Innovative paint shop facilities at Porsche cuts emissions

The Porsche factory in Stuttgart, Germany, is expanding its innovative automobile production operations at the main factory in Zuffenhausen with one of the most modern and environmentally-friendly paint shops in the world, and one that will incorporate cutting-edge technology never before used in the car industry.

Work began a few weeks ago and the steel construction is set to be completed early 2010. This will be followed by the construction of the facade and technically complex internal facility structure. The new paint shop will be formally commissioned in 2011. The facility is being built directly adjacent to plant 1 and 5 on a property that previously belonged to Durr AG, which Porsche acquired in early 2008. The paint shop will be run on a two-shift-operation with a daily capacity of up to 170 Boxster and 911 vehicles.

The latest technologies, particularly in the area of environmental protection, are being used throughout the new building. The painting process features complete dust protection as it is encapsulated 100 per cent. This method not only enhances the already high quality of the vehicle paint coat, but also reduces the required amount of conditioned hall air required.

A particularly innovative electrostatic precipitator for paint dust cuts the emission of solvents and particles to a minimum. The painting process is able to do without the mandatory 60 metre-high chimney. This is attributed to the increased amount of circulated air and the exceptionally effective exhaust air purifier that only requires a small smokestack, which extends 10 metres over the roof. Another environmentally-friendly innovation is a highly efficient energy management system.

"With the new paint shop, Porsche is ensuring that it will deliver unsurpassed quality in Zuffenhausen today and tomorrow - while also conserving resources in an exceptionally ecological and economical manner," explained Wolfgang Leimgruber, head of Production and Logistics at Porsche.

Porsche is relying on specialists from the region for the technical undertaking. The Stuttgart Maschinen- und Anlagenbaukonzern Durr AG, as the general contractor, is equipping the painting lines with the latest application technology, driers for hardening the paint as well as control and conveyor technology.

The pre-treatment system and cathodic paint dipping system with novel conveyor technology and the electrostatic separator for paint particles will be supplied by the Boblingen company, Eisenmann, a sub-supplier of Durr AG. In combination with a comprehensive waste water treatment facility, the environmentally-friendly technology maintains emissions levels that are many times lower than the legal limits. Porsche will be the first automobile manufacturer in the world to use this technology.