First time installation of Dürr’s EcoDry X technology
Pune, March 2017 – “Today, we will set an example for the world: with boldness, with confidence and relentless optimism.” In accordance with this company manifesto Mahindra & Mahindra Limited keeps accomplishing its sustainable strategy for production facilities. Against this background the Indian based car manufacturer awarded Dürr to install an innovative and environmental friendly painting line in Pune, India. The new line includes the first time installation of Dürr’s EcoDry X cardboard filter box system for cost and energy efficient overspray separation.
Shortly after the start of production in November 2015, the plant was ramped up to its maximum annual capacity of 120,000 units. The scope of supply consisted of a painting line including spray booth, air handling equipment, oven and conveyor. In order to meet Mahindra’s goals of simplicity, reduction of resources and energy consumption as well as reduction of water footprint and paint sludge, the customer set a new standard for the top coat line. This has been done by choosing the latest Dürr Eco+Paintshop products such as Eco+Layout, EcoSmart AC and EcoDry X.
With the Eco+Layout it was possible to create a simplified and more compact building design by placing the spray booth air recirculation unit operator friendly on the ground floor. The add-on of the EcoSmart AC to the regular air conditioning control system in the spray booth air handling units optimizes the energy consumption during running production, especially during start-up times and extreme weather conditions. The improved control of the process window leads to major energy savings in cooling and heating, including reduction of CO2 emissions.
With the selection of the cardboard filter box system EcoDry X out of the Dürr dry separation family, Mahindra completely avoids coagulation chemicals and water in the overspray separation and thereby the resulting paint sludge. EcoDry X is a semi-automatic filter system, consisting of a filter trolley equipped with six filter boxes. The disposable cardboard filter boxes can be swiftly replaced with minimum effort using the filter trolleys – even during production, if necessary. The system is intentionally simple and robust and can be easily operated.
Customer expectations outperformed
With more than one year in operation, the performance of the cardboard filter boxes in their first application outperforms customer expectations towards handling and filter box consumption. The filter boxes of the EcoDry X set a benchmark in paint separation capacity and filter costs. This efficiency is based on the principle of the technology: No impact separation, but filtering, is the order of the day.
Further highlights are the EcoClean and the top coat heat exchanger. EcoClean is a feather duster unit at the beginning of the top coat line for the improvement of the exterior surface cleaning quality. The installed air-to-air heat exchanger at the exhaust duct of the top coat oven preheats – depending on the demand – the recirculated air to the air supply unit.
As provision for future sustainable technology, Mahindra designed the roof of the building for the installation of a solar-thermal oven pre-heating system, which will help the customer to reduce the heating energy and CO2 emission even further.
Due to the good and energy optimized performance of the new TC-Line, Mahindra awarded Dürr the contract to increase the capacity of the line to up to 120,000 units a year.