Crazy for coconuts

Ford and The Scotts Miracle-Gro Company are researching the use of coconut fibre reinforcement for moulded plastic parts to reduce the use of petroleum and make the parts lighter and more natural looking.

The coconut coir, or husks, are a waste stream from Scotts’ soil and grass seed products. The team is investigating their use as a renewable feedstock for Ford’s vehicles.

“This is a win-win situation. We’re taking a material that is a waste stream from another industry and using it to increase the sustainability in our vehicles,” said Dr Ellen Lee, technical expert for Plastics Research at Ford. “We continue to search for innovative renewable technologies that can both reduce our dependence on petroleum as well as improve fuel economy.”

Coconut coir is a natural fibre from the husk of a coconut. Scotts Miracle-Gro uses the material as a carrier for its soils and grass seed products, including Scotts Turf Builder EZ Seed and Miracle-Gro Expand ‘n Gro Concentrated Planting Mix. Both products use the coir’s natural fibres to hold 50% more water than basic potting soil and release it as plants need it - helping homeowners save water.

“Scotts Miracle-Gro uses more than 70 million pounds (31.7 million kg) of coir a year in our consumer products,” said Dave Swihart, Scotts Miracle-Gro Senior Vice President of Global Supply Chain. “Teaming up with Ford to find a high-value use for our leftover coir material is very exciting for us as we continually work to make our products and operations more sustainable.”

Once the coconut coir comes to Ford, researchers combine it with plastic to deliver additional reinforcement to the part while eliminating the need for some petroleum. Along with making use of a renewable resource, the new part would be lighter in weight. The natural long fibres also are visible in the plastic and offer a more natural look than typical materials.

In the interior, the material could be used in storage bins, door trim, seat trim or centre console substrates. It could also potentially be used on underbody and exterior trim.

Ford is currently testing the material’s properties to ensure it passes all of the company’s durability tests. Coconut coir is very difficult to burn, and Ford is researching whether it has natural flame-retardant properties.

Over the past several years, Ford has concentrated on increasing the use of nonmetal recycled and bio-based materials to reduce its carbon footprint. Materials already in use include soy foam seat cushions and head restraints, wheat straw-filled plastic bins, castor oil foam in instrument panels, recycled resins for underbody systems, recycled yarns on seat covers and natural-fibre plastic for interior components.