Resource-efficient painting with the EcoBell4 Pro
Volskwagen Autoeuropa uses the EcoBell4 Pro Hu with 2x2K technology for its clear coat process. It specifically selected the 2x2K variant to enable the application of both glossy and matte clear coats using a single applicator, while also minimizing rinsing agent consumption during product changes. The high-speed rotary atomizer works according to the “High Transfer Efficiency” (HTE) principle developed by Dürr, achieving application efficiencies of up to 90 percent. The HTE-optimized operating parameters along with the specialized bell disc and shaping air ring system, enable a lower rotational speed, a shorter painting distance, and a 30 percent reduction in shaping air consumption. This results in less clear coat being used per body. At the same time, the reduced overspray lowers the demand for air treatment, resulting in additional energy savings.

Low-energy intelligent drying
Body drying is performed by an electrically heated EcoSmartCure system. The straight-through oven, designed with stop-and-go operating concept, provides targeted heating – particularly for electric vehicles – and reduces energy consumption through demand-based temperature control. The result is shorter drying times and reduced CO₂ emissions.

Centralized SCADA system for three paint shops
In parallel with the plant engineering, Dürr is implementing a modern, future-ready software architecture: DXQcontrol connects the new paint shop as well as two existing buildings – the main paint system and the separate two-tone system for roof painting – within a single, unified SCADA environment. The integration is challenging, because it involves both migrating third-party software and upgrading an outdated system to the latest generation of DXQcontrol. “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.” 

Precise planning for the model launch
The turnkey project also includes an offline measurement cell, a paint mixing room, as well as work platforms and internal conveyor systems. In its role as general contractor, Dürr is coordinating all trades and project activities. “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 run in three phases and is scheduled for completion by mid-2027.

The x-road curve supplied by Dürr is a multifunctional roll test stand, which is equipped with steerable roll sets on the front axle, allowing driving functions to be tested during cornering maneuvers and without vehicle restraint. In combination with the portal system and the simulation environment, the solution enables effectiveness tests to be carried out for the entire chain of sensors, actuators and controllers.

On May 21, a pre-opening event for KADAS was held at the KOTSA Sejong Vehicle Inspection Center with participants including representatives from the Ministry of Land, Infrastructure and Transport as well as other related organizations. Dürr Korea’s Managing Director Byungwook Lee stated at the event:“Through this project, we contribute to Vision Zero and ensure the safety of advanced driver assistance systems, which can now be tested for the first time during Periodic Technical Inspections in Korea.”

For future applications in Periodic Technical Inspections, Dürr is currently optimizing and integrating its x-road curve roll test stand, portal system, and a simulation environment into a single turnkey vehicle-in-the-loop testing setup. It is scheduled to be introduced by the end of this year.

Automation and flexibility are key requirements of the project. Dürr is setting up a highly flexible assembly system using automated line-side equipment – including AGVs, robotic arms, and tightening systems – along with intelligent marriage pallets and pallets storage systems. The new set up offers several benefits for production: it enhances assembly efficiency and production continuity, enables precise material supply, optimizes the working environment, and allows the production of multiple vehicle models. The system also meets the specific assembly requirements of electric commercial vehicles, achieving increased capacity and optimized cycle times within the existing workshop layout. In addition, to meet the sealing requirements of electric vehicles, Dürr has already successfully introduced robotic systems to upgrade sealing processes and added new glass dispensing stations, thereby improving sealing quality and consistency.

Within the Dürr Group, this project is led and coordinated by Dürr China, successfully bringing together expertise from specialized teams in conveying, dispensing, assembly, and filling technology. Despite a tight schedule and stringent standards, the team completed critical milestones during the National Day holiday, ensuring timely resumption of production for the customer and demonstrating Dürr’s comprehensive execution and integration capabilities in complex projects.

The modified production line is designed to enable the mass production of Mercedes-Benz’s new electric commercial vehicles. Li Jian, Project Manager of Dürr China’s Automotive Assembly Division, said: “We are honored to work with Fujian Benz on this modification. Dürr China is committed to supporting the automotive industry’s transition to smart and electric mobility, leveraging our innovative engineering and local service expertise.”

“It is impossible for anyone to predict today what source of energy will be available in plentiful supply and at a reasonable cost tomorrow,” says Dr. Heiko Dieter, product manager at Dürr, in explaining the benefits of the new concept. “If, for example, the gas supply is interrupted at short notice, there is a risk of costs increasing and even production being interrupted. Energy-flexible ovens guarantee an alternative supply in this case. If a source of energy is no longer economical, operators can switch to another source with minimal effort – without having to interfere with the oven’s structural fabric. Choosing a hybrid system also makes it possible to automatically switch to the cheapest energy source depending on the time of day.” 

Qflex technology as the technological foundation
At the heart of the concept is a central heating module that generates heat for drying car bodies and supplies it as needed to the individual zones using a heating circuit. The standalone heating module can be powered using gas or electricity. If an operator wishes to switch the energy source later, for example because it is installing its own solar power system, there is no change to the oven and only the heating module is modified. The Qflex technology also makes it easy to integrate innovative technologies such as electric high-temperature storage units to store energy for later use.

