Integrated cleaning equipment control
The cleaning equipment for the various Dürr atomizers is now fully controlled via the EcoAUC2. This significantly reduces the integration effort, especially when safely shutting down the high voltage before the high-speed rotary atomizer EcoBell2 enters the special cleaning equipment. This function is now performed by the EcoAUC2: It automatically detects whether the applicator is de-energized, and only then does it enable the cleaning cycle. This avoids potentially hazardous situations.

Increased color and hardener capacity
The control unit can now control up to 20 colors – twice as many as the predecessor model. “We are seeing a clear trend towards personalization in many applications, which is why we doubled the color selection during the development process,” says Stephan Voigt, product engineer at Dürr. In addition, the EcoAUC2 now supports up to five hardener components, instead of the previous three. This means that infrequent but complex paint formulations are now also possible.

Ready to start without delay, intuitive to operate
The EcoAUC2 components are compactly housed in a control cabinet. Integrated in this cabinet are the process controller, the compressed air control system, the visualization system, and the interfaces for robot control and the safety PLC. Like its predecessor model, the EcoAUC2 is also fully embedded in Dürr’s ready2integrate concept. This works according to the plug-and-play principle familiar from computers: The pre-tested, certified unit is tailored to the respective dosing and application technology and can be started up on site in the shortest possible time without any additional adaptation. An intuitive visualization system with an oversized display simplifies process monitoring and operation. The EcoAUC2 thus significantly extends the possibilities of automated application technology – for anyone who wants flexible, reliable, and versatile coating in an industrial environment. 

Dürr will be presenting the new EcoAUC2 for the first time at the PaintExpo in Karlsruhe (Hall 3, Booth 3320) in a live demonstration. Further information on processes, system innovations, and complementary solutions can be found in the current Dürr catalog for industrial painting technology.

Drop-on-demand: Painting at the highest resolution
EcoNextJet is based on drop-on-demand technology. This involves attaching a printhead with 2,000 individually controllable nozzles to a painting robot. Each nozzle dispenses paint only when needed. Up to six drops can be dispensed per pixel. As the drops fly through the air, they merge into one larger drop before reaching the surface of the vehicle body. This technology allows size and speed to be controlled with a very high degree of precision. Pixel by pixel, a paper-thin image is produced, with approximately five micrometers of paint film thickness and resolution up to 720 dpi. The two-channel printhead can dispense two colors simultaneously. A software program, specially developed by Dürr, controls the robot’s path and calculates the point of impact for each drop – even on convex or vertical surfaces. Importantly, the same paint is used for all surfaces, simplifying the process and ensuring consistent finish quality.

Partnership as the key to innovation
EcoNextJet was developed through close partnerships: Dürr handled process integration, robotics, and software for the painting process; paint manufacturer Axalta developed the appropriate paints; and printhead manufacturer XAAR provided the printhead. “Our customers want their designers to have more freedom, especially when it comes to high-resolution graphics. The partnership with Axalta and XAAR significantly shortened the development time and made it possible to offer a complete system that meets the automotive industry’s requirements,” says Frank Herre, Director Automotive (Paint Shop) at Dürr.

Ready for practical use
EcoNextJet is available for initial testing in Dürr’s test centers in Bietigheim, Germany, and Southfield, Michigan, USA. At these facilities, manufacturers can observe how graphics and patterns are produced in an automated painting process that uses no films, reduces waste, and saves labor time. At the same time, the high resolution opens up new design possibilities. EcoNextJet is thus not only a technological innovation, but also a means of more efficient and more sustainable processes in vehicle production.

“The paint used is special—it serves multiple functions,” explains Fabian Schilt, Head of the European Industrial Sales Team at Dürr. “In addition to providing color, it provides the necessary conductivity. Since the chairs are used in cleanrooms and ESD areas, among other environments, it is essential that no static charge is generated.”

Compact paint supply with EcoSupply2 Core
In September 2025, Dürr supported PU plant specialist Hennecke with the installation of painting equipment on an existing robot at the Interstuhl site in Meßstetten-Tieringen. The system includes a painting robot equipped with the EcoGun AS AUTO pro spray gun, six EcoSupply2 Core stations for paint supply, and the EcoAUC 2K control unit. Interstuhl currently processes three colors, but the system is already designed to handle up to five colors.

The EcoSupply2 Core paint supply station is space-saving and user-friendly. It is ideal for industrial applications where painting occurs in confined spaces. At Interstuhl, the systems are additionally equipped with pumps from the EcoPump9 series, valves, and paint change blocks—components that have particularly impressed the company. This is due to the paint material used has special requirements: it is difficult to flush, hardens quickly, and tends to clog valves.

