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Automotive recycling solutions already in production

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Sometimes the path to a greener world just means taking a close, introspective look at existing processes—and making the most of materials to reduce waste and energy. This way of thinking led to Johnson Controls’ use of material recycling processes for the automotive industry. And it’s a boon to the environment.
The key to the program’s eco-benefits lies in the parts punching process, where substrate is punched out into a predetermined shape. Johnson Controls developed two such material recycling processes—one for natural fiber materials and one for glass fiber-reinforced plastics. Here’s how they work:
  • Recycling Natural Fiber:
The process that uses natural fiber material takes the punching waste that accumulates during the production of seat back panels and reuses the natural fiber material, called “Fibrowood.” The punching scrap is separated, crushed and mixed with polypropylene pellets. Then, the substance is ready for further processing as injection molding components. Because the “post-punching” material was similar to the “first punch” material used in the manufacturing of the seat back panels, it stood to reason that the recycled materials could be used in the manufacturing of more seat back panel parts, such as the fastening hooks used in the seat back components.
  • Recycling Glass Fiber:
Johnson Controls also uses a material recycling process for glass fiber-reinforced plastics. Typically, such materials are used in instrument panels and dashboards, so scrap material could be reused and reintroduced into the production cycle of more panels and dashboards. This involves first grinding the scrap and separating the glass fiber-reinforced substrate material from the other component materials, like PVC and PUR foam. After grinding, the material is reprocessed into glass fiber-reinforced material pellets, which can be used to manufacture components for the same part.
Regardless of which type of fiber is recycled, there are the same end results: Less spoilage. More recycling. Less energy usage. More savings.
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