{"id":17530,"date":"2024-07-10T06:00:26","date_gmt":"2024-07-10T12:00:26","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=17530"},"modified":"2024-07-22T13:58:47","modified_gmt":"2024-07-22T19:58:47","slug":"pe-forvia-unit-looks-boost-supply-of-sustainable-materials-for-the-automotive-sector","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/17530\/pe-forvia-unit-looks-boost-supply-of-sustainable-materials-for-the-automotive-sector\/","title":{"rendered":"Forvia unit looks to boost supply of sustainable materials for the automotive sector"},"content":{"rendered":"

ORLANDO, FL \u2013\u2013 French automotive supplier Forvia Group is taking steps to accelerate the development and delivery of recycled compounds for the automotive industry in North America.<\/p>\n

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Forvia created the MATERI\u2019ACT Dallas joint venture with PCR Recycling in February.<\/figcaption><\/figure>\n

Formerly known as Faurecia, the company \u2013\u2013 the world\u2019s seventh-largest auto supplier \u2013\u2013 created a sustainable materials subsidiary called MATERI\u2019ACT in 2022 to further this cause, and in February formed a joint venture in Dallas with PCR Recycling. The aim of the JV is to help secure a steady supply of recycled materials<\/a>.<\/p>\n

Called MATERI\u2019ACT Dallas, the new venture is just the latest move by the firm to develop and deliver recycled compounds that can help to reduce carbon dioxide emissions for automotive products by 85 percent by 2030. Forvia, as part of its Scope 3 objectives, says it plans to integrate 70 percent of recycled plastics into its interior automotive<\/a> products by 2030.<\/p>\n

At the time of the JV\u2019s launch, Forvia stressed how this new strategic partnership marries the strengths of both companies. \u201cPCR Recycling brings capabilities in accessing sources of recycled plastics,\u201d it said, \u201cwhile MATERI\u2019ACT contributes its expertise in refining, adaptive formulations, compounding, and post-processing capabilities. Together, we’re poised to transform the industry.\u201d Their stated goal: To ignite demand for recycled plastics in North America.<\/p>\n

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Leo Mazurek, general manager of MATERI\u2019ACT North America, shows some samples on the firm\u2019s NPE booth. Photo by Robert Grace<\/figcaption><\/figure>\n

In a May 6 interview at the NPE 2024 expo in Orlando, two of the company\u2019s executives shared their visions for the effort. J. Leo Mazurek, general manager of MATERI\u2019ACT North America, said that \u201cmost companies, especially automotive tier ones, and our OEM customers have defined different dates by which they want to be net zero. For us, it’s 2045.\u201d<\/p>\n

Materials are key to reducing carbon footprint <\/strong><\/p>\n

Tackling the question of sustainable materials is core to achieving any such goal, he said. \u201cYou must address materials if you, if any company, ever wants to meet their emission factor reduction goal.\u201d<\/p>\n

The Nanterre, France-based Forvia, whose roots (as Faurecia) trace back to 1914, has the heft to move the needle. The company says it is number one among auto suppliers for vehicle interiors and emission control technology. The company equips one of every two automobiles made.<\/p>\n

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French vehicle manufacturer Groupe PSA was a majority shareholder in Faurecia until 2021, when it merged with Fiat Chrysler to form Stellantis. Faurecia then became independent and acquired a controlling interest in Hella, after which the entity rebranded as Forvia. The company reported 27.3 billion euros \u00a0in fiscal 2023 sales.<\/p>\n

Launching MATERI\u2019ACT<\/strong><\/p>\n

In 2022, Mazurek said, the company \u201cdecided to create a separate division, a separate legal entity, \u00a0MATERI\u2019ACT,<\/a> where we create sustainable compounds, whether it’s bio-based plastic compounds, or recycled plastic compounds. Although Forvia is intended to be our largest customer,\u201d he added, \u201cwe certainly don’t discriminate. We’ll sell to anybody.\u201d<\/p>\n

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Wojtek Zarzycki, CEO of MATERI\u2019ACT Dallas, came to the JV from PCR Recycling. Photo by Robert Grace<\/figcaption><\/figure>\n