Ready for practical use
Extensive testing at the Dürr Test Center in Ledeč nad Sázavou, Czech Republic, proved that Dürr valves have no dead space – no material settles, ensuring reliable and clean processing. “We were convinced by Dürr right from the first demonstrations of the painting technology,” says Andreas Kunst from Interstuhl. “The technical team was always there to support us and led the project to success with a great deal of expertise and commitment.”

Efficient high-tech products benefit the environment
CEER relies on Dürr's new generation of ovens. The EcoInCure heats the body from the inside to reach massive body components more directly. This is particularly advantageous for electric vehicles, as they require – among other things – well reinforced rocker panels to protect their batteries in the event of a side impact while simultaneously preventing overheating in thinner parts of the body shell. This drying method is more environmentally friendly, reducing the required heating process time for the body is by up to 30% compared to conventional systems. An Oxi.X RV from Dürr CTS cleans exhaust air from the oven using the principle of regenerative thermal oxidation (RTO). The oxidation reactions, which purify the process exhaust, occur entirely within the heat exchange media. Since the system operates using electricity, there is no open flame and therefore none of the unwanted by-products of flame combustion.

Another notable feature is Dürr’s EcoPaintJet Pro, an award-winning overspray-free painting system. CEER can utilize this to offer its customers cars with a two-tone paint finish. The EcoPaintJet Pro technology marries customer-specific product design with automated production. Bodies can be painted with two contrasting colors simultaneously, reducing paint consumption and eliminating plastic waste since the EcoPaintJet Pro does not require masking with adhesive tape. The system can also paint complex patterns such as lettering and logos.

“Innovation is a key driver of performance and sustainability in vehicle production. The paint shop of the future will deliver great flexibility, energy and paint efficiency, and exciting premium vehicle paint finishes,” said Dr. Lars Friedrich, CEO of Dürr Systems AG. “We are pleased to have the opportunity to partner with CEER to create one of the most modern car production lines in the world.”

Flexible box concept instead of rigid painting lines
CEER can swiftly incorporate new models and easily scale production capacity with the paint shop of the future. The key lies in implementing a modular concept, where flexible EcoProBooth boxes replace traditional lines with their rigid cycle times. In the box concept, the robots paint the interior and exterior of the car bodies in just one box. The new universal atomizer from the EcoBell4 Pro series meets the highest painting quality standards. Dürr’s EcoProFleet AGVs are constantly in motion and flexibly transport bodies between workstations and the high-bay warehouse based on demand. DXQlogistics.control, Dürr’s tailored software solution for the AGVs’ control logic, controls material flow digitally following work deck utilization, equipment, and availability. 

Smart factory due to DXQ software
Digital solutions from Dürr's DXQ product family turn CEER's paint shop into an intelligent factory. The DXQcontrol modular solution is an innovative manufacturing operations management (MOM) system with a microservices architecture that delivers a high level of flexibility and consistency. The MOM comprises over 50 functionalities for manufacturing planning, execution, control, monitoring, optimization, and predictive analysis. DXQanalyze provides information based on specific systems and uses, enabling it, for example, to forecast the remaining service life of system components or to establish links between quality results and machining processes, taking transparency about the operating behavior of machines and systems to a whole new level.

“Our goal at CEER is to build a world-class manufacturing facility, setting new benchmark for efficiency and sustainability,” said James DeLuca, CEO of CEER. “This Paint Shop of the Future will place CEER at the forefront of automotive manufacturing innovation, allowing us to offer our customers in Saudi Arabia and the wider region a level of customization they have never seen before. The result will be a more environmentally friendly manufacturing process and the ability to offer customization in car colors, finishing, and intricate details that will excite the public.”

In autumn 2024, Dürr opened its subsidiary Dürr Systems Arabia LLC in Jeddah, Saudi Arabia, to further strengthen its customer relations in the region.

Revised operating concept
Dürr has significantly improved the spray guns’ operation with larger adjustment elements and optimized haptics for easier control. A new ergonomically correct rotary knob replaces the previous lever for regulating the spray air. This prevents accidental adjustments and can be completely closed if necessary. The optimized air valve makes you reliably set the pressure right from the first trigger pressure point.

Fewer variants, greater reliability
The EcoGun ACE pro requires just four air cap variants. Two conventional and two low-volume, low-pressure air caps cover all diameters from 1.2 to 2.5 millimeters across seven different nozzles sizes. This simplifies storage and reduces the risk of mix-ups. Plus, to make handling easier and avoid loose parts, the air cap and union nut remain connected after removal.

New design as a visible change of generation
Visually, the EcoGun ACE pro stands out with a new bronze-colored housing and black controls. The design signals a new generation without changing the proven system principles. Dürr continues its line of low-pressure spray guns offering robust industrial quality, precise spray patterns, fast color changes, improved ergonomics, and cost-effectiveness.

