Cleaner Production in the Automotive Industry

Ford Starts Going Green

A number of technologies were investigated to replace the caustic process, including shot blasting, sand blasting, fluidized bed stripping and chemical stripping. After careful consideration, a process utilizing a high pressure jet of water operating at 15,000-20,000 pounds per square inch was chosen. The water jet undercuts the paint and lifts it off the skid. The paint residue, in the form of flakes and suspended particulate matter, is separated from the water by a filtration process and then disposed of in the general waste stream. The company is still evaluating the possibility of recycling the water in the cleaning process.

Since participation in the Cleaner Production Demonstration Program, Ford has implemented a number of other initiatives including:

 A planned upgrade of the paint facilities and change to a water-based process. While this has clear benefits in reducing the amount of solvent used in the painting process, it has the disadvantage of being more energy intensive as it requires higher heat inputs to cure the coating. Ford is currently looking at optimizing the paint application and curing process to minimize the additional energy input that will be required.

 Implementation of an energy monitoring process which involves 25 "smart" meters and 6 gas meters which record energy consumption at 15 minute intervals. It is intended to link this system up with the Gee long engine, stamping and casting plants to provide almost instantaneous energy use data. The information gathered from this system will provide valuable data for energy demand management within the plant.

A number of initiatives to address waste water generation are currently being evaluated, including a total water balance for the site, recycling of treated effluent, collection and use of storm water from roofed areas and development of a wetland system for water storage and treatment.

 Exploring the opportunity for component suppliers to use reduced levels of packaging, within the constraint of providing effective protection of the components. This would help reduce the amount of cardboard and plastic, which together currently contribute significantly to the total waste stream.

Volkswagen also starts Going Green

"How Do They Do It" takes a look at the cutting edge technology that sets new standards in green production in the new Volkswagen plant in Chattanooga, TN. See their innovations for a cleaner production.

 The plant was designed with Volkswagen’s Think Blue initiative in mind and is a real-world example of our holistic approach to environmental sustainability. This approach not only allows for an efficient production process, but it also has positive effects on the surrounding community.

Watch this interesting video:

SOURCES:
       http://youtu.be/sDLNcxrkIpQ
       http://infohouse.p2ric.org/ref/04/03189/