BMW Group has inaugurated its state-of-the-art paint shop at the new Debrecen plant in Hungary, marking a significant milestone in sustainable automotive production. As the first in the BMW Group’s global network to operate entirely without fossil fuels, the facility showcases advanced technologies aimed at reducing the environmental impact of car manufacturing.
The paint shop, covering 33,000 square meters, is designed to process 30 vehicle bodies per hour, with the capacity to increase significantly in the future. It will initially utilize BMW iX1 bodies, employing cutting-edge systems developed within BMW’s production network.
This facility is part of BMW’s broader commitment to sustainable production, aligned with the principles of the BMW iFACTORY, which guides the company’s future plant designs.
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Innovative Technologies Power Sustainability
Key to the paint shop’s eco-friendly operations is the power-to-heat system, which replaces natural gas with electricity for all heating processes, dramatically cutting the facility’s carbon footprint. The electricity required for these operations is sourced entirely from renewable energy, reinforcing BMW’s commitment to sustainability.
Another innovative feature is the Heat Grid project, which enables up to ten percent energy savings by recovering waste heat from various processes. This heat is used to preheat water, which then supplies the plant’s ventilation systems. Remarkably, the system operates at a reduced water supply temperature of 65 degrees Celsius, compared to the 90-120 degrees typically required, contributing to further energy efficiency.
Advanced Exhaust Purification and Digitalisation
The Debrecen paint shop also employs an advanced eRTO (electric regenerative thermal oxidation) process for exhaust purification. This process cleans exhaust air at high temperatures using electricity, retaining heat within the system for enhanced energy efficiency.
Environmental considerations extend to the dry separation technology used in the spray booths, which filters out overspray and mixes it with limestone powder, significantly reducing water consumption. This method also allows up to 90 percent of the air to be recirculated, cutting down on the energy needed to control temperature and humidity.
Comprehensive digitalisation underpins the efficiency of the new plant, with Automated Guided Vehicles (AGVs) transporting car bodies, and Automated Surface Inspection (AOI) systems using AI to identify any imperfections post-painting. Virtual planning and training further streamlined the plant’s construction and preparation phases.
The Debrecen plant, where pre-series production of BMW’s Neue Klasse will begin later this year, sets a new standard for sustainable automotive production, providing a blueprint for future BMW facilities worldwide.
Source: BMW Group’s New Debrecen Plant Launches with Advanced Paint Shop Technology
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