www.durr.com

Ecopaint Booth EfficiEnt and sustainaBlE painting

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focus on EfficiEncy and sustainaBility

classical spray Booth for optimum application

and sustainability – this is the concept which rules all

Dürr products and innovations. To live up to it, we developed the , a paint shop

optimized for highest efficiency, which now is the benchmark in automotive paint finishing.

The is efficient in every aspect: optimized processes, fewer emissions, reduced energy consumption, less material used, and a flexible system with a space- saving layout – these criteria are of top priority for Dürr.

The paint booth is at the heart of the paint shop. Here, the painted surfaces get their finish – and it is the quality of the finish that

forms the impression of the quality of the product as a whole.

The spray booth as heart of the paint shop has a modular structure and easy to clean components and can be flexibly adapted to all requirements. The customer specifies process parameters such as structural cons-traints, space requirements, capacities, and cycle times. Based on this information, Dürr implements the spray booth with integrated appli-cation technology and conveyor system. With our in-depth knowledge of the processes involved based on decades of experience, we ensure optimum co-action of all components via standardized interfaces. This allows for fast assembly and smooth start of production and results in high first-run rates with optimized unit costs – not least due to early-stage testing of processes in realistic simulations of the painting pro-cesses. We guarantee this security for new installations as well as for retrofits or extensions of your existing lines.

for optimum application

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EcoreBooth – thE idEal paint Booth concEptpaint booth concept

With EcoReBooth, Dürr has completely transformed the paint booth. We integrate the ducts, the air conditioning and the air recirculation system in the booth cross-section below the spray booth. This is where the reliable EcoDryScrubber modules are located as well. In this way, all of the relevant components are arranged on one level. The building-independent concept is highly modular. The integrated process air system serving each booth unit separately allows for individual conditioning of each painting zone. These benefits are complemented by a small footprint and an excellent energy efficiency.

Because of the compact layout, a modular arrangement of the paint booth in a line without interfering contours is possible. In ideal cases, an entire building level (the pent-house) can be completely omitted thanks to the integrated process air technology. This makes the EcoReBooth perfect for retrofitting or refurbishment of existing painting facilities where limited space is available. The modular concept further more makes the conversion of existing facilities much easier.

This newly designed paint booth has already been proven and tested in practical use: The EcoReBooth is operating successfully on the shop floor of a reputable German OEM.

» EcoReBooth – compact and modular.

» All relevant components are arranged on one level.

EcoDryScrubber

Fan and air conditioning

Paint booth

Police filter

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one step ahead

In wet paint application, the efficiency depends on the degree of automation. But even with the most favorable scenario of automated exterior painting, up to 15 % of the paint does not end up on the car body. Dürr offers a number of innovative systems for resource-efficient separation of this paint overspray.

one goal – four routes

Ecodry X Ecodry B Ecodryscrubber EcoEnvirojet

sEparation systEm Dry separation Wet separation

charactEristics Simple, stable process Highest degree of separation Standard

paint aBsorption capacity + + ++ ++

Emissions 0,5 – 3,0 mg / Nm³ 0,5 – 3,0 mg / Nm³ < 0,1 mg / Nm³ < 3,0 mg / Nm³

prEssurE drop Increasing Increasing Constant Constant

opEration and maintEnancE Instructed personnel Instructed personnel Qualified personnel Qualified personnel

suitaBlE for Greenfield and Brownfield solutions

paint sEparation – onE stEp ahEad

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by dry separation

With this technology, Dürr revolutionized paint overspray separation. This system, used successfully all over the world, relies on dry separation with limestone powder as binding agent for the overspray. This system works without water and coagulation agents.

