New paint technique at VW reducing hazardous waste

VOLKSWAGEN in Uitenhage is the first paint shop in the Volkswagen Group to introduce a revolutionary new paint technique.

The water-borne paint technique has resulted in a reduction in hazardous waste and dramatic improvement in painting efficiency levels. The painting of cars at the Uitenhage factory has only ever been done with solvent-borne paint.

The paint shop project, which had become a benchmark in the entire Volkswagen Group production network, converted the painting technique to 100% electrostatic, called the Bell Bell process, VWSA paint shop head Nico Serfontein said.

"There are two different application processes, one for uni- base colours [for example red, white and black] and a second for metallic colours [for example silver or shadow blue].

"The first application process employed in base coat station 1 is used for all colours, uni-base and metallic, and is referred to as an Esta or Bell application.

"The second, more conventional application process, is used in base coat station 2, where only metallic cars are painted for a second coat.

"This system works on the same principles as a manual spray gun, except that a double gun configuration is mounted at the end of a robot arm. It is referred to as a spraymate system," he said.

Paint usage has been reduced by as much as 50% at the robot station, where modifications are made and currently half a litre of paint less is being used than before. Less compressed air is also used, which results in increased energy efficiency.

With the Bell Bell painting process, the application is a lot softer. Over-spraying is lessened, resulting in fewer chemicals in the washout area, which in turn has lowered the volatile organic compound emissions.

"This advanced technology is in line with the Volkswagen Group's Think Blue.Factory strategy, which aims to reduce the environmental impact by 25% per car produced," managing director David Powels said. - Business Reporter