Ford Motor Company and McDonald’s USA joined forces to give vehicles a caffeine boost by using part of a familiar staple in the morning routine, coffee beans, in vehicle parts such as headlamp housing. Every year, millions of pounds of coffee chaff – the dried skin of the bean – naturally comes off during the roasting process. Together, Ford and McDonald’s can provide an innovative new home to a significant portion of that material. The companies found that chaff can be converted into a durable material to reinforce certain vehicle parts. By heating the chaff to high temperatures under low oxygen, mixing it with plastic and other additives and turning it into pellets, the material can be formed into various shapes.