Furthermore, the EcoDryScrubber convinces with the following benefits: » Up to 60 % less energy consumption in the spray booth » Up to 95 % recirculated air » Stable processes practically unaffected by climatic changes » Constantly high painting quality » Limestone material as binding agent, readily available worldwide » Fully automated feed of limestone material » Re-use of the paint-saturated limestone powder

Ecodryscrubber – EfficiEncy By dry sEparation

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For facilities with small to medium overspray volumes, EcoDry X is the first choice. It is a multi-stage filter system with disposable paper filters that are extremely easy to replace. Filter replacement trolleys ensure fast filter change, if necessary also during ongoing production. When the filters are saturated, the replacement trolley is undocked manually and replaced by another trolley prepared with new filters. The saturated paper filters are then comfortably disposed of in containers at a well-ventilated preparation station.

» Successfully used for years in industrial series painting » Separation filters adapted specifically for automotive series painting » Low-cost, easy to operate technology » Suitable for greenfield and brownfield solutions » Quality of the filtered air equivalent to wet separation level » In many countries, the saturated paper filters may be disposed of as industrial waste

paint overspray separation

Ecodry X – thE intEntionally simplE and roBust paint ovErspray sEparation

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EcoDry B is a dry separation system for any volumes of overspray. The over-spray is caught by rotating brushes. Once it has dried, it is removed from the brushes by means of scrapers. What is more, EcoDry B works without any wa-ter, chemicals, or additives. Accordingly, this system can likewise be operated primarily with recirculated air, which reduces energy consumption and stabili-zes the painting process.

» Quality of the filtered air equivalent to wet separation level » For many years, the process has been used very successfully in industrial series painting

» Based on our many years of experience in paint separation, the design of this system has been improved for automotive painting

» Automated drying, cleaning, and pre-coating of the brushes » Disposal of almost pure paint » Extremely easy to operate technology for greenfield and brownfield solutions

without additives

Ecodry B – thE EXclusivE paint ovErspray sEparation without additivEs

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EcoEnvirojet – wEt sEparation with minimum dEsign hEight

Our constantly improved wet washing process is an excellent alternative to dry separation. Our EcoEnvirojet 3 system allows for high-end paint overspray separation with low noise level thanks to intelligent sound reflection. This technology convinces with its small paint build-up attributable to its superior flow properties.

» Extremely flat improved version EcoEnvirojet 3S » Perfect for applications with severe structural constraints due to low overall height

» Ideal for retrofit of existing lines » Good accessibility for cleaning and maintenance purposes » Time-proven individual components, combined in an intelligent overall system

The decision for the type of separation actually employed depends on various factors, such as the conditions on site, the degree of sustainability sought, or the scheduled line capacity.

with minimum design height

With a fluidized-bed process customized to the EcoDryScrubber, Dürr now makes recycling of the limestone possible – directly at the customerʼs site. In this oven, the saturated limestone is separated from the overspray in the paint shop ready for re-use. This on-site treatment can be repeated several times.

It is based on a simple principle: The process air extracted from the ambient environment by a fan is heated and used for direct heating of the oven. A temperature control ensures that only the paint is burned, leaving the pure limestone powder. The re-use of the limestone significantly reduces the supply and disposal logistics on site.

The fluidized-bed oven can easily be integrated in an existing dry separation system. Only the support concept is changed, the EcoDryScrubber itself is not affected. The oven can be started up fully independent of the operation of the system.

Our new conveyor system increases the capacity while improving the quality of the paint application. The system has been specifically designed for the stop-and-go operation in the paint booth. It uses the time-proven skid technology. The carrying and guiding functions are implemented by non-driven roller beds. The drive is provided by linear units arranged centrally.

The reduction of nonproductive times increases the capacity. With

limEstonE powdEr rEcycling for thE Ecodryscrubber

thE spEEdy paint stationThe speedy painT sTaTion

, Dürr manages to reduce the transfer time by 50 % from 16 to 8 seconds without interruption of the positive locking. The high positioning accuracy during application achieved in this way ensures superior quality. These benefits are further enhanced by the speedy color change in 8 seconds with AB technology.

A speedy paint station: the result of a combi-nation of various innovative Dürr technologies. A minor but attractive aspect is the reduced cleaning effort on the smaller footprint.

