint process allows Ford to eliminate one of the five steps in the paint shop, resulting in a
total estimated cost savings of $7 per vehicle. Furthermore, the smaller paint shop consumes less energy, resulting in
fewer C02 emissions.
In the new paint shop, the prime-coat application and its related processes are eliminated. Three coats of wet paint
are applied one after another without sags, runs and other defects - thanks to the new chemical formulation.
Waste Management
Ford is not only interested in managing waste, but eliminating it. Innovative technology, such as the patented Fumes
to Fuel, nonhazardous sludge recycling, and high-transfer efficiency are among the methods Ford is currently
using.
A new bell-shaped spray applicator minimizes overspray. As a result more paint adheres to the vehicle. Even with more
efficient applicators, there is overspray - which is consolidated into nonhazardous sludge. Ford is installing a
recycling system at Michigan Truck Plant in Wayne, Mich., that dries the sludge and recycles it into auto parts that
help quiet the passenger compartments of cars and trucks. Instead of going to the landfill, the sludge is recycled into
a liquid-applied, sound-deadening material, called LASD.
Michigan Truck Plant also features a permanent installation of Fords patented Fumes-to-Fuel technology, which turns
paint fumes into electricity that is returned to the plant power grid. Its enough electricity to light a typical
suburban block of homes. The permanent installation follows a successful pilot of the technology at the Ford Rouge
Center in 2004.
VOCs are pulled from the paint air emissions by carbon beads. The clean air is then released from the facility. The
scrubbed VOCs are sent to a generator where they are transformed into electricity.












Reader Comments (Page 1 of 1)
Mal Fuller 10:45PM (12/18/2005)
Painting vehicles is arguably the auto industrys biggest challenge, said Mary Ellen Rosenberger, manager, Paint Strategy, Ford Motor Company.
Ford ought to know. The company was once especially challenged trying to get paint to stick to their trucks. There were so many paint failures it would have been less work to have their dealers paint the trucks in the first place!
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md 10:45PM (12/18/2005)
I hear you Mal. the only well painted Ford truck we owned was our 91 explorer.
Ford does have some interesting designs in their manufacturing processes that reduce environmental impact. It is too bad they aren't more public about it especially with the Excursions and other full size trucks that make them a popular target of environmentalists.
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FurdSox 10:45PM (12/18/2005)
Good headline for this article would be: "Ford Stinks So Much That Odor Can Be Recycled."
Nice to learn that Ford is environmentally friendly while building junk.
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FurdSox 10:45PM (12/18/2005)
Are you guys believing how gay I really am?
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Shifty 10:45PM (12/18/2005)
*sigh* @ #3
i guess your damned if ya do, damned if ya dont.
not only does this article have no mention of anything bad done by ford, its all positive. but i guess your rideing the anti-ford bandwagon so any news related to ford you have to jump in and insult the company.
all the paintjobs on our fords have been equal with the industrys standerds, maybe im just lucky.
autoblog should start filtering out pointless bashing. and they should drop the email varification.
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Charles S 10:45PM (12/18/2005)
Ford bashing and defending aside, I don't see people commenting on the real substance about Ford's efforts in being environmentally friendly.
Ford has always been two-sided (or two-faced) about being dedicated to environmental causes. There are always lots of PR such as this post about paint technology; press coverage about Ford's commitment to hybrids; and chest-thumping about their new environmental friendly auto plant. Yet, Ford can't let go of the money-makers: SUVs and trucks.
When California passed regulations that required a percentage of all cars sold in CA be zero-pollution vehicle, Ford quickly bought up small electric cars companies, but at the same time, join all other car companies in lawsuits against CA to eliminate the regulation. Ford had no interest in any real EV development, and all their EV holdings end up being scrapped, soon after they won the lawsuit.
I don't know which is worse, be like DC and simply have no real interest in being environmentally friendly, or be like Ford and pretend to be green, and only stick to it when it is good PR.
I guess some efforts is better than none. This is a good time for Ford to "focus" more on the small cars, rather than trying to ride on the success of the Mustang or the F-150. I know automakers have to make money, but all the green PR with no follow through is getting old.
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Adam H. 10:45PM (12/18/2005)
Excellent work, Ford. Not only does it make them more cost competitive in the industry, the process makes for excellent PR, which in itself is probably worth more than the $7-$11/vehicle it saves.
As always, nice continued anti-Americanism.
