Dürr has got a major contract from Volkswagen Autoeuropa to build a next-generation paint shop in Portugal, combining advanced low-carbon painting technologies with a plant-wide digital control platform designed to boost efficiency and cut emissions.
The project, underway at Volkswagen Autoeuropa's Palmela facility, comes as the automaker prepares for future vehicle launches. The factory produced 236,100 vehicles in 2024—an average of 955 vehicles per day—and is now investing in new manufacturing capabilities to support its next generation of models.
At the heart of the new paint shop is Dürr's EcoBell4 Pro Hu application technology, which Volkswagen Autoeuropa selected for its ability to apply both glossy and matte clear coats using a single applicator. The system's 2x2K technology reduces rinsing agent consumption during product changes while maximizing paint efficiency.
The high-speed rotary atomizer operates using Dürr's High Transfer Efficiency (HTE) principle, achieving application efficiencies of up to 90%. Optimized operating parameters, combined with a specialized bell disc and shaping air ring system, reduce rotational speeds, shorten painting distances and cut shaping air consumption by 30%.
The result is lower paint usage, reduced overspray and additional energy savings through lower air-treatment requirements.
The paint shop will also feature Dürr's electrically heated EcoSmartCure drying system. Designed with a stop-and-go operating concept, the oven delivers targeted heating, particularly for electric vehicles, while demand-based temperature control reduces energy consumption. The system is expected to shorten drying times and lower CO2 emissions.
Alongside the physical installation, Dürr is implementing a comprehensive software modernization program that will connect three separate paint facilities into a single supervisory control and data acquisition (SCADA) environment.
The new DXQcontrol platform will integrate the new paint shop with the plant's existing main paint system and dedicated two-tone roof-painting facility. The project involves both migrating third-party software and upgrading legacy systems to the latest DXQcontrol generation.
“With the cross-plant software solution, we are bringing together three separate paint shops with different technological baselines – an extremely complex task,” says Felix Losch, Senior Manager Digital Products at Dürr.
“But it is precisely this integration that adds the greatest value for the customer: One system instead of three, one user interface instead of multiple platforms, and full transparency across all processes. This not only cuts costs but also makes production significantly more flexible and efficient.”
Beyond the paint process itself, the turnkey package includes an offline measurement cell, a paint mixing room, work platforms and internal conveyor systems. As general contractor, Dürr is overseeing all project activities and coordinating every stage of the build.
“The launch of the paint shop project coincides with the market introduction of a new model, requiring precise planning and close coordination across all construction phases,” explains Marcus Treppschuh, Senior Vice President Sales & Marketing at Dürr.
“Drawing on our experience from numerous turnkey projects, we will reliably deliver on this commitment and provide Volkswagen Autoeuropa with a paint shop that sets new benchmarks both technologically and environmentally.”
The project will be executed in three phases and is scheduled for completion by mid-2027.