Less energy, less production space
Dry coating offers clear advantages over conventional wet coating in electrode production: it reduces space requirements by up to 65% and lowers energy consumption by up to 70%. These savings are mainly due to the elimination of dryers and solvent recovery. "The successful proof of concept is a major step forward for us. We have demonstrated that the new kind of dry coating with free-standing film works reliably and delivers consistently good quality. It can be scaled up, making it the basis for initial pilot projects in industry," explains Bernhard Bruhn, Vice President of Dürr's Global Business Unit LIB. The process is suitable for today's lithium-ion batteries and also for solid-state batteries.

Free-standing film reduces scrap
The proof-of-concept plant is located in Chassieu in southern France, in a dry room environment at Ingecal, a Dürr Group company specializing in calender technology. Calenders are machines with rollers that compress materials into an even layer. Dry coating starts with film formation: A horizontal calender forms the dry powder into a film. It is referred to as “free-standing” because it runs through the machine without a carrier foil. In the second step, additional calenders compress the film to the desired layer thickness, density, and porosity. Finally, one film is laminated onto the collector foil from each side – thus producing the electrode. “Since we don't need a carrier foil until the final step, we can return the film to the process in its entirety if it does not meet the desired specifications. Thanks to the closed loop, no valuable active material is lost and we significantly reduce waste – an important point in battery production,” explains Bruhn.

Improved further processing 
The special characteristic of X.Cellify DC lies in its web guidance: the system transports the free-standing film in a self-supporting manner and compresses the film before it is applied to the current collector. The subsequent lamination onto the current collector requires less force than calendering in the wet coating process, which means that the foil does not deform – improving its processability for the downstream process steps of notching and stacking.

Combined strengths
The new approach to dry coating combines Dürr's expertise in electrode manufacturing and system integration, Dürr Ingecal's high-precision calenders, and LiCAP's patented Activated Dry Electrode^® technology. “To take the next step, we are actively seeking pilot partners in the industry for gigawatt-scale projects. This will enable us to bring the technology into real production environments – whether for electric cars, stationary storage or other applications,” says Bernhard Bruhn. Dürr is thus ready to partner in the next generation of battery production – with solutions for wet and dry coating.

Painting technology for high model variance
The two identical painting lines feature 170 sealing and painting robots, with the corresponding application technology for sealing and coating the different Volkswagen models in the future. This encompasses EcoRS Clean F, a prime example of Dürr’s efforts to bolster system technology to equip it for growing model diversity. It combines the thorough, gentle cleaning prowess of a feather roller system with the high flexibility inherent to a robotic setup. This makes it perfect for lines that paint many body variations with complex contours. The contract scope also includes the complete paint and PVC supply and software solutions with AI applications from Dürr’s proprietary DXQ product family.

Substantial reduction in CO₂ emissions
A central factor in CO₂ emissions reduction is body drying since it consumes the most energy in the painting process. Operating the ovens with regenerative energy, like green electricity, reduces the CO₂ emissions from the overall system by around 40 percent compared to a paint shop using natural gas. “This was one of the reasons why Volkswagen opted for the EcoInCure electric drying system,” explains Bruno Welsch, COO Automotive at Dürr. “Another is its special air duct system that heats the bodies from the inside out. This technology results in more uniform heating and cooling behavior and reaches solid body components like the rocker panels more directly than conventional systems, cutting the body heating times by 30 percent.”

Electric package concept for oven and exhaust air purification
Another cornerstone for minimizing CO₂ emissions is linking the electric oven to an electric air pollution control system. Dürr is the only provider on the market with an overall blended concept of this kind. It combines the EcoInCure with an Oxi.X.RV, an electric exhaust air aftertreatment system that purifies the polluted exhaust air using the principle of regenerative thermal oxidation (RTO) – with no open flame. Unlike conventional combustion processes, no additional CO₂ is produced by the operation. The system is also extremely energy efficient and achieves autothermal operation even with small quantities of solvent, i.e., it maintains its operating temperature by itself. It uses the significant energy produced during oxidation of the solvents to keep its process going.

Dürr is also installed an energy-saving, environmentally-friendly system for overspray separation. EcoDryScrubber uses limestone powder as a natural binder to separate paint overspray. Highly efficient HEPA12 filters remove all particles from the process air. The saturated limestone powder is disposed of fully automatically via a piping system – with no process interruption. The dry separation system at Volkswagen Puebla minimizes the required fresh air supply to 5 percent maximizing the proportion of recirculated air. This reduces the paint booth’s energy consumption by well over 60 percent compared with wet scrubbing. 