Two ovens designed for distinct application profiles
The EcoInCure transverse oven, which has proven itself in over 30 paint shops worldwide, meets the highest requirements for heating response, process reliability, and paint quality. The EcoSmartCure is an innovation based on the traditional longitudinal mode of operation. What makes it innovative is how it combines the central heating concept with a stop-and-go principle, in which the body goes through defined stationary phases. Compared with conventional ovens, this mode of operation enables much more precise temperature control. The body is strategically heated where necessary, rather than applying air to large areas. This reduces thermal stress, especially for thicker parts like the sills of electric vehicles, and improves paint quality. 

Compact design for new builds and modernization of existing plants
Both ovens are compact single-level systems that do not require any additional power unit levels. Their low space requirement makes them easy to integrate into existing buildings. EcoInCure and EcoSmartCure are therefore an economically attractive solution for brownfield modernizations – for both CAPEX and OPEX projects.

The EcoSmartCure is currently being tested for industrial use. “The strong customer interest and two projects already underway confirm to us that we have hit the mark with this new development,” says Dr. Dieter with conviction. “Energy flexibility is no longer a distant vision. The Qflex technology in our ovens now offers a solution for responding flexibly to volatile energy markets and changing conditions in automotive production.”

“This fourth generation of robots is designed through and through for economy. Fewer components, a simplified mechanical system, and an easy-to-maintain design reduce the lifecycle costs when compared with previous generations, without affecting the process technology,” says Andreas Bokermann, product manager at Dürr.

Asymmetry moves the applicator closer to the interior 
A central design feature of the EcoRP4 is the asymmetrical architecture of the robot arms. The tool center point (TCP), also known as the center point of the applicator, is offset laterally from the main axis by more than 200 millimeters. This increases the distance between the potential interference contour of the robot arm and the body. As a result, the applicator can reach even hard-to-access areas such as door rebates, hinges, and transition zones much more easily. To support use on both sides of the body, Dürr offers the new robot in mirrored versions.

Slim design, high efficiency
In addition to the asymmetric arm geometry, arm 1 of the EcoRP4 is more compact. The slim design reduces the amount of space needed in the working area and increases clearance near the body. Arm 2 still carries the applicator, color changer, and metering pumps in close proximity to the paint outlet. As a result, the tubing lengths remain short. This enables fast valve switching times and minimizes paint and rinsing agent loss during color changes.

Easier access to the process technology 
As in previous generations, most of the process control technology in the EcoRP4 is integrated in arm 1 – a characteristic feature of Dürr painting robots. As part of the redesign, the housing concept was revised. Consequently, all process-related components can now be integrated into arm 1, that is, as close as possible to the atomizer for maximum efficiency. Arm 1 also features a continuous cover that can be accessed from the side. “For the redesign, we placed great emphasis on making it easier to access the process technology. “With fewer covers and side access, the new design simplifies maintenance and significantly shortens service times,” explains Mr. Bokermann. 

Simplified drive technology for less maintenance
In addition to the above-mentioned changes, the design of the drive units for axis 2 and axis 3 has been simplified. Instead of utilizing an angular gearbox with a reduction gear, the pinion gear drive of the respective motor now sits directly on the motor shaft. Eliminating additional gear stages reduces both the number of components and the amount of wear and maintenance, further boosting the cost efficiency of the new robot generation.

The EcoRP4 also supports the HTE process and can be combined with Dürr’s latest application technology in a wide range of configurations. The market launch is planned for 2027.
 

Turntable replaced by a curved route 
Another key innovation is the curved line route. While RoDip E uses turntables for direction changes, the trolleys in RoDip E^zy can navigate right-hand and left-hand curves. Technically complex turntables are no longer necessary. This reduces plant complexity and allows a more flexible process line. In addition to the classic two-loop system with separate trolleys for pretreatment and cathodic electrocoating, it is also possible to implement a shared loop (one-loop system) with the same trolleys for both pretreatment and cathodic electrocoating. This configuration requires less external conveyor technology as well as fewer rails and trolleys. “RoDip E^zy is suitable for both new plants and for modernizing existing factories,” says Klaus Heinsohn, product manager at Dürr. “Since RoDip E^zy can navigate curves of 180 degrees or more, it means we can adapt the routing to challenging spatial conditions or different distances between the process steps as required.”

Lightweight aluminum profiles 
The new rail system is made of standardized aluminum profiles already used by Dürr elsewhere, such as in final assembly. Because the elements are lighter, they are easier to integrate and can be assembled more quickly. Extensive adjustment work, as was required with the previous steel elements, is no longer necessary. 

More than 100 million vehicles worldwide have been protected against corrosion using RoDip. The system is regarded as the benchmark for the rotational dip process. The space-saving and resource-efficient method turns bodies around their own axis, and therefore only needs short immersion tanks for immersion, flooding, and draining. In addition to the mechanically robust RoDip M, the flexibly programmable RoDip E^zy adds a new variant to the lineup that enables a high degree of flexibility when planning plant layouts.

