en.Wedoany.com Reported - Dürr has secured a contract from Volkswagen Autoeuropa to build a new-generation paint shop at its Palmela plant in Portugal. The facility integrates low-carbon coating technology with a plant-wide digital control platform, aiming to enhance efficiency and reduce emissions.
The plant is preparing for future vehicle models, producing 236,100 cars in 2024 at an average of 955 units per day. It is currently investing in expanding manufacturing capacity to support the production of the next generation of vehicles.
At the heart of the paint shop is Dürr's EcoBell4 Pro Hu application technology. Volkswagen Autoeuropa selected this technology for its ability to apply both high-gloss and matte clear coats using a single applicator. The system's 2x2K technology reduces rinsing agent consumption during color changes and maximizes paint utilization efficiency.
The high-speed rotary atomizers operate according to Dürr's High Transfer Efficiency (HTE) principle, achieving an application efficiency of 90%. By optimizing operating parameters, combined with dedicated rotary bells and shaping air rings, the rotation speed is reduced, the spraying distance is shortened, and shaping air consumption is decreased by 30%.
This results in lower paint usage, reduced overspray, and additional energy savings through decreased air handling requirements.
The paint shop will also be equipped with Dürr's electrically heated EcoSmartCure drying system. This oven employs a start-stop operating concept for targeted heating, particularly suitable for electric vehicles; demand-based temperature control reduces energy consumption, expected to shorten drying times and lower CO2 emissions.
In addition to physical equipment installation, Dürr is advancing a comprehensive software modernization plan, connecting three separate painting facilities into a unified Supervisory Control and Data Acquisition (SCADA) environment.
The new DXQcontrol platform will integrate the new paint shop with the plant's existing main painting system and a dedicated two-tone roof painting facility. The project involves migrating third-party software and upgrading legacy systems to the latest DXQcontrol generation.
Felix Losch, Senior Product Manager for Digital Products at Dürr, noted that integrating three independent paint shops with different technological foundations through a cross-plant software solution is an extremely complex task. However, it is this integration that creates maximum value for the customer: one system replaces three, one user interface replaces multiple platforms, and all processes are fully transparent. This not only reduces costs but also enhances production flexibility and efficiency.
The turnkey package includes, in addition to the painting process itself, offline measurement units, a paint mixing room, work platforms, and an internal conveyor system. As the general contractor, Dürr is responsible for overseeing all project activities and coordinating the various construction phases.
Marcus Treppschuh, Senior Vice President of Sales and Marketing at Dürr, stated that the paint shop project is being launched in parallel with the introduction of new vehicle models, requiring precise planning and close coordination across all construction phases. Leveraging experience from numerous turnkey projects, Dürr will reliably deliver on its commitments, providing Volkswagen Autoeuropa with a paint shop that sets new benchmarks in both technology and environmental performance.
The project will be executed in three phases and is scheduled for completion by mid-2027.
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