Wojtek Zarzycki, CEO of MATERI\u2019ACT Dallas, comes into the venture after having led PCR Recycling<\/a>. He noted how the industry in North America tends to recycle more polyethylene than polypropylene. \u201cNow,\u201d he said, \u201cas we partner with Forvia, we’ve started focusing more on the polypropylene side\u201d \u2013\u2013 both homopolymer and copolymer grades.<\/p>\n

The Dallas operation, with 20-some employees at the moment, is aiming to install additional lines by 2025\u2019s first quarter and to produce more than 60 million pounds a year of recycled resins. While Forvia\u2019s focus is on first making the Texas JV a success, it clearly has its sights set on creating similar regional ventures around the U.S. Such expansion will be market dependent, Zarzycki said.<\/p>\n

MATERI\u2019ACT\/Forvia has been active in several projects aimed at advancing the use of recycled compounds. Just this April it said it had signed a letter of intent with Gree Green Recycle Resources, a unit of Zhuhai Gree Electric Appliances Co. Ltd., a leading Chinese home-appliance maker. The deal calls for the firms to set up, by the end of this year, joint ventures to develop, manufacture and sell recycled plastics. Their goal is to sell 150,000 tons of compound by 2030.<\/p>\n

Using ocean-bound plastics <\/strong><\/p>\n

Forvia also has developed a concept car integrating instrument and door panels made with ocean-bound plastics (OBP). This is in the form of a partnership between the Forvia Foundation and Plastic Odyssey<\/a>, a non-governmental organization that supports local communities in the collection, treatment and recycling of OBP. Forvia serves as a sort of R&D adviser in this arrangement, while also benefiting from the feedstock source.<\/p>\n

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Recycled sources for MATERI\u2019ACT include post-consumer waste (PCR), end-of-life vehicles (ELV), ocean-bound plastics (OBP) and post-industrial waste (PIR). Courtesy of Forvia<\/figcaption><\/figure>\n

 <\/p>\n

Earlier this year MATERI\u2019ACT revealed a vehicle door panel where black virgin materials were replaced by a deep blue engineered experimental compound made of plastic material collected by Plastic Odyssey on beaches in northern Africa, and oyster shells.<\/p>\n

In March, at Forvia\u2019s Sustainability Day event in France, it displayed a complete cockpit interior with four door panels and one instrument panel integrating OBP. \u201cThe combination of OBP and biomass allows a 20 percent reduction in CO2<\/sub>\u00a0impact,\u201d the firm said, \u201copening the path toward MATERI\u2019ACT\u2019s target of up to 85 percent CO2<\/sub>\u00a0reduction.\u201d<\/p>\n

Integrating natural fibers
\n<\/strong>It integrates up to 20 percent of recycled OBP into a compound material in the firm\u2019s NAFILean Vision range, which stands for \u201cNatural Fillers for Lean and Visible\u201d design. In this case, the bio-based fillers are oyster shell particles.<\/p>\n

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The firm\u2019s NAFILean Vision composite contains up to 20 percent recycled ocean-bound plastics. Courtesy of Forvia<\/figcaption><\/figure>\n

Forvia notes that one can maximize the decarbonization of plastics by combining low-carbon, recycled plastics and renewable, bio-based fillers that can also sequester CO2<\/sub>. This also reduces the need for post-processing with paint or film in automotive applications, further lowering both the carbon footprint and the cost.<\/p>\n

Ocean-bound plastics present a potential source of recycled feedstock, supplementing other sources such as post-consumer recycled (PCR), end-of-life vehicles (ELV), and post-industrial recycled (PIR).<\/p>\n

Meanwhile, last fall Forvia introduced Ecorium<\/a>, which it describes as a low-carbon alternative to animal leather for use in vehicle trim. It is made from recycled PET bottles, combined with a micronized hemp in the coated layer. Automaker Renault plans to use this material in its all-new Rafale model, which is just hitting the market now.<\/p>\n

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Natural material sources include hemp fibers, wood fibers, olive stones, oyster shells, reed fibers, vine shoots, and pineapple fibers. Courtesy of Forvia<\/figcaption><\/figure>\n

