Accepting The Challenge of Carpet Recycling

This paper will take us on a three-year journey on how a Ford idea was turned into reality through a supplier/customer partnership with Wellman and Bosch. We will examine how a process was developed that exceeded Ford's quality and cost requirements.

The overview will begin with collection and take us through the development of a PCR (post consumer) nylon engineering resin. Why EcoLon was placed in the 1996 Windstar fan and shroud program will be presented. We will look at how the fan and shroud program has expanded as Ford drives to increase post-consumer content in their vehicles. Highlighted also will be the growth of EcoLon into additional applications at Ford.

Finally, we will look into the future as to how the percentage of post-consumer nylon from carpet can be increased in existing and new applications. The objective will remain the same - meet or exceed quality standards while providing a lower cost material. “Carpet to Car Parts” - yesterday's dream has become today's achievement!