Dürr's EcoDryScrubber, the innovative system for dry separation of paint overspray, is being put into operation once in Ningbo. This technology saves 60% energy in the spray booth by means of up to 95% air recirculation. This air recirculation contributes significantly to a painting process that is nearly independent of the outside climate, thus contributing to a consistently high application quality. The EcoDryScrubber needs no water or detackifier chemicals, and no paint sludge is produced that requires costly disposal.
The rotating dip-coating system RoDip M will be used for pretreatment and electro dipping. It has already been installed in 46 other paint shops for PT / ED application worldwide. The rotation of the entire car body in the tank optimizes the immersion, flooding and draining process. By eliminating the entry and exit ramps the tank volume is decreased, dramatically reducing the need for energy and chemicals.
Dürr is equipping the lines for underbody protection with four robot stations with a total of 26 EcoRS robots and application technology for automatic seam sealing, underbody protection and rocker panel coating. One such robot also handles the installation of roof reinforcement dampings in a gluing station. In addition, an automatic cavity flood system for the preservation of body cavities is included in the scope of delivery. In order to meet capacity, this equipment is constructed in two tracks.
The top coat line also works in two tracks. Before applying the base coat and clear coat, the exterior of the bodies are cleaned with sword brushes by two EcoRS 60 type robots. 32 type EcoRP L133 painting robots in each of the two lines provide fully automatic interior and exterior painting. The opening of hoods and doors for interior painting is also fully automated with robots from Dürr, as is the measuring of film thickness in the top coat line. The EcoLCC linear color changer used in the base coat area minimizes paint loss considerably when changing colors.
The new paint shop – configured for a primer-free process and the use of water-based paint – is designed for 62 units per hour. The contract, with a volume in the three-digit million euro range, was awarded in the fourth quarter of 2011. Starting in August 2014, this paint shop that is dedicated to sustainability will start up operations and paint vehicles for Volkswagen and Skoda.