Dürr is constructing a turnkey paint store for Volkswagen Autoeuropa whereas concurrently implementing a complete software program resolution. The challenge combines state-of-the-art software and drying applied sciences designed to maximise CO2 discount, together with an progressive SCADA integration that unifies three separate paint retailers in a single system.
In 2024, a complete of 236,100 autos – a median of 955 per day rolled off the manufacturing line at Volkswagen Autoeuropa. The manufacturing facility within the Portuguese city of Palmela is at the moment making ready for future mannequin launches with the addition of a brand new paint store and superior course of optimisation software program.
Useful resource-efficient portray with the EcoBell4 Professional
Volskwagen Autoeuropa makes use of the EcoBell4 Professional Hu with 2x2K expertise for its clear coat course of. It particularly chosen the 2x2K variant to allow the applying of each shiny and matte clear coats utilizing a single applicator, whereas additionally minimising rinsing agent consumption throughout product modifications.
The high-speed rotary atomiser works in line with the “Excessive Switch Effectivity” (HTE) precept developed by Dürr, reaching software efficiencies of as much as 90 p.c.
The HTE-optimised working parameters together with the specialised bell disc and shaping air ring system, allow a decrease rotational pace, a shorter portray distance, and a 30 p.c discount in shaping air consumption.
This leads to much less clear coat getting used per physique. On the identical time, the decreased overspray lowers the demand for air remedy, leading to further power financial savings.
Low-energy clever drying
Physique drying is carried out by an electrically heated EcoSmartCure system. The straight-through oven, designed with stop-and-go working idea, gives focused heating – significantly for electrical autos – and reduces power consumption by demand-based temperature management. The result’s shorter drying instances and decreased CO2 emissions.
Centralised SCADA system for 3 paint retailers
In parallel with the plant engineering, Dürr is implementing a contemporary, future-ready software program structure: DXQcontrol connects the brand new paint store in addition to two current buildings – the principle paint system and the separate two-tone system for roof portray – inside a single, unified SCADA setting.
The combination is difficult, as a result of it includes each migrating third-party software program and upgrading an outdated system to the newest technology of DXQcontrol.
“With the cross-plant software program resolution, we’re bringing collectively three separate paint retailers with completely different technological baselines – an especially complicated process,” says Felix Losch, senior supervisor digital merchandise at Dürr.
“However it’s exactly this integration that provides the best worth for the client: One system as a substitute of three, one person interface as a substitute of a number of platforms, and full transparency throughout all processes. This not solely cuts prices but additionally makes manufacturing considerably extra versatile and environment friendly.”
Exact planning for the mannequin launch
The turnkey challenge additionally contains an offline measurement cell, a paint mixing room, in addition to work platforms and inner conveyor methods. In its function as basic contractor, Dürr is coordinating all trades and challenge actions.
“The launch of the paint store challenge coincides with the market introduction of a brand new mannequin, requiring exact planning and shut coordination throughout all development phases,” explains Marcus Treppschuh, senior vice chairman gross sales and advertising and marketing at Dürr.
“Drawing on our expertise from quite a few turnkey initiatives, we are going to reliably ship on this dedication and supply Volkswagen Autoeuropa with a paint store that units new benchmarks each technologically and environmentally.”
The challenge will run in three phases and is scheduled for completion by mid-2027.
