From zero to 100 percent production within just four days
September 2012 – Despite limited space and a tight schedule, Dürr converted the water-borne paint line 2 to a two-component solvent-borne clear coat system at the BMW plant in Dingolfing. The EcoDryScrubber is used as part of this system.
It was the fourth time that this technology was installed at a German BMW plant. The German carmaker already uses the system in Leipzig and twice in Regensburg, thereby benefiting from substantial energy savings in paint application, which is by far the most energy-intensive manufacturing process in vehicle construction. The EcoDryScrubber works with recirculation of the booth process air. The dry separation of excess particles during paint application without the use of water in the paint booth allows for recirculation to take place. This ensures that the humidity remains stable and that, unlike conventional wet scrubbing, around 90 percent of the air supplied here is recirculated air. As a result, only a small part of the fresh air needs to be conditioned. This leads to a substantial reduction in energy consumption. The separation of the paint particles is also far more efficient than in wet scrubbing.
Due to the space restrictions at the Dingolfing plant, Dürr delivered 26 specially dimensioned filter modules. With just 28 filter elements each, they reliably separate the paint overspray from a supply air volume of more than 175,000 cubic meters per hour in two painting zones. Two silos with a capacity of more than 45 cubic meters each are used for the supply and removal of limestone powder to and from the paint booth.
The service team of Dürr’s Paint and Final Assembly Systems business unit (PFS-PSE) completed the modification project within just five weeks. Work started on May 25 and the plant was commissioned on June 18. The ramp-up phase, from zero to 100 percent production, was extremely short at just four days. The first-run rate is well above 95 percent. The schedule was ambitious from the start, as noted by Project Manager Joself Dull from the PFS service area. “Our experienced assembly team deserves huge credit: everything went like clockwork.”
Thorough planning was conducted beforehand in cooperation with the BMW Group, otherwise the project would not have been completed that quickly. Four weeks prior to the start, a new exhaust-air purification system and two silos had already been installed.