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Ecopaint airhandling –Ecopaint AirhAndling –

Dürrʼs performance is measured by the quality of the paint application and the perfection of the painted car body. One of the decisive factors for this per-fection is the optimum conditioning of the booth air. To this end, Dürr offers its customers innovative solutions for complete routing of the air flow around the booth.

complete routing of air flow with dürr products

supply and circulation air control For inlet and circulation air treatment, Dürr offers a new premium product: EcoSmart AC – the next generation of temperature and humidity control.

This new product for an optimum regulation of the supply and circulation of air systems creates the prerequisites for stable and energy-efficient operation of your facility. The setpoint value is adjusted fully automatically to the external conditions ten times per second, and the different variables are optimally coordinated. In this process, energy potentials which cancel each other are determined by software beforehand, and the individual setpoint values are output in an energetically optimized manner.

The system is very easy to configure: An intelligent process management allows for flexible adaptation of the system be-havior to the customerʼs preferences. This makes it possible to save time and money when configuring the conditioning process, and to minimize operating costs.

EcoSmart AC is not only designed for integration in new equipment but also for comfortable expanding of existing facilities, irrespective of whether these have been manufactured by Dürr or another supplier.

heat recovery

hot air saves energy Despite the increasing use of circulation air units in spray booths, made parti-cularly economical by our dry separation technologies, there is still a residual content of fresh outside air which needs to be put into the proper state for the process conditions.

EcoHeat Recovery – the Dürr heat recovery technology – uses the thermal ener-gy from the exhaust air to heat up the incoming outside air, thus reducing the

» EcoSmart AC

» EcoAir Supply

Process air conditioning for

the Ecopaint Booth

Concentratio

n

Exhaust air

Supp

ly air

Recirculated air

» Ecopure KPR-Rotor

» Ecopure RTO

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Ecopaint airhandling – good atmosphErE for top quality good atmosphere for top quality

energy consumption of the spray booth. Whether regenerative thermal wheels, recuperative plate heat exchangers, or a circulation system – we are offering the system solution which best matches the overall situation.

the environment breathes a sigh of relief

Exhaust air purification plants The painting process leaves traces in the air which – if untreated – may harm the environment. To protect the environment, the process air must be cleaned

before it is discharged to atmosphere.

Ecopure rto The Ecopure RTO is primarily intended for

exhaust air volume flows with pollutant concentrations of up to approx. 10 g / mN3.

Autothermic operation of the equipment is already possible starting from a

pollutant concentration of approx. 1.5 g / mN3. In this case, it is possible

to do totally without addi tional fuel. Regenerative thermal oxidation is indicated if heating of the process

exhaust air during cleaning is not desired or required. For the disposal of combustible, organic pollutants, oxidation is the most efficient method of exhaust air purification.

Ecopure Kpr – voc concentrator For high volume flows and low pol-

lutant concentrations, Ecopure KPR units are particularly efficient. Exhaust air

with a low content of pollutants is concentrated by means of adsorption via continuously rotating

rotor systems, which makes the purification of this air more economical. The KPR is characterized by its intelli-

gent modular design and optimum accessibility. Manufactured in-house by Dürr, the Ecopure KPR units offer excellent quality and high flexibility.

The above-listed products for the process air circuit are examples for Dürrʼs extensive expertise in respect of the regulation and purification of process air. Based on our many years of experience, we have the matching solution for every customer requirement.

Process air conditioning for

the Ecopaint Booth

Concentratio

n

Exhaust air

Supp

ly air

Recirculated air

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dürr – leading in production Efficiency

Four divisions, one goal: maximum production efficiency for our customers

» paint and assembly systems: Paint shops and final assembly plants for the automotive industry and aerospace construction » application technology: Robot and application technology for applying paint, adhesives and sealants » measuring and process systems: Balancing technology, cleaning and surface processing technology as well as testing, filling and assembly products

» clean technology systems: Exhaust air purification systems, energy efficiency technologies