Under Stellex’s ownership, the environmental technology business is well positioned to expand its leadership, benefitting from resources to support the expected growth. In 2024, environmental technology generated sales of €407 million and employed around 1,300 people, including around 450 in Germany. The head office is located in Bietigheim-Bissingen and the business is operated at 16 locations in 12 countries worldwide. Environmental technology systems from Dürr are used in various end-markets, including chemicals, odor control and automotive, for example.

Concentration on the core business

Dr. Jochen Weyrauch, CEO of Dürr AG: “The environmental technology business has grown strongly in recent years and has established itself as the global market leader. However, it lies outside our strategic core business relating to automation technology. The new owner, Stellex, therefore offers better opportunities for further growth for environmental technology. Through this sale, the Dürr Group will become leaner and sharpen its strategic focus. We will use the proceeds from the sale to strengthen our company.”

Karthik Achar, Partner at Stellex: “We look forward to becoming the next steward of Dürr’s Clean Technology Systems Environmental division and we welcome the company into our investment portfolio. We view the division as a global leader in environmental filtration and pollution control solutions - critical technologies that serve a wide range of industrial and adjacent markets. Its long-standing customer relationships are a testament to the company’s engineering excellence. We are eager to partner with the management team and its employees in an effort to shape the next phase of its growth.”

Dr. Sebastian Baumann, Head of the Clean Technology Systems Environmental division: “We can look back on a successful development in the environmental technology business and are convinced that we can develop our potential even better as an independent company. With Stellex at our side, new opportunities for growth and innovation are opening up, both in our established business areas and in pioneering technology areas such as carbon capture and heat storage.”

In spring 2025, the company expanded its training center in Bietigheim-Bissingen with a sealing robot cell equipped with EcoRail HS and two latest-generation robots: the EcoRS N20i and EcoRS L15i. These are complemented by EcoShot Meter and EcoGun2 3D dosing and application technology. The EcoTemp PT temperature control system is also included, bringing the highly viscous sealing material to the required processing temperature.

Dr. José Gamero, head of the training center at Dürr, summarizes the advantages: “The expansion allows us to offer ideal training for our customers using the latest Dürr sealing technology. We offer courses on mechanical and electrical maintenance of the technology, including assemblies and control systems.” Furthermore, robot programming and plant operator training for sealing can be provided at this new training cell.

Courses under real conditions

Thanks to the expansion, participants can now gain practical experience operating the new EcoRS robot generation under real-world conditions. The additional robot cell gives the training center greater flexibility to meet customer requests and accommodate more simultaneous courses. 

In 2024, around 1,000 participants received training in various technical disciplines in Bietigheim. In addition, approximately 100 training courses were conducted on-site at customer locations.

EcoY – vertical farming on a new level
Controlled Environment Agriculture (CEA) refers to the modification of the natural environment to boost crop yield or extend the growing season. CEA systems are typically housed in enclosed structures such as greenhouses or buildings, where environmental factors like air, temperature, light, water, humidity, carbon dioxide, and plant nutrients are controlled. In most vertical farming systems, the crops are grown in horizontal layers stacked one on top of the other with no access to daylight. These setups demand massive amounts of energy for artificial lighting, mechanical ventilation, and climate control – costs that cannot be offset by raising prices for low-margin produce. 

Dürr has reimagined this system using its engineering expertise. “With our EcoY solution, we’re taking a different approach,” explains Michael Broek, Company Chairman at Dürr Africa. “Our objective was to develop a system that delivers maximum yield with minimum energy consumption. It’s essentially a hybrid hydroponic solution, independent of external climatic conditions. The system can even operate in extreme environments such as deserts or regions with extreme cold.” Together with CAN-Agri, Dürr developed a solution that harnesses natural resources like sunlight for vertical plant growth in a greenhouse, while conserving energy and water through efficient manufacturing, patented technologies, and digitalization. This greatly reduces operating costs while ensuring consistent quality and yield per square meter. 

Grow tubes and digital control for optimal yield
All key factors for plant growth – light, humidity, temperature, and CO₂ – are digitally monitored and adjusted in EcoY’s high-tech greenhouse, in line with the technology-based concept of CEA. What sets EcoY apart are the grow tubes in which the plants are cultivated. Developed and patented by CAN-Agri, these tubes arose from the idea of turning the traditionally horizontal plant layers 90 degrees, stacking 80 seedings, one above the other, vertically in each tube. The grow tubes are positioned in the greenhouse to ensure that sunlight reaches all plants. “The grow tubes not only increase plant density but also help regulate the climate,” completes François van der Merwe, CEO at CAN-Agri.

