en.Wedoany.com Reported - Dürr is building a turnkey paint shop for Volkswagen Autoeuropa and simultaneously implementing a comprehensive software solution that integrates three separate paint shops into a single system.

In 2024, Volkswagen's Autoeuropa plant in Palmela, Portugal, produced 236,100 vehicles, with an average daily output of 955 units. To prepare for the launch of future models, the plant is adding a new paint shop and deploying advanced process optimization software.

For resource-efficient painting, Volkswagen Autoeuropa's clearcoat process uses EcoBell4 Pro Hu high-speed rotary atomizers equipped with 2x2K technology. The customer chose the 2x2K model to spray both glossy and matte clearcoats with a single applicator and minimize cleaning agent consumption during product changes. The atomizer operates based on Dürr's "High Transfer Efficiency" (HTE) principle, achieving a coating efficiency of 90%.

HTE technology achieves lower rotational speeds and shorter spray distances by optimizing operating parameters and using a dedicated atomizer cup and shaping air ring system, reducing shaping air consumption by 30%.

This reduces the amount of clearcoat used per vehicle body. At the same time, the reduction in overspray lowers the demand for air treatment, further saving energy.

For body drying, the project uses an electrically heated EcoSmartCure system. This through-type oven applies a "stop-and-go" operating concept, enabling targeted heating—especially suitable for electric vehicles—and reducing energy consumption through on-demand temperature control, ultimately shortening drying time and reducing CO₂ emissions.

Alongside the plant engineering design, Dürr is implementing a future-oriented modern software architecture. The DXQcontrol system integrates the new paint shop with two existing buildings—the main painting system and a separate two-tone system for roof painting—into a single SCADA environment. This integration is challenging, involving the migration of third-party software and upgrading legacy systems to the latest generation of DXQcontrol.

Felix Losch, Senior Manager of Digital Products at Dürr, stated: "With the cross-plant software solution, we are integrating three separate paint shops with different technical foundations into one—an extremely complex task. But it is precisely this integration that delivers the greatest value to 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 makes production more flexible and efficient."

The turnkey project also includes an offline measuring unit, a paint mixing room, as well as work platforms and an internal conveyor system. As the general contractor, Dürr is coordinating all trades and project activities. Marcus Treppschuh, Senior Vice President of Sales and Marketing at Dürr, explained: "The start of the paint shop project coincides with the market launch of new models, requiring precise planning and close coordination of all construction phases. With our experience from numerous turnkey projects, we will reliably fulfill this commitment, providing Volkswagen Autoeuropa with a paint shop that sets new benchmarks both technically and environmentally."

The project will be carried out in three phases and is scheduled for completion in mid-2027.