Floor Pan Plug from Paint Sludge "From Paint to Part"
Application Description: Resin contains 25-27% paint sludge that was formerly landfilled. 600,000 lbs/yr that were being landfilled are being diverted to pan plugs.	Single Most Unique Feature: The Haden Type II sludge drying process produces a product of quality, properties and characteristics that can now be reused in vehicle components.
Process Descriptions:The material is extruded, die cut, and then heat staked to a stamping. The combination of composition, curing system, and particle size makes this possible.	First Usage of Process?: Yes. Previous attempts to re-use sludge processed differently resulted in a product that abraded molding/extrusion equipment, a non-uniform particle size distribution, particles too large to incorporate and clogged filters.
Formerly Used Process: Attempts were made to grind the sludge produced by other processes, but the cost was $0.10 -$0.15/lb--cost prohibitive.	Tooling Innovations: Haden type II dryer
Material Innovations: Composition and curing system.	Mass Savings: 13%
Cost Savings: Cost of landfill avoidance +$450,000 total. Suppliers have offered $240,000 to buy this material, F.O.B. our facility.	Cost Avoidance: Landfill avoidance $160,000.
Direct Consumer Benefit: NA	Is Technology Transferable?: We are in the process of introducing the Haden Type II dryer process to additional assembly plants and the parts to additional vehicles. This year 20 million parts.
Significant Safety Benefit: NA	Significant Environmental Benefit: Landfill avoidance of 600,000 lb/yr now rising to 5 million pounds as other assembly plants are converted.
Additional Information: "Guys are beating on my door to get this stuff." Quote from materials engineering supervisor at DaimlerChrysler.	Additional Information: NA