Inside the greenhouse, the grow tubes are evenly spaced in rows with nutrient-rich water circulating through them. To maintain consistent plant temperatures, the nutrient-rich water temperature is adjusted, promoting a localized microclimate where the plants need it most. This optimizes the growing environment and improves yields. This microclimate is monitored and fine-tuned automatically using the greenhouse climate control technology that includes heating, cooling, humidification, ventilation, and screening systems to create ideal growing conditions. The closed-loop system consumes up to 95 percent less water compared to traditional outdoor cultivation methods. Dürr’s intelligent ventilation concept also reduces resource usage by precisely conditioning the temperature and moisture content of the air and distributing the air throughout the greenhouse. Another special feature: in higher latitudes, where daylight is limited especially in the winter months, optional LED lights can be installed. These lights activate only when the required amount of Photosynthetically Active Radiation (PAR in mol/m²/day) falls below the required threshold – ensuring constant output with minimal energy usage.

Combined expertise from mechanical engineering and agriculture
The EcoY solution combines expertise from various areas. For the design, installation, and commissioning of the turnkey farm, Dürr contributes vast know-how from plant manufacturing – especially in ventilation and climate technology for paint shops – alongside proven international project management. Dürr’s intelligent software from the DXQ product family is also part of the project scope and is constantly being developed further. For its part, CAN-Agri, Dürr’s partner, provides extensive agricultural expertise and innovative cultivation technologies. The company operates its own vertical farm in Pretoria, South Africa, where it uses the grow tubes. The facility also functions as a research and development center, enabling CAN-Agri to collect empirical data and refine its processes and technologies.

In addition to a classic production layout with wet coating, the partners have developed a concept factory with dry coating and the new Z-folder technology: "Our concept factory, and in particular the dry coating process, represent the next generation of battery cell production. Thanks to powerful and innovative technologies, production requires 50 percent less space and energy. For our customers, this means significantly higher space efficiency and lower operating costs," explains Dr. Jochen Weyrauch, CEO of Dürr AG.

Efficient and sustainable dry coating 

Instead of conventional slurry, the Activated Dry Electrode® process uses a dry-mixed active material. This powder mixture is pressed into a free-standing film using calender machines, which is then laminated onto both sides of the collector foil. Compared to wet coating, this eliminates the drying process as well as the recovery and treatment of solvents – saving space, energy, and costs.

The free-standing film also offers advantages in terms of material efficiency, as excess film material can be completely returned to the production process before lamination onto the collector foil. After calendering, the coat weight can be measured directly, enabling better control of the coating thickness. The subsequent lamination onto the collector foil requires less force than calendering in the wet coating process, which means that the foil does not deform – improving its processability for downstream notching and stacking.

High-speed cell assembly 

With the new generation of Z-folders, which integrate the notching process, GROB achieves higher performance with less space. For particularly stable and reliable system technology, the separator is guided over a few deflection rollers with very even and low web tension. Thanks to a high-quality magazine buffer system for the electrodes, the system achieves 95 percent availability. 

Precise electrolyte filling with high pressure 

A process developed by Dürr enables battery cells to be filled in a single step without residual gas. Unlike the conventional process, the electrolyte is filled directly into the cells at up to 30 bar. The filling pressure is thus two to three times higher than the current industry standard. The process design enables precise dosing and shortens both the filling process and the subsequent penetration of the electrolyte into the active material. 

End-to-end digitalization 

The equipment technology from Dürr and GROB is complemented by end-to-end digital mapping of the production process. Even in the planning phase before production starts, a digital twin enables simulation of the entire factory and speeds up implementation on site. The data from the simulation flows into the MES/MOM software of Dürr’s subsidiary iTAC, which can be used to control and plan all production steps in battery manufacturing. Important functions here are traceability and quality analysis to avoid errors in production. This results in high overall equipment effectiveness.

Innovations in wet coating 

Dürr has also further optimized its technologies in terms of performance and energy efficiency in the classic wet coating process. One example is the automation of the coating station and the slot dies, which form a closed control loop for the layer thickness – resulting in faster production start-up and reduced scrap rate.

In the subsequent drying process, battery manufacturers can use laser dryers to achieve a 50% faster web speed and particularly energy-efficient drying. After drying, the electrode coating is densified using calendering machines. The machines from Dürr’s subsidiary Ingecal work with particular precision using “Dynamic Gap Control”: two sensors measure the distance between the two rollers with an accuracy of 0.5 µm. This results in a very uniform layer thickness, with no more force being applied than necessary. Dürr Ingecal's calenders are used for both wet coating and dry coating to compress the film.

At the Battery Show Europe 2025 from June 3 to 5, Dürr and GROB will be presenting their concept factory as a physical 3D model, along with other technologies from the field of battery production, at their joint booth E50 in Hall 10 of the Stuttgart Exhibition Center. 

