Johnson Controls Demonstrates How Material Recycling Solutions for Production Waste are Used in Series Production

BURSCHEID, Germany, September 13 --

- Closed Loop Material Recycling Reduces Production Waste

Environmental protection and careful use of resources are primary corporate objectives for Johnson Controls, one of the world's leading suppliers of automotive interior systems, electronics and batteries. Two new material recycling processes - one for natural fibre materials and one for glass fibre reinforced plastics - will dispense with thermal processing of 480 tons of production waste per year, and furthermore present a new manufacturing alternative at comparable costs.

Recycling of materials is not only carried out for scrap cars: reprocessing of punching scrap can also contribute to protecting the environment. Since this kind of residual material can be segregated cleanly without any interference from other materials, it is often even possible to retain the material properties when recycling production waste.

At this year's IAA, Johnson Controls will be demonstrating how such recycling solutions could be used in series production. The process that uses natural fibre reinforced plastics involves the reutilisation of punching waste that accumulates during production of the seat back panel for a luxury segment vehicle. In addition, recycled natural fibre materials are also used to manufacture armrests for another automaker, using recycled production waste created during manufacture of the door panel substrate of an executive segment vehicle.

Recycling of glass fibre reinforced plastics will be demonstrated by showing how waste generated in the production of instrument panels is later used to manufacture air ducts for a minivan.

Fastening hook made of recycled material

Wood fibre mats called "Fibrowood" are used in the production of the seat back panels of a luxury segment vehicle which will be launched at this year's IAA. The punching scrap that accumulates during production of these parts are segregated, crushed, mixed with polypropylene pellets and are then ready for further processing as injection molding components. Since the linear expansion coefficient of these recycled components is similar to that of the seat back panels, the logical step was to integrate the injection molded components made of secondary materials into the same part. What's more, this solution ensures a smooth material flow, since the production time is identical. In the current concept development process, the recycled materials are used for the fastening hooks used in these components.

In another executive segment vehicle, the manufacture of armrests made with door panel production waste from the same model is based on a similar principle, the only difference being that, in this case, the natural fibre substrate is made with epoxy resin.

Recycling also for glass fibre reinforced plastics

Johnson Controls has even developed a material recycling process for glass fibre reinforced plastics such as those used in instrument panels. Designed for the air duct of a vehicle in the Minivan segment, this concept involves first grinding the scrap from the instrument panel carrier and then separating the glass fibre reinforced substrate material from the PVC skin and PUR foam. The pellets of glass fibre reinforced material, which have technical properties very similar to those of new material, can then subsequently be used in the manufacture of components for the same part. Currently in concept development is a plan to produce air ducts from the recycled material. Further applications are also possible in the future.

    
    Further information is available from:

    Johnson Controls GmbH
    Automotive Group
    Astrid Schafmeister
    Industriestr. 20-30
    51399 Burscheid
    Germany
    Tel.: +49-2174-65-3189
    Fax: +49-2174-65-3219
    E-mail: astrid.schafmeister@jci.com

    Johnson Controls GmbH
    Automotive Group
    Ina Longwitz
    Industriestr. 20-30
    51399 Burscheid
    Germany
    Tel.: +49-2174-65-4343
    Fax: +49-2174-65-3219
    E-mail: ina.longwitz@jci.com

Johnson Controls, Inc., is a global market leader in automotive systems and facility management and control. In the automotive market, it is a major supplier of integrated seating and interior systems, and batteries. For non-residential facilities, Johnson Controls provides control systems and services including comfort, energy and security management.

Johnson Controls (New York Stock Exchange: JCI), founded in 1885, has its headquarters in Milwaukee, Wisconsin, USA. The company's sales for 2004 totaled US$25.4 billion, the Automotive Group worldwide generating US$20 billion of this figure. The European headquarters is in Burscheid, Germany. The company's product portfolio also includes instrument panels/cockpits, door systems, overhead systems, interior electronics and electrical energy management.

Johnson Controls GmbH, Automotive Group, Astrid Schafmeister, Tel.: +49-2174-65-3189, Fax: +49-2174-65-3219, E-mail: astrid.schafmeister@jci.com, Johnson Controls GmbH, Automotive Group, Ina Longwitz, Tel.: +49-2174-65-4343, Fax: +49-2174-65-3219, E-mail: ina.longwitz@jci.com