According to Ford, during 2010, EcoLon 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 cylinder head covers are manufactured by Dana Holding Corporation. They are used on the 3.0-liter Duratec engine in Ford Fusion and Escape, as well as on the 5.0-liter engine that powers 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 said to be the first automotive product of its kind manufactured from post-consumer recycled nylon. To re-purpose 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.
"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."
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