Trexel Inc.

The MuCell® Process Saves Gasoline, Reduces CO2 Emissions and Dramatically Reduces The Carbon Footprint of Plastic Automotive Parts

For a fleet of just 100,000 cars, Trexel estimates automakers could reduce the carbon footprint of cars that feature optimized MuCell® component applications by more than 6.3 million gallons of gasoline, along with CO2 reductions of nearly 65000 metric tons over the course of a 150,000 mile life span.
To quantify the environmental opportunity for automakers, Trexel engineers have assembled an aggregated look at the impact of the MuCell® Process on a vehicle using Trexel’s specific history of successful mold trials and commercial applications. Trexel then hired environmental firm Simply Sustain LLC to determine the environmental impact of the MuCell® process utilizing a cradle-to-grave analysis.
“Until recently,” said Trexel President and CEO Steve Braig, “most decisions to use the MuCell®
Process were made on a piecemeal, part-by-part basis. However, the industry is now recognizing the immense strategic potential that the MuCell® Process holds for reducing vehicle weight and costs. The environmental analysis of the MuCell® process conducted by a leading outside firm now shows the industry the tremendous positive environmental impact and potential for CO2 reduction when using the MuCell® process,” he said.

“As recently as 2007, the global automotive industry produced somewhere in the area of 51,000,000 vehicles, the potential of the MuCell® process to reduce the auto industry’s carbon footprint is truly significant.” said Braig.

Here’s How Trexel Conducted Its Study

To begin, Trexel reviewed 70 component applications representing approximately 194 pounds of vehicle weight, and tabulated its past results on each component based on its experiences in applying the MuCell® Process. Trexel then assigned a Phase One (straight substitution to include use of the MuCell® process) and a Phase Two weight reduction value to the components, which incorporates of MuCell® process benefits to allow redesign for significantly greater weight savings. Sustain LLC then analyzed the environmental impact of the MuCell® process utilizing a cradle-to-grave analysis.
First, if automakers were to simply adopt the MuCell® process without component redesign, automakers would realize weight reduction of 15.7 pounds per car. For a fleet of 100,000 cars, fuel savings of more than 2.8 million gallons of gasoline and CO2 emissions reductions of 29155 metric tons would be realized over the course of a 150000-mile life.

“For more than a decade, the MuCell® Microcellular Foaming Process has stood out as a proven technology, and applied in a broad, and growing range of automotive applications,” said Braig. “Our customers already know it’s flexible, globally supported, easy to implement and its appeal has continued to increase. For the first time, we can now put some realistic numbers on the environmental benefits of the MuCell® process.”

To review a copy of the complete report, please visit the Trexel website at www.trexel.com.