Manufacturing Sustainability: Green Manufacturing News


Porsche Builds New Paint Shop with Latest Environmental Technology

posted by Wendy Stott
Published: November 05, 2009

Porsche's factory in Stuttgart-Zuffenhausen where the 911 and Boxster are assembled will soon be upgraded with a new paint shop that promises to be one of the most modern and environmentally clean in the world when it opens in 2011.

Porsche AG has announced it is expanding its automobile production at the main factory in Stuttgart-Zuffenhausen to include one of the most modern and environmentally-friendly paint shops in the world that will significantly reduce overall emissions of this notoriously problematic industrial process and still result in a more superior paint finish on the cars going through it.

The factory at Zuffenhausen is where Porsche builds all its 911 and Boxsters sports cars.

The outer skeleton structure of the new paint shop has already taken shape, with the steel supports set to be completed in early 2010, and the entire facility is scheduled to be operational by 2011.

The paint shop will be run on two-shift-operation with a daily capacity of up to 170 911 and Boxster models at the Zuffenhausen facility. The latest environmentally sensitive technologies are being used during the new construction process as well as for the painting operation. For example, the painting process will feature complete dust protection with 100 percent encapsulation. 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 unique electrostatic precipitator for paint dust will further cut the emission of solvents and particles to a minimum. The painting process is able to coat the cars without the mandatory 195-foot-high exhaust smokestack usually required to dissipate paint dust exhaust. 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 33 feet above the roof.

Another environmentally-friendly innovation for the shop is a highly efficient energy management system.

"With the new paint shop, Porsche is ensuring that it will deliver surpassing quality in Zuffenhausen today and tomorrow - while also conserving resources in an exceptionally ecological and economical manner," explains Wolfgang Leimgruber, Member of the Executive Board for Production and Logistics, Porsche AG.

Porsche is relying on regional specialists for these technical innovations.

The Stuttgart-based 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.

"Porsche will have one of the most modern paint shops in the world that will initiate new potential for quality and productivity, thereby setting new standards," explains Ralf Dieter, Chairman of the Executive Board at Durr AG.

The pretreatment system and cathodic paint dipping system with novel conveyor technology and the electrostatic separator for paint particles will be supplied by the Boblingen system provider, Eisenmann, a sub-supplier of Durr AG.

With a comprehensive wastewater treatment facility, this environmentally-friendly technology enables effluent levels that are many times less than legal limits.

"Porsche is the first automobile manufacturer in the world to use this technology," explains Dr. Matthias von Krauland, spokesperson for the Executive Board of Eisenmann AG.