Audi's new paint shop facility focuses on efficient and sustainable processes, supporting both combustion and electric vehicle production.
Audi has inaugurated a cutting-edge primer facility at its Neckarsulm plant (Germany), marking a significant step towards more sustainable and efficient production processes. This new facility, designed to accommodate both combustion and electric vehicles, reflects Audi's commitment to innovation and environmental responsibility.
“With the investment in the new facility, Audi is setting the course for continuing its journey towards e-mobility and aligning the Neckarsulm site for a sustainable future. The construction project is an important milestone in the plant’s development and part of a future-proof infrastructure for production,” has stated Fred Schulze, Plant Manager at the Neckarsulm site.
The new paint shop facility covers 12,000 m2 and will handle the primer application for all models produced at the Neckarsulm site, as well as the nearby Böllinger Höfe facility. This includes the Audi A5, the upcoming A7, Audi Sport models, and various all-electric vehicles.
“With the refurbished paint shop, we have one of the most advanced facilities in the automotive industry with modern working conditions. This investment underlines our commitment to sustainability and ensures the future viability of our site,” has commented Rainer Schirmer, Chairman of the Works Council.
Innovative Technologies for Corrosion Protection
Audi’s new facility incorporates the latest in corrosion protection techniques, including E-coating. This process immerses vehicle bodies upside down, ensuring better coverage and minimising dirt deposits. A new transverse drying process also makes the cathodic dip coating more energy-efficient, ideal for electric and hybrid vehicles requiring longer drying times.
The facility introduces a revolutionary thin-film pre-treatment process, replacing the traditional phosphating method. This new technique applies a 0.2-micrometer-thin layer of zirconium and silicon compounds, offering corrosion protection and serving as a primer base. The process significantly reduces waste, water, and energy usage, contributing to Audi’s Mission environmental program.
“The innovative thin-film technology in pre-treatment, combined with the new cross-drying process, makes a special contribution to the efficiency and sustainability of the new primer facility. This allows us to significantly reduce our electricity and water requirements and make an important overall contribution to our Mission: Zero environmental program,” has added Ursula Noll, Head of Production Planning Paint Shop Corrosion Protection.
Energy Savings in Top Coat Application
The A22 primer building is connected to the top coat facility via a newly constructed bridge. The top coat facility itself has undergone major restructuring, achieving energy savings of 50 kilowatt/hours per vehicle
by switching to a dry paint separation process. This new method, which captures paint mist with filters instead of water, allows for the reuse of over 90% of the filtered air, reducing the need for energy-intensive fresh air conditioning.
Moreover, Audi has eliminated the need for a separate filler drying stage by introducing a pre-zone paint process - further reducing energy consumption by up to 140 kilowatt/hours per vehicle.