All of you delusional morons who hate on Ford's quality should watch the building of the GT video on edmunds.com's Inside Line. Please, do not reply with the argument that the quality and engineering of the Ford GT is, and always will be, exclusive to the GT. No one can help you if you are that far gone.
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David 10:45PM (12/18/2005)
I have to agree with Shifty.
I'm taking enviromental science right now, and this sounds like a BIG deal. Paint is one of the leading contributers to VOC emission, so less of it that gets in to the atmosphere, the better. Also the fact that it produces power means that less coal is burned. This is HUGE, and all you can do is complain about bad paint jobs...that's pretty damn self-centered if you ask me.
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sensitive_man 10:45PM (12/18/2005)
I agree with #6
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sensitive_man 10:45PM (12/18/2005)
Grr, well #7 was #6. I agree with David who agrees with Shifty.
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Jeff Gilleran 10:45PM (12/18/2005)
Im all for lowering VOC'S.
Nothing wrong with it whatsoever, and I class this method as an innovative way to remove them.
However, the Dupont paint process fiasco of the Mid 80s through Mid 90s produced many, very poor quality paint jobs for the Big 3.
This was a Dupont process that eliminated a stage in painting that resulted in disasterous longterm results by the paint failing to "adhere" to the primer.
Massive peeling in vehicles only a year old and in some cases the paint held up a few years longer, but wasnt exempt from the problem in one way or another.
Although I feel Ford has the Ability to build quality cars and trucks, I dont know if I trust this enviormental PR.
The Ideal Ford, Chevy and Dodge, whom ALL used the Dupont painting process at the same time saved the company revenue, at the expense of longterm finish quality.
Id rather pay the additional $18.00 in cost it saved per vehicle for a great quality finish that didnt cost me thousands at a body shop to be done "right".
And by not saying anything about it, people were unknowingly investing in a unproven process that "should do the job".
(Enter VOC recycling).
So, hundreds of thousands of vehicle owners all of whom paid TONS of money between all the Big 3 should or have probably noticed this.
Look around.
The 85-95 models that are still on the road are peeling like bananas!
And of course rusting from the primer being exposed which PROMOTES rusting since primer is PORUS and holds water in tiny little pockets. (many people dont know this fact).
I see one or two almost everyday.
How is it NOT hard to bash on "American car companies" when the car owner looses?
Its because its these things that cause people to think less of your company.
If you want to call having your entire paint job fall off daily in your driveway little by little "quality".. maybe a staight jacket is in order?
Truth is, if you cut enough corners the customer always suffers.
The japanese and korean makes are NOT exempt from this but the Big 3 have historically cut more corners to increase profits.
Quality aside, this is just a PR ploy to make Ford look "nice" and "customer friendly".
Just like Ol' George W Jr acting the part of "concerned christian" for Hurricane Katrina, but couldnt be pulled away from his vacation while thousands of people were being left homeless?
I dont trust this much.
Until I see some vehicles that can successfully maintain several years in the open sun, being bombarded with UV rays with paint thats so soft, you could use it for peanut butter, and watch it slide off your car again, Ill pass.
There is nothing more irritating than hearing people push for "americanism", but arent willing to look at the manufacturer's recent past and note that thier habits are still the smoking gun for the Big 3 that still contiue to churn out alot of the same crap they did 20 years ago even today in a different body style.
This isnt going to change my feeling to all of a sudden buy from manufacturers that by and large could care less about their customers and more about finding ways to make more profit at their expense?
Ive owned a vehicle from nearly every automaker.
Do I want to love the Big 3? Sure! Why shouldnt I?
I also live here in the US and would love to support them.
But, I just cant bring myself to do it because of the vast
Customer surveys, consumer reports, recalls of so many topics its not even funny, build inconsistancy, customer service and warranties for these messes are lackluster at best.
Not to mention working for an auto parts store for years and seeing first hand, the crap the US automakers have been dishing on the customers.
Im the kind of guy that is an equal opportunity buyer.
Im called an "Educated Customer".
Well, if some of you absolutely need to hang on to your "American Patriotism" then do so.
Its your pipe, and your grass.
Until I see some real improvements, and honest desires to improve customer relations, I will continue to ignore purchases from the Big 3 indefinately.
There are no excuses for building some of the crap they do.
Its not even logical to buy domestic.
I dont put alot of faith into the "handful" of people that report good service from thier domestics that spout, "quality" but have never owned an import to draw real comparisions.
Nor have they even "researched" what to expect from either their Big 3 autos, or from the Foreign makes for that matter.
Its just "American" so Ill buy it mentality.