To reach customers worldwide, the 2026 Open House will once again take place virtually and will be streamed live over three days across multiple time zones. Participants can follow the program—featuring presentations, live demonstrations, and panel discussions—online or attend one of the global event locations.

A holistic view of the paint shop
Dürr presents its solutions for the entire paint shop process—from planning to implementation. “Increasing efficiency begins where the groundwork is laid for energy-saving processes, cost-effective layout concepts, and optimally coordinated interfaces. Key factors for cost savings are already present in the system planning phase,” emphasizes Bruno Welsch, COO of Dürr Systems AG. “At the Open House, we’ll demonstrate potential savings in space, energy, and investment costs using concrete examples.”

Dürr’s holistic approach has given rise to EcoQPower—an energy concept that, for the first time, views the paint shop as a fully integrated system. Heating and cooling flows are no longer used in isolation but are recovered and distributed via an integrated system—energy circulates instead of being lost. Particularly suitable for electrified paint shops, EcoQPower enables savings of up to 25 percent and supports operators in achieving their CO₂ targets.

Digital control and analysis systems are becoming an increasingly important factor in optimizing plant performance. With the SCADA system DXQcontrol and DXQanalyze, Dürr presents powerful central software solutions that control processes across the entire system while delivering data-driven insights to reduce downtime and sustainably increase overall plant effectiveness.

Global project management is also a crucial success factor. Using recent examples, Dürr demonstrates how to professionally manage and complete international construction sites on schedule—from international coordination and logistics at both the plant and site levels to regulatory frameworks.

Innovations for sustainable automotive painting
Dürr is a leader in technology and continues to set new standards with its innovations for sustainable processes and reduced material consumption per painted vehicle body. “Our innovative strength is evident wherever technical progress creates measurable benefits. This is precisely what our innovations deliver: more efficient process steps, reduced energy consumption, and solutions that ensure our customers remain competitive in the long term,” explains Dr. Lars Friedrich, CEO of Dürr Systems AG.

Further Development in VBH/KTL: The successful RoDip E rotary dip coating process has been further developed into RoDip E^zy. It allows for a curved line layout, eliminates the need for separate turntables, and significantly simplifies installation and access.

Improved energy efficiency in the most energy-intensive process step: In the drying stage, Dürr is establishing new standards with energy-flexible systems such as EcoInCure and EcoSmartCure. They combine precise temperature control with centralized heating technology. Heat is applied where it is precisely where needed, significantly reducing energy consumption per body.

Booth technology reimagined: The modular booth concept EcoProBooth delivers additional savings; with its parallel booth layout, short air paths, and a recirculation rate of 95 percent, it requires up to 80 percent less energy than a conventional wet separation system.

New levels of flexibility in application and customization
With the highly efficient EcoBell4 HTE atomizer, Dürr once again reduces overspray, enabling even more compact booth layouts. Furthermore, the new EcoRP4 robot generation offers improved accessibility thanks to optimized arm geometry and ensures precise coating results with high flexibility.
In addition to the EcoPaintJet Pro for overspray-free two-tone application without masking, Dürr is introducing the EcoNextJet. It allows for the application of high-resolution custom graphics via digital printing directly onto the body.

Registration for the open house is available at https://openhouse.durr-durr.sbs/. 
Please note that participation is reserved exclusively for Dürr customers.

Integrated cleaning equipment control
The cleaning equipment for the various Dürr atomizers is now fully controlled via the EcoAUC2. This significantly reduces the integration effort, especially when safely shutting down the high voltage before the high-speed rotary atomizer EcoBell2 enters the special cleaning equipment. This function is now performed by the EcoAUC2: It automatically detects whether the applicator is de-energized, and only then does it enable the cleaning cycle. This avoids potentially hazardous situations.

Increased color and hardener capacity
The control unit can now control up to 20 colors – twice as many as the predecessor model. “We are seeing a clear trend towards personalization in many applications, which is why we doubled the color selection during the development process,” says Stephan Voigt, product engineer at Dürr. In addition, the EcoAUC2 now supports up to five hardener components, instead of the previous three. This means that infrequent but complex paint formulations are now also possible.

Ready to start without delay, intuitive to operate
The EcoAUC2 components are compactly housed in a control cabinet. Integrated in this cabinet are the process controller, the compressed air control system, the visualization system, and the interfaces for robot control and the safety PLC. Like its predecessor model, the EcoAUC2 is also fully embedded in Dürr’s ready2integrate concept. This works according to the plug-and-play principle familiar from computers: The pre-tested, certified unit is tailored to the respective dosing and application technology and can be started up on site in the shortest possible time without any additional adaptation. An intuitive visualization system with an oversized display simplifies process monitoring and operation. The EcoAUC2 thus significantly extends the possibilities of automated application technology – for anyone who wants flexible, reliable, and versatile coating in an industrial environment. 

Dürr will be presenting the new EcoAUC2 for the first time at the PaintExpo in Karlsruhe (Hall 3, Booth 3320) in a live demonstration. