The paint shop is by far the biggest energy thief in vehicle production. This stage in production accounts for 70 percent of a factory´s energy consumption, and it is the ovens and spray booths that consume the most. The problem is the large heated air flow, which is now kept at a constant level, regardless of whether there are bodies undergoing the paint process or not. The project Energy-efficient paint shop is finding a way to adapt the airflow to vehicle quantity.

The project is owned by Saab Automobile and the partners are Sweden´s other body-manufacturer, i.e. Volvo Cars, AB Volvo, Scania and Pininfarina. University West, Linköping University, Midroc Automation and Innovatum Technology Park are also involved in the project.

- The reasons why the project was started include the difficulties, that all body factories have, in maintaining a balance when trying to regulate the airflow in the paint shops in relation to load. “The air balance is extremely sensitive and no one has previously dared to experiment with this in a live situation before", says Lars Anger, project coordinator in production technology at Innovatum Technology Park.

But now experimental equipment is being installed in a spray booth as well as a drying oven for one of Saab Automobiles´ topcoat lines. Sensors will measure the airflow and air pressure. These sensors send signals to a control system which compares the input of bodies and controls the speed of the plant´s fans. In this way it should be possible to find a way to control the airflow based on the number of cars.

- The potential is a 25 percent reduction of the paint shop´s energy consumption. If we succeed then it represents both a financial saving and reduced environmental impact. “We also see the opportunity to spread the knowledge to other industries", says Lars Anger, project coordinator at Innovatum Technology Park.

The project, Energy-efficient paint shop, runs until the first quarter of 2012 and is financed by Vinnova.