The Big 3 have always had a place in American culture, and they can blame nobody but themselves and thier arrogance for todays market issues and weak sales volume.
GM is nearly bankrupt, and Ford isnt doing much better.
Chrysler has only improved because of Mercedes.
They are at least churning out some better products than in years past and it shows with sales.
Could it be the "Foreign" Dna?
Thinking with a different business strategy?
Sure it is!
But I say that with "tepid breath".
Even with the merger, several of Chryslers products are still "poor" or "questionable".
Some of you are bitching about not being loved by being a domestic owner.
Well, in the Big 3s case, you have to take steps to pamper the customer before you get that love you are looking for.
The Koreans and Japanese seem to get it with thier business models which is building what the customer wants and needs.
Backing up thier products, fresh product designs and maintaining build quality as much as realisticly possible all while maintaining reasonable prices is the business model they use.
Ok, so the UAW is crushing the domestic automakers profits.
Why havent they made more concessions?
BECAUSE they are Greedy.
However, I see no aggressive measures by Ford or GM in particular this last 20 years to do anything about this issue while the competition walks right past them.
Domestic market shares have plummeted against, "import brands" for good reason.
They just didnt think the competition would be so strong.
So whos to blame here?
The Japanese? Koreans?
They are where they are for a reason.
Many americans, tired from the typical, mundane, poorly built vehicles embraced the competition and didnt just buy them under "percieved quality".
As so many Domestic owners seem to say.
Some of you that cant seem to get over an event that happened over 60 years ago while under the thumb of a certain evil bastard named, "Adolph Hitler".
Hitler gave an ultimatum to the Japanese to basically "do what I say, or DIE".
The Japanese, a small island barely the size of California couldnt possibly take on the US head on.
Why did they even bother?
The Japanese knew this wouldnt work!
Keep in mind the US also KNEW about the presence of the Japanese at Pearl harbor over an hour before the event happened.
What better way to pull the US into the war then hit them at the easiest point accessible to japan and drag us into someone elses war.
At the time, we were still reeling from the great depression, and the market was stagnant.
They say, "War" builds the economy.
So, as usual.. Money was involved here.
Hitler: "You do it, or you and your country will die" was what really happened to Japan.
For many years, the US has been friends with the Japanese and they have apologized so many times for the effects of one man.. Thier emporer, Hirohito, was forced to be Hitlers puppet.
How was it all of Japans fault for the voice of one man?
History reports say that the Japanese were dragged into a battle the public didnt even agree with, but the honor of thier emporer was important, and he obviously knew what he was doing?
Just like our boys and gals in Iraq, they listened to George W Bush and his "WMD" Bull, and us, being patriotic folk we are, are now stuck building an economy overseas with people that really truly HATE us all while Bush is performing his expansion into pouring coin into the military all for a problem that really didnt "exist".
But we arent there for the Countr
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Shifty 10:45PM (12/18/2005)
jebus jeff it says "add your comments" not "add your full opinion on anything that might relate"
cliffnotes are your friend, ill provide cliffnotes for those that dont want to read it
jeff's not sure of the paint quality, dont hate the japs because of what they did in ww2.
now for my short opinion, in fords press release they say this new paint is more durable and longer lasting, is that true? who knows but give them the benefit of the doubt for now. american vs import is always a battle here, i cant say this paint story really relates to it but while you mentioned it...
i drive a ford, i didnt buy it cuz i love american things, i baught it because you cant argue with a 3 year old 200hp RWD 25mpg coupe for $8000(baught it used, yes its a v6). no other brand has anything that could compare.
my mom drives a 97 explorer that has about 165k, it has given us very little trouble. we have put my sisters taurus through hell and back and it still runs and drives great (~135k).
my points are,
no car is perfect, were happy with our fords, so why switch.
now some of you seem to think the only reason people buy american is bacause there just pro-american, this is not true, most compare all the makes and deside that the american choice is the better one (sometimes price helps the decision, sometimes it does not). now there are people that buy american just cuz its american, but there are people that buy imports that are just as blind. but most american buyers do compare and deside that the american car fits them better, or is a better value. ahh look now im rambleing.
personal experience, since i know ya all care about me :D
ive driven many cars, personally i like just as many american cars as i do forign. i personally dont like camrys (too dull and a bore to drive). but i can see the appeal to familys. i just did not like the scion tC, i had a hard time getting into it, especially compared to a mazda3 (i love the 3). well i could go on but ill stop since i was giving jeff a hard time.
maybe autoblog could hire me to review cars? *ponder*
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Jeff Gilleran 10:45PM (12/18/2005)
Shifty,
Yeah, my earlier post was pretty long.
