Did you know the carpet underfoot in homes often ends up in strange places? Well, thanks to Ford's drive to use sustainable materials in its vehicles, some old carpet is landing in an usual spot – the cylinder head covers on vehicles like the Mustang, Fusion, F-150 and Escape.

Wellman Engineering Resins' EcoLon material, a nylon resin made from 100 percent recycled carpet, makes its way over to automotive supplier Dana for injection into molds to make the cylinder head covers for Ford. In order to repurpose the nylon, Wellman grinds used carpeting into fiber and recaptures the material through a patented process.

Ford's use of EcoLon has, according to the automaker, saved more than 4.1 million pounds of carpet from piling up at landfills and has slashed its consumption of oil by 430,000 gallons. The cylinder head covers are but one example of Ford's use of eco-friendly materials in its vehicles. Other products include soy-foam seats, recycled yarns on seat covers and discarded blue jeans for sound-dampening material

[Source: Ford]
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From under Your Feet to Covering Your Engine – Ford Finds New Use for 4.1 Million Pounds of Recycled Carpet

The EcoLon material from Wellman Engineering Resins offers an eco-friendly, high-quality alternative to typical cylinder head covers and is one more example of Ford's continued dedication to finding renewable material solutions for use in its vehicles. The cylinder head cover can be found on the 5.0-liter engine, which powers Mustang and F-150.

* Ford's use of EcoLon® material, a nylon resin made from 100 percent recycled carpet, has resulted in saving more than 4.1 million pounds of carpet from landfills, the equivalent of nearly 154 football fields. EcoLon is used for cylinder head covers
* Additionally, the use of EcoLon results in a reduction of more than 430,000 gallons of oil consumed
* The cover is the first automotive product of its kind manufactured from post-consumer recycled nylon and is used in Ford Escape, Fusion, Mustang and F-150
* The cylinder head covers are another example of Ford's use of sustainable materials in its vehicles. Other materials include soy foam seat cushions, recycled yarns on seat covers and recycled blue jeans for sound-dampening material

Ford Finds New Use for 4.1 Million Pounds of Recycled Carpet (PDF)

Dearborn, Mich., April 8, 2011 – The carpet underfoot in homes sometimes ends up in strange places, and now Ford's efforts to use sustainable materials in its vehicles have landed carpet in another unique spot – the cylinder head covers on some Ford engines. Even more impressive are the benefits it has for the environment.

During 2010, the use of EcoLon® material, a nylon resin made from 100 percent recycled carpet, 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.

The EcoLon material from Wellman Engineering Resins offers an eco-friendly, high-quality alternative to typical cylinder head covers and is one more example of Ford's continued dedication to finding renewable material solutions for use in its vehicles. The cylinder head covers are manufactured by Dana Holding Corporation.

"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 cylinder head covers are used on the 3.0-liter Duratec engine in Ford Fusion and Escape. They can also be found on the 5.0-liter engine, which powers Mustang and F-150.

"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."

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.

Eco-friendly solutions
Ford's "Reduce, reuse and recycle" commitment is part of the company's broader global sustainability strategy to reduce its environmental footprint while at the same time accelerating the development of advanced, fuel-efficient vehicle technologies around the world.

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.

Additional material on Ford's commitment to "Reduce, reuse and recycle": Fact Sheet | Graphic

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About Ford Motor Company
Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles across six continents. With about 164,000 employees and about 70 plants worldwide, the company's automotive brands include Ford and Lincoln. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford's products, please visit www.ford.com.

About Wellman Engineering Resins
As one of the leading compounders and suppliers of thermoplastic resins in North America, Wellman Engineering Resins has been leading the way to "green" manufacturing for over 35 years. The company's patented, proprietary manufacturing processes recycle used carpet into consistent, high quality, low cost resins. WellmanER, based in Johnsonville, S.C., has hundreds of automotive approvals as well as significant non-automotive business. For more information, please visit www.wellmaner.com.

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