Dürr is building a turnkey paint shop for Volkswagen Autoeuropa while simultaneously implementing a comprehensive software solution. The project combines advanced application and drying technologies designed to maximise CO₂ reduction with an innovative SCADA integration that will unify three separate paint shops into a single system.
In 2024, Volkswagen Autoeuropa produced 236,100 vehicles at its facility in Palmela, Portugal – an average of 955 vehicles per day. The plant is now preparing for future model launches with the addition of a new paint shop and advanced process optimisation software.
Resource-efficient painting with EcoBell4 Pro
Volkswagen Autoeuropa will use the EcoBell4 Pro Hu with 2x2K technology for its clear-coat process. The company selected the 2x2K variant because it enables the application of both glossy and matte clear coats using a single applicator, while minimising rinsing-agent consumption during product changes.
The high-speed rotary atomiser operates according to Dürr’s High Transfer Efficiency (HTE) principle, achieving application efficiencies of up to 90%. HTE-optimised operating parameters, combined with a specialised bell disc and shaping air ring system, allow for lower rotational speeds, shorter painting distances and a 30% reduction in shaping air consumption. This reduces the amount of clear coat required per vehicle body. At the same time, lower overspray reduces the demand for air treatment, generating additional energy savings.
Low-energy intelligent drying
Vehicle bodies are dried using the electrically heated EcoSmartCure system. The straight-through oven features a stop-and-go operating concept that provides targeted heating – particularly for electric vehicles – and reduces energy consumption through demand-based temperature control. The result is shorter drying times and lower CO₂ emissions.
Centralised SCADA system for three paint shops
Alongside the plant engineering project, Dürr is implementing a modern, future-ready software architecture. Its DXQcontrol platform will connect the new paint shop and two existing facilities – the main paint shop and the separate two-tone roof-painting system – within a single SCADA environment.
The integration presents significant challenges, as it involves migrating third-party software while simultaneously upgrading an outdated control system to the latest generation of DXQcontrol.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,” said Felix Losch, Senior Manager Digital Products at Dürr. “However, this integration delivers the greatest value for the customer: one system instead of three, one user interface instead of multiple platforms, and complete transparency across all processes. This not only reduces 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, work platforms and internal conveyor systems. As the 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,” said 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 be executed in three phases and is scheduled for completion by mid-2027.