Mexico. The consortium builder of machines and facilities, Dürr, will build in San José Chiapa one of the automotive painting plants that they call the most environmentally friendly in the world for the vehicle manufacturer Audi.
Under the name of Eco+Paintshop the plant will offer a low consumption of water, energy and materials. It also has pre-treatment and cathodic immersion coating (KTL) systems, booths with technologies for the application of paint and drying ovens.
In the base layer application area, for pre-treatment and cathodic immersion coating, the Ecopaint RoDip rotary immersion system is applied. The smaller volume of this immersion tank for these baths of shortened duration, reduces the need for water and chemicals, and consequently the energy consumption for the conditioning of the bath. RoDip also offers corrosion protection through a streamlined process of immersion, flooding and drainage.
A total of ten EcoRS16 type robots are in charge of the application of bass protection and seam sealing. In addition, 36 EcoRP L133 type robots, equipped with EcoBell3 high-speed rotary atomizers, are responsible for the fully automated interior and exterior painting in the first and top layer line.
This atomizer and the EcoLCC2 base layer color changer allow a color change with the Push-Out method (ejection process) in 10 seconds. In the Push-Out process, the paint valve is closed before the painting process is finished, and the remaining paint on the hose is propelled towards the atomizer with the help of a solvent medium. Paint loss during layer color change is reduced to between 10 and 15ml.
In the supply of paint for standard colors, Audi uses circulation technology, while special colors will be promoted in multiple ways with the flexible pigging system EcoSupply P (pig = pipeline inspection gauge), which means that the color moves inside the hoses without leaving residue and without finding resistance.
Excess spraying is separated through the energy-efficient system of the EcoDryScrubber paint booth. Dry separation of paint mist completely renounces water and chemicals. This makes it possible to feed the paint booth with up to 90% recirculated air. The EcoDryScrubber saves up to 60% of the energy in the paint booth, as less air conditioning is needed.
Audi commissioned Dürr this highly efficient Eco+Paint Shop in December 2013. The Q5 models will roll off the production line in San Jose Chiapa starting in mid-2016.
