Cam Covers to become green

The demand in the automotive industry for sustainable materials, recycled or bio-based, is continuously increasing. Consumers changed their mindset over the last years and Original Equipment Manufacturer (OEM) recognized that the use of sustainable materials is becoming a selling argument.

“If OEM’s have the choice between prime and ECO, they will always go for the more sustainable solution. What was once a cost down for companies in the U.S. a decade ago has now become a strategic pillar,” said President & CEO of MOCOM Americas Tony Smith.

MOCOM and a developer and producer of high-quality sealing systems for the automotive industry, worked in close collaboration to enlarge the use of those sustainable materials. Under the hood, Altech® ECO Near-to-Prime® Recycling compounds proved to be the right choice as a sustainable alternative in highly demanding applications where performance and value are the desirable criteria for a new cam cover of the OEM.

For high tech applications like cam covers, typically a prime PA66 GF plastic compound like Altech® PA66 A 2035/507 GF35 EF has been used. In cooperation with the OEM and the producer, MOCOM developed, tested and approved a sustainable Altech® grade with a high amount of post-industrial-recycled (PIR) PA66 combined with prime glass fibers: Altech® PA66 ECO 2035/500 BK2656-15.

Typically, hot oil storage and long term heat resistance are critical success factors for these applications. Also, when located on the cylinder head, the cam cover in the Altech® ECO grade must show the same level of creep behavior as a prime grade under load from an elastomer gasket with which the components get a secure seal. Other components need to be fastened to the cylinder head cover with screw-in bushes. In addition, the sustainable Altech® ECO material must be able to mold on the same tool as the prime material. Finally, the processability, i.e. injection molding and vibrational welding, of the cam covers with the sustainable material must remain on the same level as prime materials. A durability tests of components also known as the “vibration test” has been undertaken on parts made out of Altech® ECO material and performed at the same level as the prime resin. The test determines the performance of the component and its strength under varying loads and temperatures.

Sustainable materials reduce the CO₂ footprint

Moreover, the benefits of recycled materials are evident as they can reduce the Global Warming Potential (GWP) in comparison to prime materials. Results calculated with the well-known GaBi software, which performs the analysis according to DIN EN ISO 14040 standard, show a CO₂ reduction of almost 70% or higher by using Altech® PA66 ECO 2035/500 BK2656-15.

“Since the end of 2018, the serial production, using Altech® PA66 ECO 2035/500 BK2656-15, is running in several applications. Apart from this grade, a complete ECO portfolio has been developed and is supporting customer needs of today and tomorrow,” said Smith.

About MOCOM

MOCOM GmbH & Co. KG is a global compounder of thermoplastic polymers and offers the plastics processing industry a comprehensive range of high-performance customized and standard compound solutions. The high performance (Alcom®, Tedur®) and engineering compounds (Altech®, Altech NXT® PP, Alfater XL®) ranges are complimented by the Altech® ECO range of recylate based compounds which deliver Near-To-Prime properties. MOCOM supplies a wide range of industries including: Automotive, Energy and Electronics, Home and Garden, Sports and Leisure, Transportation, and Healthcare.

The compounder currently employs over 700 people with its headquarters located in Hamburg, Germany. Especially proud is the company of its production site in Duncan, South Carolina (USA). Besides this, MOCOM has locations in three German locations (Hamburg, Obernburg, Zülpich) as well as and Changshu (China).

The company is rated Gold by the independent rating agency EcoVadis. All sites are certified in accordance with IATF 16949, ISO 14001 and ISO 45001 standards.

MOCOM sustainable product portfolio

Altech® ECO

Altech® ECO are high quality recycling compounds that are based on PIR (Post Industrial Recyclate) or PCR (Post Consumer Recyclate) for technical and engineering applications that encompass a broad range of engineered resins. These compounds combine a low carbon footprint with high quality properties close to virgin materials, offering sustainable compound solutions for customers.

Alfater XL® ECO

Alfater XL® ECO is a thermoplastic vulcanizate elastomer (TPV) based on recycled PP from PIR (Post Industrial Recyclate) and/or bio-based materials. These flexible compounds combine a low carbon footprint with thermoplastic processability, recyclability and typical elastomer properties for sustainable technical applications.

Cellidor®

Cellidor® is an amorphous thermoplastics based on cellulose drawn from sustainable, natural resources, and partially bio-based. These compounds features particularly high impact strength even at low temperatures. They combine resistance to water, grease, mineral oils and sweat and a very high degree of light transmission. Its surface is characterized by an elegant gloss with brilliant depth of color.

WIC

The WIC portfolio stands for high-tech carbon-fiber compounds based on recycled carbon fibers. These compounds offers advantages over glass fiber reinforced compounds in terms of lightweight construction, lower carbon footprint, higher strength and stiffness as well as better price-performance ratio.

For more information visit mocom.us.

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