Dürr will be appearing with a new name concept for the first time. Dürr is bringing together its products for electrode coating and electrolyte filling under the new name “X.Cellify.” 

Latest robot generation for painting process 
The plant’s painting lines are equipped with Dürr's EcoRP series robots in both 6-axis and 7-axis models, automating interior and exterior painting in coordination with handling robots. The 7-axis robot also assists with opening the hoods, while the 6-axis robot efficiently paints the exterior of the vehicles.

Innovative technology drives sustainable production 
BYD has adopted Dürr's EcoBell3 high-speed rotary atomizer to ensure flawless painting quality with uniform shade, flow, and layer thickness. In combination with advanced environmental and color-changing technology, the atomizer family enables fast color changes and reduces energy consumption.

The integration of the standardized and modular EcoSupply P special paint system from Dürr will further increase efficiency. The piggable system returns paint residue to the container, leaving no residue. This significantly reduces both paint and solvent residue.

For BYD's various EV models, Dürr has customized flexible-action feather rollers cleaning robots to efficiently remove dust and dirt particles from complex body surfaces. 

Globalized expertise supporting Chinese automakers abroad 
With 139 subsidiaries in 33 countries, Dürr leverages its global project experience and localized networks across Europe, Southeast Asia, and South America to provide comprehensive support for Chinese automakers in their international expansion.  Dürr’s expertise in local regulations, engineering design, equipment manufacturing, and intelligent control ensures efficient project execution, helping Chinese automotive companies establish a strong overseas presence. 

Cathodic electrocoating: flexible, compact, and scalable 

After pretreatment, the bodies are conveyed to the cathodic electrocoating system. This process ensures that a seamless primer coat is applied to the body’s surfaces, providing corrosion protection and serving as an adhesive base for future topcoats. In contrast to conventional PT/EC systems, EcoProWet is the only system on the market that is scalable and sets new standards in terms of space requirements, sustainability, and investment costs. 

The innovative design of the EcoProWet EC system features individual compact basins instead of continuous systems filled with paint. Two independently controllable pendulum towers lift the car bodies from the roller conveyor and gently guide them into the bath. With an immersion angle of up to 60 degrees, automakers can customize the immersion process for different models. Each dip tank supports up to ten units per hour. During the three- to five-minute dip, the paint is energized, forming a thin even coating on the body surface. 

The EcoProWet system is ideal for small to medium production capacities. Its modular design allows for staged expansion from 7.5 to 30 units per hour without significant operational disruptions. This enables automotive manufacturers to scale the system according to their production needs, reducing paint and operating costs compared to continuous systems. Additionally, it minimizes the space required for a paint shop while allowing for a flexible layout. 

All-in-one solution

The EcoProBooth, combined with the EcoBell4 Pro generation, enables both vehicle interiors and exteriors to be painted in the same booth using either solvent- or water-based paints. The universal atomizers generate narrow jets for the interior and wide jets for the exterior, including the use of metallic paints. This eliminates the need to move car bodies between spray booths, which saves time. Tasks are distributed effectively, allowing idle robots to undergo cleaning or maintenance without production downtime. For this, robots can move to integrated service cubicles located in each corner of the spray booth. 

Maximum production and energy efficiency 

The booth size accommodates all car types, from compact models to SUVs. Instead of a traditional linear layout with fixed cycle times, the painting boxes are arranged in a parallel production layout such as Dürr’s "paint shop of the future". This allows for flexible tact times and maximum efficiency. Additionally, EcoProBooth achieves a 95% air recirculation rate, using only 5% fresh air—minimizing energy consumption and CO₂ emissions. In total, it reduces energy use by up to 80% compared to wet scrubbers in classic lines and by 45% compared to conventional dry scrubbers in line. 

The 5th annual PACE Pilot program was presented by Automotive News. The competition was open to suppliers and startups that invented products, software/IT systems or processes and idea incubators that have the capacity to transform the automotive industry. The Automotive News PACE Pilot program is leading the way in distinguishing global emerging innovators. 

Energy efficient and economical

Oxi.X RE systems purify the solvent-laden exhaust air from production processes by oxidizing nearly all organic substances at temperatures between 800°C and 900°C. Despite these high temperatures, the system uses minimal primary energy due to its integrated regenerative heat exchanger, which preheats inflowing exhaust air to nearly 800°C using energy from previously purified exhaust air. Once the Oxi.X RE reaches operating temperature, it runs autothermally (i.e., without the need for gas or heating oil), even with a very low solvent load. This not only reduces energy costs but also makes the air pollution control system extremely economical and productive.

