With its efficient and resource-conserving technologies, the paint shop at the site in Győr sets new standards; it is one of the most environmentally friendly automobile paint shops in the world. When developed to full capacity, 250 employees and 80 robots will work here – the latter primarily in the paint cabins and PVC area, where underbody sealant is applied.
The paint is conveyed to the robots along pipes from the tanks in the so-called paint mixing room. There are 26 standard colors of base coat. Towards the end of the year, the special paint shop will go into operation in a separate building; it will be responsible for the individualized paintwork that Audi customers can order.
An important innovation in the paint shop in Győr is the dry separation in the air recirculation system. It cleans the air by removing paint particles. The proportion of recirculated air is 80 to 90 percent; this saves more than 50 percent of the energy required for heating and cooling and humidity regulation. In all paint cabins – for filler, base coat and final coat – a dry separator is integrated into the process for the paint mist that is not deposited onto the car bodies. The air stream carries this overspray out of the cabins; in a separate room it passes through powdered stone and is deposited there. The filtered clean air flows back into the recirculated air. The used powdered stone can be reused in the cement industry.
There is another innovation between the colored base coat and the clear varnish: The interim dryer works with extremely dry air instead of with the usual infrared radiation. To enhance quality, the final coat, which protects the bodywork from scratches and environmental influences such as acids and ultraviolet radiation, is the only paint that is not water based. An additionally installed special system cleans the waste air from the paint cabins to remove solvents: An absorption wheel conveys them into a carrier medium which stores them; they are blown out with hot air and then burnt in a thermic processing plant. With this additional cleaning of waste air, emissions of solvents can be reduced by more than 70 percent.
At the finish line, the final station, LEDs fitted in tubes illuminate the car bodies indirectly – extremely evenly and with a maximum degree of energy efficiency.