In 2024, a total of 236,100 vehicles – an average of 955 per day rolled off the production line at Volkswagen Autoeuropa. The factory in the Portuguese town of Palmela is currently preparing for future model launches with the addition of a new paint shop and advanced process optimization software.
Resource-efficient painting with the EcoBell4 Pro
Volskwagen Autoeuropa uses the EcoBell4 Pro Hu with 2x2K technology for its clear coat process. It specifically selected the 2x2K variant to enable the application of both glossy and matte clear coats using a single applicator, while also minimizing rinsing agent consumption during product changes. The high-speed rotary atomizer works according to the “High Transfer Efficiency” (HTE) principle developed by Dürr, achieving application efficiencies of up to 90 percent. The HTE-optimized operating parameters along with the specialized bell disc and shaping air ring system, enable a lower rotational speed, a shorter painting distance, and a 30 percent reduction in shaping air consumption. This results in less clear coat being used per body. At the same time, the reduced overspray lowers the demand for air treatment, resulting in additional energy savings.
Low-energy intelligent drying
Body drying is performed by an electrically heated EcoSmartCure system. The straight-through oven, designed with stop-and-go operating concept, provides targeted heating – particularly for electric vehicles – and reduces energy consumption through demand-based temperature control. The result is shorter drying times and reduced CO2 emissions.
Centralized SCADA system for three paint shops
In parallel with the plant engineering, Dürr is implementing a modern, future-ready software architecture: DXQcontrol connects the new paint shop as well as two existing buildings – the main paint system and the separate two-tone system for roof painting – within a single, unified SCADA environment. The integration is challenging, because it involves both migrating third-party software and upgrading an outdated system to the latest generation of DXQcontrol. “With the cross-plant software solution, we are bringing together three separate paint shops with different technological baselines – an extremely complex task,” says Felix Losch, Senior Manager Digital Products at Dürr. “But it is precisely this integration that adds the greatest value for the customer: One system instead of three, one user interface instead of multiple platforms, and full transparency across all processes. This not only cuts costs but also makes production significantly more flexible and efficient.”
Precise planning for the model launch
The turnkey project also includes an offline measurement cell, a paint mixing room, as well as work platforms and internal conveyor systems. In its role as general contractor, Dürr is coordinating all trades and project activities. “The launch of the paint shop project coincides with the market introduction of a new model, requiring precise planning and close coordination across all construction phases,” explains Marcus Treppschuh, Senior Vice President Sales & Marketing at Dürr. “Drawing on our experience from numerous turnkey projects, we will reliably deliver on this commitment and provide Volkswagen Autoeuropa with a paint shop that sets new benchmarks both technologically and environmentally.” The project will run in three phases and is scheduled for completion by mid-2027.
