One's scrap, another's resource
Although it will take some time before the project’s solutions become industry standard, there is optimism among the participants. New EU legislation aimed at promoting circular solutions in vehicle design is on the horizon, and several other processes are already in progress. National Sweden, supplier of components for the automotive industry, has managed to recycle all production waste for its panels made in Gent. Furthermore, IAC Group is gearing up to produce a door panel made from 50 percent natural fibers, targeting zero percent production waste.
"One of the project's goals was for one company’s scrap to become raw material for another supplier. Scrap, or waste, occurs, for example, in door panel manufacturing. Next year, we will start a new production facility where door panels made from 50 % natural fibres will be produced. The production begins with rectangular sheets from which the door shape is pressed. This results in large amounts of cut waste, approximately 40 % of the panel's weight, says Markus Akervall, Advanced Engineering Manager at IAC Group, and continues:
"Our goal is to eliminate waste by reusing it in various ways. There are several methods to achieve this. For instance, we’ve tried making a plastic granule, a new compound, where the fibre cut waste is incorporated as a component. The waste is mixed with virgin materials, resulting in a fibre-reinforced PP granule. The results show that this granule maintains reasonable quality and can be used in the production of other vehicle components. So, we now have a plan to handle the waste that would otherwise have been incinerated."
Do the components measure up?
Modifying a component’s composition necessitates a range of tests to confirm that the new component meets the specifications. Given that these are vehicle components, safety is a critical consideration. In the previously mentioned pillars, the project experimented with altering the composition by including production waste, which required the new pillars to undergo crash testing.
"One of our engineers performed the tests based on our established standards and testing methods," says Sandra Tostar at Volvo Cars. "We received good results; they passed our tests."
Another conclusion drawn from the project was the importance of "one polymer solutions." Although the pillars’ mix of plastics produced good mechanical properties, it is generally much easier to recycle materials that consist of only one polymer.
"Our conviction that one polymer solutions represent the future has only been strengthened. During the project, we experimented with producing components in the trunk using only one polymer. If polymeric materials are properly managed, traceable, and free from contamination, they can be recycled repeatedly. I anticipate a reduction in material diversity on the polymeric side within the automotive industry moving forward, and I also hope to see increased collaboration across the entire value chain," says Joakim Fritz, Vice President and Business Development Manager at National Sweden.