en.Wedoany.com Reported - Dürr is developing a new paint line for Volkswagen's Autoeuropa plant in Palmela, Portugal, employing painting and drying technologies designed to reduce CO₂ emissions, while simultaneously implementing a software solution that integrates three paint lines into a unified control platform. In 2024, the Volkswagen Autoeuropa plant produced 236,100 vehicles, with an average daily output of 955 units. The plant is preparing for the launch of new future models, equipped with a new paint line and advanced process optimization software.
Currently, the plant uses EcoBell4 Pro Hu high-speed rotary atomizers with 2x2K technology in the clear coat application process. The 2x2K variant allows a single applicator to simultaneously apply high-gloss and matte clear coats, while minimizing flushing agent consumption during material changes. The atomizer operates based on Dürr's "High Transfer Efficiency (HTE)" principle, achieving a painting efficiency of 90%. The HTE-optimized operating parameters, combined with a dedicated bell cup and fan air ring system, enable lower rotational speeds, reduced spray distances, and a 30% decrease in fan air consumption. This reduces the amount of clear coat used per body, and the reduction in overspray also lowers air treatment requirements, resulting in greater energy savings.
Body drying is accomplished using the EcoSmartCure system with electric heating. This direct-fired oven employs a "stop-and-go" operating concept, providing targeted heating, particularly suitable for electric vehicles, and reduces energy consumption through demand-based temperature control, shortening drying times and lowering CO₂ emissions. Concurrently with the plant engineering design, Dürr is implementing a future-oriented modern software architecture—DXQcontrol—which connects the new paint line, as well as the main painting system and the separate two-tone roof painting system, into a unified SCADA environment. The integration involves migrating third-party software and upgrading existing systems to the latest generation of DXQcontrol, which presents a significant challenge. Paulo Sentieiro, Vice President of Sales and Marketing at Dürr Brazil, stated that integrating three independent paint shops with different technical references through a multi-plant software solution is an extremely complex task, but it is precisely this integration that creates the greatest value for the customer: one system, one user interface, complete transparency across all processes, reducing costs while significantly increasing production flexibility and efficiency.
The turnkey paint shop project also includes an offline measurement cell, a paint mixing room, work platforms, and an internal material handling system. Dürr, as the general contractor, coordinates all commercial and design activities. Sentieiro explained that the launch of the paint line project is synchronized with the market introduction of new models, requiring precise planning and strong coordination for each construction phase. Leveraging Dürr's experience in numerous turnkey projects, it will provide Volkswagen Autoeuropa with a paint line that meets high standards in both technology and environmental performance. The project is being executed in three phases and is expected to be completed by mid-2027.
