Portugal. The engineering company Dürr is building a new turnkey paint plant for Volkswagen Autoeuropa in Palmela, Portugal, a project that combines application, drying and digital integration technologies to reduce CO₂ emissions, improve energy efficiency and optimize plant operation.
The installation will accompany the launch of new models of the automaker and is part of its sustainable manufacturing strategy.
The new plant incorporates the EcoBell4 Pro applicator with 2x2K technology, capable of applying glossy and matte finishes with the same equipment. Thanks to the High Transfer Efficiency (HTE) principle, the system utilises up to 90% of the applied material, reducing paint waste, reducing energy consumption and optimising product changeovers.
In addition, the technology reduces forming air consumption by 30% and minimises excess paint, also reducing air treatment needs and contributing to greater energy efficiency in the process.
Another of the developments implemented is the EcoSmartCure drying system, which uses electric heating and stop-and-go operation to adapt energy consumption to the real production demand. According to Dürr, this solution is particularly suitable for the manufacture of electric vehicles, as it reduces process times and contributes to lower CO₂ emissions.
In the field of digitalisation, the project includes the implementation of the DXQcontrol software, which will integrate the new paint plant together with two other existing facilities into a single SCADA system: the main painting line and the independent two-tone ceiling painting system. The platform will replace different technological solutions with a single operation interface, improving process visibility and production flexibility.
"With the cross-plant software solution, we are integrating three independent paint plants with different technology bases, which is an extremely complex task. But it is precisely this integration that brings the greatest added value to the customer: a single system instead of three, a single user interface and full transparency in all processes," explained Felix Losch, Senior Manager Digital Products at Dürr.
The project also includes the installation of an offline measuring cell, a paint mixing room, work platforms and internal conveyor systems. As general contractor, Dürr will be responsible for the comprehensive execution of the work, which is scheduled to be completed by mid-2027.
Marcus Treppschuh, Senior Vice President Sales & Marketing at Dürr, stressed that the execution of the project must be aligned with the launch of a new Volkswagen Autoeuropa model, so planning and meeting deadlines will be key factors to ensure a successful start-up.
The Volkswagen Autoeuropa plant, located in Palmela, produced more than 236,100 vehicles during 2024, equivalent to an average of 955 units per day, consolidating itself as one of the main automotive production centers in Portugal. The new project seeks to strengthen this productive capacity through more efficient processes and with a smaller environmental footprint.