Technically, this efficiency is achieved through special ceramic honeycomb bodies in the heat exchanger, which can store and transfer substantial heat thanks to their high thermal conductivity and large surface area. The design enables the process to be highly energy-efficient recovering over 96% of the energy required to operate the system through the integrated heat exchanger, meaning that only around 4% needs to be supplied externally. The newly installed Oxi.X RE also leverages the solvent energy from the exhaust air to heat the thermal oil for the ovens, thereby covering the heat supply for the production plant. This approach positively impacts Orafol’s carbon footprint.

Turnkey complete solution

Orafol operates thirteen air pollution control systems, in its roughly 280,000 m² headquarters, including nine Oxi.X RE systems from Dürr. “Our long-standing cooperation, which also includes service, replacement, and modification, ensures that Dürr’s team understands our requirements well and provides tailored technology that enables us to achieve exhaust air purification results significantly higher than legally required,” explains Marcel Janßen, Senior Vice President Engineering & Technology at the Orafol Group. “Efficient and even productive energy recovery is a crucial component in the sustainable development of our high-performance production infrastructure.” The new RTO system was delivered as a turnkey project, encompassing development, design, production, installation, and commissioning. It included all associated piping and air duct systems between the air pollution control and coating systems, as well as a boiler for generating process steam from the excess heat.

New heat management system increases operational reliability

The new RTO is Dürr’s largest installation for Orafol to date. Previously, two large coating systems were connected to a common air pollution control system – now it’s three. A key innovation is the advanced energy management system, which includes two specialized modules: XtraBalance equalizes temperature differences between the three RTO media chambers packed with ceramic heat exchange material. XtraControl establishes an overall “average system temperature” and monitors it through multiple sensors in the heat exchange tanks and combustion chamber, using the data to control the system. Together, these modules ensure reliable and trouble-free operation, high system availability, and uniform conversion of released energy into usable thermal energy for production. This further reduces operating costs and enhances resilience, even under highly fluctuating operating conditions.

Over the many years of successful collaboration, Dürr has precisely and efficiently adapted and optimized its technology to Orafol’s specific needs and operating conditions. Looking ahead, Dürr has already planned for an additional Oxi.X RE system for purifying the exhaust air from the coating systems as part of Orafol’s production hall expansion.

Energy savings through a flexible control window 

Smart AC calculates an energy-optimized range for temperature and humidity based on the specific system and the local climate conditions. The minimum and maximum values define the setpoint range, which is displayed to the system operator as a ‘control window.’ The larger the window, the less energy is required to control the heating, cooling, and water input. Traditionally, supply air systems have been set to fixed setpoint values that maintain safe margin from critical limits for the paint application, often leading to unnecessary heating or cooling. “Our digital solution, with its optimized control strategy, enables precise and efficient regulation of supply air systems within a defined range,” explains Jens Häcker. “Instead of conditioning air to a fixed temperature, such as of 23°C, the system can flexibly adjust between 21°C and 25°C. This reduces consumption while maintaining consistently high coating quality”

An intuitive user interface provides operators with real time insights into all relevant data, ensuring end-to-end process transparency. The overview displays current consumption values of the conditioning modules, setpoint values and trends for booth conditions, control options, and a detailed comparison energy consumption between window control compared to the previous point control method. The impact is illustrated with the following example: An air supply system for base coat and clear coat lines with a capacity of 350,000 m3/h operates with 80% recirculated air, and 30% of the days require a rapid adjustments due to weather fluctuations. Regardless of the location, annual energy costs using the flexible window approach were approximately 30,000 euros lower. The warmer and more humid the climate, and the higher the energy cost, the greater the potential savings.

Advanced Analytics Smart AC is a new module of the DXQequipment.analytics software developed by Dürr for acquiring, evaluating, and visualizing robot and process data. To support more sustainable operation of supply air systems, Smart AC can be integrated into both new and existing systems.

Last year, Dürr and GROB expanded their machine and system portfolios for the production of battery cells and made them more efficient. Process steps previously covered by Manz can be taken over by the two remaining partners.

The strategic cooperation focuses on the automotive sector and the market for stationary battery storage systems, which are experiencing a significant increase in demand. Stationary storage systems absorb surplus energy from solar and wind power so that fluctuations in the electricity supply can be balanced out. They also serve as home storage solutions for solar power from private systems.

The strategic cooperation focuses on the automotive sector and the market for stationary battery storage systems, which are experiencing a significant increase in demand. Stationary storage systems absorb surplus energy from solar and wind power so that fluctuations in the electricity supply can be balanced out. They also serve as home storage solutions for solar power from private systems.

Lower consumption of energy and raw materials

The cooperation between Dürr and GROB aims to minimize energy consumption in cell production and increase the quality of the battery cells produced. “We achieve this, on the one hand, through the high availability of our automated machines and systems and, on the other, through a consistent digitalization concept that allows our customers to monitor all production steps,” explains Dr. Jochen Weyrauch, CEO of Dürr AG.