My first Rig was a 68 F100 with a 390.
Was a major Gas sucker (and expensive) at 8 MPG but it was reliable.
My truck had its share of issues, but mainly minor in the few years I had it.
Since then, Ive owned several more domestics, and the same number of imports.
I have been treated better by the imports both pricewise and through low maintenence costs, and much less time in the shop.
In light of what I was saying in my older post is that I feel that the attempts being made at Ford or GM at this point may not be enough to save them through the financial mess they are currently in.
Low VOC or no.
I cant say Ive ever really "hated domestics" but I do wish they were built better in general.
I can say although the distance between foreign and domestics in build quality has closed somewhat, I feel that foreign makes are built with different objectives to what quality means and hold themselves to much higher standards than the domestic name plates do.
Yeah, I agree with your statement of "bland" vehicles.
The last 10 years, both for domestic and foreign have had many ups and downs.
Ive never much cared for the look of a Camry in any year even though I know they are all built well.
Id love a new Mustang, but its just too impractical for me these days, but I have to admit, I have to question the cars reliablity given the past.
Sharp car though!
So, I can say that I am open to domestics on the whole, but there are a few people here on Autoblog that preach, "nothing is better than domestic" which really is asinine.
All one sided, biased points of view with no real credibility from being on BOTH sides of the fence.
Just, "It is because its Ford Chevy or Dodge".
So Im just calling "bullshit" on them.
Since bloggin is for opinions, Ive stated mine.
Not sure if the paint quality will be better, but Dupont tried to convice the Big 3 it was the best way to have a "quality" paint job, for less money.
You already know how THAT turned out!
The bad thing, is the Big 3 didnt do anything about it.
Just kept on goin and didnt do a thing for their customers.
Its exactly this kind of thinking and treatment of the customer that makes you really "question" any manufacturers motives since they are usually profit motivated decisions.
Ive known far too many people that have been dragged through the mud by the Big 3, and not just with paint.
GM has had numerous electrical issues with serious electrical design flaws with Ignition modules and ECUS, as well as under designed alternator bearings and poorly designed interior switch systems.
Ford has been having some dangerous electrical issues in designs covering the last 8 years, with the problems just now really showing up, but they were always "there".
Dodge has had both these issues, in addition to the Hideous 2.7 V6 that is lucky to last 60K miles before catastrophic failure and they STILL put the damn thing in the new magnums!
The list for the domestics goes on and on.
Where is the LOGIC?
So, that shows even with Mercedes at the wheel, sometimes even a shitty engine like that still slips through the cracks if they can sell them to unknowing customers!
Granted, all manufacturers make mistakes but it shouldnt be a norm, and since the domestics tend to make more "recalls" and have more mistakes than anyone, ones got to put up a red flag somewhere!
The domestics say its "normal" for this stuff to fail.
In 20K, 30K or even just 50K miles? this ISNT normal.
They have since abandoned many of these older designs, but built millions of "defective" components knowing damn good and well they wouldnt last, but are great for aftermarket parts sales!
I should know since I spent 7 years behind a parts counter and Ive monitored, ordered and sold parts for ALL manufacturers!
So, ones gotta question the intent in all areas and what it means for the customer.
There is a point where building a turd matters not what shape it is, but that its still a turd.
Domestics have made far more of these "turds" than not and continue to build them which is the reason people are moving to other automakers.
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Shifty 10:45PM (12/18/2005)
i made a long post but never got the email, eh.
cliffnotes: i agree with ya jeff, it does take the domestics longer to fix a problem, but at least there turning things around.
and i wouldnt worry about mustangs reliability, they are built to be beaten to they can take anything, most problems with mustangs can be traced back to owners improperly modding them.
just avoid the 94-98 v6's, best headgaskets ever!
heh, seriously mustangs are reliable, i read somewhare a 2005 mustang has fewer tsb's then a 2005 corolla.
i love my mustang, 60k, not a problem, fun to upgrade, fun to drive, fun to watch people in pos cars looks at me like "i hate that kid". good times....
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Pinkerton 10:45PM (12/18/2005)
Ford continues to improve their paint facilities, hooray! When I grew up in a Ford town during the 70s and 80s, the entire city would smell of oranges as Ford was trying to mask their (F-Series) paint plant emissions.
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Charles Lingo 10:45PM (12/18/2005)
Response to # 11, Jeff Gilleran
Jeff, You've got more FUD than Microsoft's PR Department.
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