Frédéric Rabain

Materials Management Engineer

GREEN MATERIALS an SMM practice in the automotive industry

Reduce environmental impact at each step in the vehicle life cycle

ECODESIGN >> Sustainable Materials Management

Manufacturing

ISO 14001 + Reducing energy use

Engines

Cut fuel consumption and CO2 emissions

Lower vehicle mass

Materials

Optimise the use of resources

Lower vehicle mass

Recyclability (85/95%) >> Reduce the impact of end-of-life vehicles

Green materials

Low particulate matter

and CO2 emissions

Low fuel consumption;

Hybrid engine

OBJECTIVE: 20% green materials by 2011 (European production)

SCOPE

70% of metals

100% recycled

5% of fluids, 5% various

20% of polymers

150 to 250 kg of plastics

Same Quality

without Cost and Weight increase

OBJECTIVE: 30% green materials by 2015 (European production)

3 families of materials

DEFINITION: Green Materials

Recycled materials

Renewable resources

Waste Toxic emissions

Global warming

Materials from parts recovered at end of life

Natural fibres

Renewable resources

Energy Global warming

Used in blends with polymers to a rate of up to 80%

Biomaterials

Renewable resources

Soil use

Global warming

Polymers produced using renewable resources

35%

30%

25%

20%

15%

10%

5%

0%

2007 2010

AMBITIOUS POLICY

3

1

6% 7%

Design 07/08

Vehicle development – 3 years

families of materials for all vehicles

families of materials for all vehicles

35%

30%

25%

20%

15%

10%

5%

0%

2007 2010

AMBITIOUS POLICY

1

6% 7%

2011

2

Objective 2011 = 20%

Design 07/08

Vehicle development – 3 years

3

AMBITIOUS POLICY

TREND BEFORE GREEN MATERIALS PLAN

35%

30%

25%

20%

15%

10%

5%

0%

2007 2010 2011 2015

Objective EU 2011 = 20%

Objective EU 2015 = 30%

3

2

1

6% 7%

Vehicle development – 3 years

Design 07/08

families of materials for all vehicles 3

AMBITIOUS POLICY

Design 07/08

TREND BEFORE GREEN MATERIALS PLAN

Vehicle development – 3 years

35%

30%

25%

20%

15%

10%

5%

0%

2007 2010 2011 2015

3

2

1

6% 7%

Natural Materials

Recycled

Biopolymers

Objective EU 2011 = 20%

Objective EU 2015 = 30%

families of materials for all vehicles 3

New Citroën C4

Peugeot 508

AMBITIOUS POLICY

TREND BEFORE GREEN MATERIALS PLAN

35%

30%

25%

20%

15%

10%

5%

0%

2007 2010 2011 2015

Objective PSA EU 2011 = 20%

Objective PSA EU 2015 = 30%

3

2

1

6% 7%

Vehicle development – 3 years

Design 07/08

families of materials for all vehicles 3

Green Materials Plan

Launch in Latin America:

20% in 2015

Natural Materials Recycled

Biopolymers

GLOBAL MANAGEMENT

Short term

Implement

Include green materials in our guidelines

Extend use to all current development projects

Medium term Innovate

New materials and processes

Extend to large body and impact parts

Work closely with parts suppliers

Long term

Step up research on automotive applications

External partnerships, on bioplastics in particular

Cooperative research projects

CASE STUDY: the bumper

Three eligible areas:

supports, absorber and spoiler

Criteria: features, mass and cost price

Applications: 750 g in supports and 1.1 kg in the spoiler

Total: 1.85 kg of green materials in an 8 kg component

New materials currently under review to reach 4 kg

Mid term: 4 kg of recycled plastics, or 50% of bumper weight

For each vehicle sub-assembly, a green materials solution is identified and included in projects under way, depending on feasibility

ENVIRONMENTAL IMPACT

Natural fibres: Hemp fibres vs glass fibres

Data from lifecycle analysis in 2009 by EVEA agency for PSA, on a

Peugeot 207 rearview mirror plate in PP/Hempfibre, in comparison with

PP/fiberglass (ISO 14040 et 14044)

- 5% reduction in weight

- 43% reduction in water consumption

- 14% reduction in greenhouse gases

- 25% non renewable resources use

CONCLUSION

Ambitious policy on materials in line with the “Three R’s”

principle on reducing environmental footprint

Green materials plan is a part of PSA Peugeot Citroën sustainable

developement approach

Reduce

Reuse

Recycle

GREEN MATERIALS

MAIN CHALLENGES

Availability of recycled materials

Need to promote recycling channels in all countries

Bio-based polymers: opportunity and risk

Lower maturity of bio-processes / petrochemicals >> R&D

Environmental questions to address:

Competition with food production

Soil use

Need for complete LCA for each bio-process (fertilizers,

transport, GMO…)

GREEN MATERIALS