In December, Dürr received a major order from the Italian battery manufacturer FIB and will install a turnkey system for electrode coating at the plant in Teverola near Naples. The plant is designed for the production of lithium-ion battery cells with a total output of 8 gigawatt hours per year.

The cooperation partners are already implementing their first projects together. For example, Dürr and GROB are supplying a European cell manufacturer with machines for the production of high-performance battery cells. Dürr is installing systems for the conventional wet coating of electrodes, which corresponds to the current state of the art,  and is planning a pilot system for efficient and sustainable dry coating. GROB supplies the complete cell assembly based on innovative lamination technology, which enables a significant increase in production speed and therefore low manufacturing costs.

“The Dürr-GROB cooperation stands for the highest quality and reliability in mechanical and plant engineering. Our systems verifiably meet the requirements and specifications of battery cell producers worldwide,” says German Wankmiller, CEO of the GROB Group. GROB is working with several well-known cell manufacturers on the development of production systems.

The expanded collaboration with Cellforce, a subsidiary of sports car manufacturer Porsche, focuses on integrating LiCAP's patented Activated Dry Electrode^® technology into Cellforce’s battery production line. Combined with Dürr's expertise in electrode coating, this marks a significant step toward an innovative overall approach to industrial-scale dry electrode coating.

LiCAP's Activated Dry Electrode^® technology is pivotal, improving battery performance while minimizing environmental impact. By eliminating toxic solvents and energy-intensive drying ovens, it significantly reduces energy consumption, shortens process times, and CO₂ emissions by roughly one ton per 10 kilowatt hours of electrode capacity produced.

Cellforce recently licensed LiCAP's Activated Dry Electrode^® technology, marking an important milestone in the potential scaling up this revolutionary process. Dürr has already commissioned a gigawatt-scale proof-of-concept cathode line in Chassieu, France. "By collaborating with LiCAP, Dürr is broadening its dry coating solutions to support customers like Cellforce in adopting this innovative dry electrode production process," said Bernhard Bruhn, Vice President Global Business LIB.

“The maskless application of paint for two-tone and graphics takes collaboration,” said Hadi Awada, President, Global Mobility Coatings, Axalta. “Through our partnership with Dürr, we can better serve OEM customers, building on Axalta’s coatings know-how and Dürr’s robotics integration. Together we are driving the future of digital paint technology.”

Dr. Lars Friedrich, CEO, Dürr Systems AG, added “We are excited to collaborate with Axalta on the next generation of digital paint. As a pioneer in the field of overspray-free application, Dürr understands the requirements that OEMs demand for individual designs on their vehicles. This agreement will enable our joint technology to come faster to market and meet the needs of our customers.”

This partnership leverages the digital paint expertise Axalta and Dürr have each cultivated over recent years. In 2023, Axalta and Xaar announced their digital paint partnership that brought their unique capabilities together to offer solutions to light vehicle OEMs. Xaar will continue to be an integral part of the digital paint solutions that Axalta and Dürr will offer to the OEM market.

Demonstrations with Axalta NextJet™ on Dürr robotics have already begun at Dürr’s test center in Bietigheim-Bissingen, Germany. OEMs can reach out to their Dürr or Axalta representative for more information.

Latest robot generation for painting process
The painting lines will use Dürr’s latest EcoRP series painting robot, available in both six- and seven-axis variants for interior and exterior painting. The seven-axis robot offers high precision and flexibility for interior painting, reaching even the most difficult to access areas. Six-axis robots will handle exterior painting. The scope of supply also includes the corresponding door, lid, and flap openers as additional aids for the painting process.

Sustainable paint application
EcoBell3 high-speed rotary atomizers ensure flawless painting quality with uniform shade, flow, and layer thickness. When combined with the associated cleaning equipment and color change technology, the atomizer family minimizes paint and solvent consumption and enables fast color changes within the cycle time. In future, BYD will also be able to sustainably implement customers' special color requests using Dürr's standardized, modular EcoSupply P paint supply system with pigging technology. The ”pigs” – which are what the fitting bodies matched exactly to the internal diameter of the hoses are called – push paint to the color changer and return any leftover paint back into the paint container, leaving absolutely no trace of residue and eliminating the need for cleaning. This process reduces both paint and the rinsing agent consumption, benefiting both budget and the environment.

Automated body cleaning
The supply scope also includes cleaning robots that remove dust and dirt particles from the bodies before painting. Flexible-action feather rollers clean different body shapes efficiently and independently of each other in nearly any combination and order – ideal for BYD’s various NEV types.