CO2-Efficient Paint Shop for Vehicles

State-of-the-art application and drying technology ensures maximum CO2 reduction in a new automotive paint shop. An intelligent software solution integrates three separate paint shops into a single, unified system.

Dürr is building a turnkey paint shop for Volkswagen Autoeuropa and, at the same time, implementing a comprehensive software solution. The project combines state-of-the-art application and drying technology for maximum CO2 reduction with innovative SCADA integration that links three separate paint shops into a unified system. 955 cars per day—a total of 236,100 in 2024—rolled off the assembly line at Volkswagen Autoeuropa. The plant in Palmela, Portugal, is currently preparing for future model launches with an additional paint shop and modern software for process optimization.

For its clear coat process, Volkswagen Autoeuropa relies on the Dürr EcoBell4 Pro Hu with 2x2K technology. The 2x2K variant was specifically chosen to enable the application of both glossy and matte clear coats using a single applicator, thereby minimizing solvent loss during product changes. The high-rotation atomizer operates according to the “High Transfer Efficiency” (HTE) principle developed by Dürr and achieves application efficiencies of up to 90 percent. The HTE-optimized parameters, along with the special bell plate and air guide ring system, enable a reduced rotational speed, a shorter spray distance, and 30 percent less air guide volume. This reduces clear coat consumption per car body. At the same time, the reduced overspray lowers the energy requirements for air treatment.

Body drying is handled by an electrically heated EcoSmartCure from Dürr. The continuous-flow dryer, which operates in stop-and-go mode, heats electric vehicles in a targeted manner and reduces energy consumption through demand-based temperature control. The result: shorter drying times and lower CO2 emissions.

Alongside the plant engineering, Dürr is implementing a modern, forward-looking software architecture: DXQcontrol connects the new paint shop as well as two existing buildings—the main paint shop and the separate two-tone system for roof painting—within a common SCADA environment. The integration is challenging because it involves both migrating third-party software and upgrading an outdated system version to the current generation of DXQcontrol. “With this cross-plant software solution, we’re bringing together three independent paint shops with different technological starting points—that’s highly complex,” says Felix Losch, Senior Manager of Digital Products at Dürr. “But it is precisely this integration that delivers the greatest value to the customer: one system instead of three, a single user interface instead of several, and full transparency across all processes. This not only saves costs but also makes production significantly more flexible and efficient.”

The turnkey project also includes an offline measurement cell, the paint mixing room, as well as work platforms and internal conveyor systems. As the general contractor, Dürr is responsible for coordinating all trades. “The launch of the paint shop is tied to the market introduction of a new model. This requires precise planning and close coordination across all construction phases,” explains Marcus Treppschuh, Senior Vice President of Sales & Marketing at Dürr. “Drawing on our experience from numerous turnkey projects, we are reliably executing this project and delivering a facility to Volkswagen Autoeuropa that sets new standards in terms of both technology and environmental performance.” The project will proceed in three phases through mid-2027. (OM-6/26)