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 Instrument Panel Recovery:
Elimination of Waste |
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| Application Description: ACI has a new technology that separates multi-layer plastic automotive instrument panels. The new system separate the three individual materials substrate, foam and skin with a 99.7% purity level. | Single Most Unique Feature: Previously this technology was unavailable and all scrap IP's were being landfilled. Now the separated materials are being reused to make new IP's. |
| Process Descriptions:Parts are shredded and fed through the separation system. | First Usage of Process?: Yes. In North America. |
| Formerly Used Process: Other mechanical attempts have been made to separate this material unsuccessfully. Therefore, the vast majority of imperfect IP's have been sent to landfill. | Tooling Innovations: None. |
| Material Innovations: New product recovered runs in conjunction with virgin material requirements. | Mass Savings: N/A |
| Cost Savings: This process typically saves 30% of the original virgin material cost. Also, eliminates the cost of disposal of scrap IP's and trim. | Cost Avoidance: Saves one manufacturer alone, approximately $2,100 per day in landfill avoidance. |
| Direct Consumer Benefit: Reduces the cost of manufacturing IP's, equates to lower product cost. | Is Technology Transferable?: Can separate almost any combination of hard and soft laminated plastic materials. This provides great flexibility in recovering any manufacturer's IP's, door panel, console and all related trim scrap. |
| Significant Safety Benefit: This system is highly automated and requires very little manual labor. It is a very safe operation. | Significant Environmental Benefit: Prevents the land filling of millions of pounds of scrap parts. |
Dylark Regrind
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Shredded IP |
Foam |
PVC Skin |
Metal Clips |
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PVC Skin, Foam, & Dylark Substrate |
