Dürr creates state-of-the-art paint shop on the Indian market
Sanand, November 2015 – Fewer pollutants, lower cost per unit, higher paint finish quality: India's most modern painting line has begun operation at the new Ford Motor Company factory in Sanand. Dürr’s Eco+Paintshop sets new standards for the Indian market in terms of paint finish quality as well as eco-efficiency.
The core components in the new paint shop, inaugurated in March 2015, include not only pretreatment, cathodic electro-coating and fully automatic paint application, but also a high-performance pollution control system for reducing VOC emissions, a heat recovery system for oven heating, and highly efficient electrical pumps for paint circulation. Dürr's system and application technology was customized to the carmaker's specific requirements during planning. For example, the painting line in Sanand was designed on the basis of Ford's energy-efficient 3-wet-paint technology process. This is an automated painting process whereby three paint layers (primer, base coat and clear coat) are applied one after the other and then dried together in a subsequent step.
Despite the high temperatures and humidity typical of India, the EcoSmart AC air conditioning system offers precision and long-term stability. This reduces energy consumption by up to 30 percent while lowering production costs.
The innovative EcoSmart AC air conditioning system for incoming and recirculating air ensures optimum air management and thus contributes to the high-quality paint finish at Ford in Sanand. Despite the climatic challenges such as high temperatures and humidity, the air conditioning system ensures precision and long-term stability. This reduces energy consumption significantly by up to 30 percent while lowering production costs. The investment in EcoSmart AC will have paid off within a year.
Right from the beginning, the focus of the painting process at Ford Sanand has been on quality and performance: In pretreatment the white body is initially cleaned, phosphated and provided with a first even coating during the subsequent cathodic electro-coating (EC). Here Dürr uses its space-saving and energy-efficient Ecopaint RoDip M process, which requires no entry or exit ramps and thus shortens the length of the dip tanks by several meters.
Fully automated sealing plant
After the EC, the individual spot-welded seams of the primed car body are sealed in a Dürr sealing plant. At the same time an underbody sealant that protects the vehicle from stone-chipping and corrosion is applied here. This process is fully automated using eight standard Dürr EcoRS robots.
A total of 32 EcoRP L033 painting robots apply the primer, base and clear coats in three consecutive steps. All robots are equipped for this task with the proven EcoBell2 high speed rotating atomizer. Dürr’s EcoEMOS supervisory control system ensures the control and visualization of the entire production.
The final drying booth and the oven following the EC are equipped with Dürr’s exhaust-air purification system, Ecopure TAR. By means of downstream heat recovery systems, residual heat from the cleaned exhaust air is returned to the manufacturing process, leading to a further considerable reduction in the use of resources and in CO2 emissions. The CO2 reduction in Sanand is equivalent to the level generated during the combustion of 32,800 Nm³/year of natural gas.
Once 240,000 passenger cars have rolled off the assembly line at the new Ford factory in Sanand after a year has passed, the vehicles will have undergone a consistently resource-saving paint process of pretreatment, seam sealing, application technology and automation, right up to air pollution control.