Biocomposite in an instrument panel <\/strong><\/p>\n

Meanwhile, in its 5 E-Tech electric city car model, due to go on sale this fall, Renault also is using NAFILean-R in its instrument panel. NAFILean-R is a biocomposite incorporating 20 percent natural hemp fibers with a matrix of fully recycled PP from post-consumer waste. MATERI\u2019ACT partnered with recyclers Veolia and APM on this material, which is said to slash CO2 <\/sub>emissions by 73 percent together and reduce part weight by 20 percent \u2013\u2013 all without compromising on stringent specifications for resistance, crash safety, and cabin air quality.<\/p>\n

\"\"
MATERI\u2019ACT\u2019s display of materials includes pellets for the NAFILean product line. Courtesy of Forvia<\/figcaption><\/figure>\n

Asked if automotive OEMs are demanding these sustainable materials, Zarzycki said yes, that even in the absence of rules in the U.S., there are regulations being drafted in Europe, and the international OEMs are starting to adopt such guidelines in North America, as well.<\/p>\n

And so the efforts to develop the sustainable materials market for automotive continues.\u00a0\u00a0 \u201cCompounding is difficult enough,\u201d notes Zarzycki. \u201cAnd then you do recycled feedstock, which has its variability and that makes it 10 times more difficult. And so merging the two is really the hard part to bring into the market.\u201d But Forvia, via MATERI\u2019ACT, is on a mission to do just that.<\/p>\n

 <\/p>\n

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 <\/p>\n

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 <\/p>\n","protected":false},"excerpt":{"rendered":"

ORLANDO, FL \u2013\u2013 French automotive supplier Forvia Group is taking steps to accelerate the development and delivery of recycled compounds for the automotive industry in North America. Formerly known as Faurecia, the company \u2013\u2013 the world\u2019s seventh-largest auto supplier \u2013\u2013 … Continued<\/a><\/p>\n","protected":false},"author":23,"featured_media":17536,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[607,21],"tags":[206,214,807],"ppma_author":[1244],"class_list":{"0":"post-17530","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-articles","8":"category-plastics-2","9":"tag-sustainability","10":"tag-plastics","11":"tag-automotive","12":"entry"},"yoast_head":"\nForvia 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He has broad global experience and for more than 35 years has worked as a journalist, editor-in-chief, publishing executive and key connector of like-minded parties. He has launched successful publications and C-level events on three continents. While with Crain Communications Inc., he oversaw the relaunch of the 100-year-old European Rubber Journal in London and helped to start Urethanes Technology magazine there. \u00a0In 1988 Bob returned to Akron, Ohio, to serve as founding editor of Plastics News, an award-winning, weekly business newspaper. In 2005 he oversaw the editorial launch of the bilingual (Chinese and English) PN China e-newsletter and website. For more than a decade at PN he also held the titles of associate publisher, editorial director and conference director, and most recently served as business development director. A long-time affiliate member of the Industrial Designers Society of America, Bob has organized numerous design-focused events, earned a Personal Recognition Award from IDSA in 2013, and constantly strives to help bridge the gap between the design and manufacturing communities. In 2014 he left Crain and created RC Grace LLC in Akron, Ohio, as a consultancy that aims to help companies to enhance their branding and market presence, find business partners, connect with design resources (here or in Asia), secure funding and advance their growth initiatives. Email Bob or visit his website at www.rcgrace.com to learn more about how he can help you.","sameAs":["http:\/\/ulprospector.com"],"url":"https:\/\/ulprospector.ul.com\/author\/robert-grace\/"}]}},"authors":[{"term_id":1244,"user_id":23,"is_guest":0,"slug":"robert-grace","display_name":"Bob Grace","avatar_url":"https:\/\/ulprospector.ul.com\/media\/2017\/10\/Robert-Grace_avatar_1508791447-96x96.jpg","0":null,"1":"","2":"","3":"","4":"","5":"","6":"","7":"","8":""}],"_links":{"self":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts\/17530","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/users\/23"}],"replies":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/comments?post=17530"}],"version-history":[{"count":0,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts\/17530\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/media\/17536"}],"wp:attachment":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/media?parent=17530"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/categories?post=17530"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/tags?post=17530"},{"taxonomy":"author","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/ppma_author?post=17530"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}