Automotive

ECOBUS

NEW, SUSTAINABLE COACH MANUFACTURING TECHNOLOGIES

COACH MANUFACTURING INVOLVES CONSTANT PRODUCT DEVELOPMENT. The chief aim of IRIZAR, the sector leader, is to differentiate itself from its competitors, constantly investing in technological improvement, developing new and improved products, and improving customer care and service. IRIZAR proposes ECOBUS to position itself as a leading brand at the forefront of eco-design in its sector, with environmentally sustainable coaches which are endorsed by an Environmental Product Declaration (EPD).

IRIZAR
OBJECTIVES
  • Lighten materials to reduce consumption and GHG emissions in the use phase.
  • Replace technology and materials with more environmentally-friendly ones: using composite and sandwich-panel materials for ceiling and floor construction solutions; replacing anti-corrosive paint with chromates; using new types of adhesive and sealing putty outdoors and indoors; implementing new technologies for side, rear and front panels; analysing and designing new luggage ducts; looking for alternative materials for fenders.
  • A type III eco-label EPD.
RESULTS
  • A prototype of a differentiated high-performance coach was designed and produced.
  • 10% reduction of coach GHG emissions, which represents up to 139 tonnes of CO2 equivalent per unit.
  • 40% weight reduction of ceiling and floor
  • New, lighter side, rear and front panels with improved surface quality
  • More sustainable and lower density adhesive putties were used.
  • 30% reduction of weight in fenders
  • Weight reduction in luggage ducts of 30 % without aeroplane covers and 50 % with aeroplane covers.
  • Reduced manufacturing cost of the company’s coaches by 8% thanks to improved production processes.
  • An EPD by means of a type III environmental label.
CONCLUSIONS
  • ECOBUS will enable penetration into new markets thanks to the product’s environmental impact transparency endorsed by an EDP, which, although not yet mandatory in the sector, is expected to increase the company’s sales by 12% in the coach sector.
  • ECOBUS must be compliant with EC Regulation R66 coach rollover Type Approval and R80 on energy absorption requirements, in addition to load assumptions defi ned in the load logbook to maintain stiffness and strength of the current assembly. Likewise, with a view to the EPD, it is necessary to work towards an inventory of 99% of the weight of coaches, which is not always possible due to the lack of traceability of data obtained and absence of suppliers with environmental LCA approaches. Along these lines, IRIZAR continues to research into new manufacturing materials and eco-sustainable manufacturing processes.

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