Keep your motor running

December 2, 2015

We are recycling old engines so they can be saved from the scrapyard and reused – a process that produces only half the CO2 emissions required to build a new engine.

“We have taken a process that was originally developed to enhance performance models such as the all-new Ford Mustang Shelby GT 350R and used it to remanufacture engines. It is just one example of how we are looking to reduce our environmental footprint,” said Dr Juergen Wesemann, manager, Ford Research and Advanced Engineering.


The special plasma coating technology applies a spray inside of the worn-out engine block that helps restore it to its original factory condition. The process is among sustainability innovations that we are researching and developing at the Ford Research and Innovation Center in Aachen, Germany, and around the world. We also are investigating creating lighter vehicles, as well as using more renewable resources, and recycled materials.

REPREVE fibre, made from recycled plastic bottles, is available for the cloth seats of the F-150 vehicle, an iconic pick-up in the U.S., meaning we will divert more than 5 million plastic bottles from landfills this year. Other eco-conscious materials used includes rice hulls, castor bean oil, soybeans and post-industrial recycled cotton.

Here in Europe, current products applying light-weighting know-how include the B-MAX, Fiesta, Mondeo and S-MAX – and the company’s engineers are developing new production processes using low-cost, high-volume carbon fibre composites in future products

We also are investigating the use of a wide range of renewable resources, including a shrub called Guayule, dandelions, sunflowers, and sugarcane. Working with H.J. Heinz Company, Ford is even looking into the use of the dried tomato skins that are a by-product of Heinz Ketchup production. Already Ford has in the Ford Focus, for the front grille, used a hybrid plastic-metal for the first time, and created a prototype glove box using the plant sisal.