The extension of the installation to the full nominal capacity improves the already low energy consumption of the system to achieve the optimum value of less than 500 kWh per vehicle. This is barely a third of what was common ten years ago. The energy-saving measures of Dürr and BMW are effective already in pretreatment and electro-coating area where RoDip M rotational dip coating is used. It reduces the bath volume and therefore also the energy and chemical consumption.
The new, second painting line also uses the fully automated Integrated Paint Process (IPP), which eliminates the need for primer and thus a drying phase as well. The spray booths are equipped with the EcoDryScrubber, the innovative dry separation system for overspray. This technology requires no water or chemicals. Recirculation of the process air results in 60% energy savings in the spray booth. 65 painting lines around the world already produce or are currently being equipped with the EcoDryScrubber.
As is the case with the first line, the paint is applied using 32 Dürr EcoRP E033 and EcoRP L133 painting robots. The compact design of the new-generation EcoBell3 atomizer enables painting both the exterior as well as the interior with a single rotating atomizer.
The other already-installed technologies enabling environmentally friendly, sustainable automotive painting will be adapted to the higher production capacity. These include heat recovery from the supply and exhaust air streams as well as the recovery of waste heat from the ovens with the help of waste heat boilers. As a further environmental protection measure, the exhaust air from the clear coat booth is purified before leaving the plant.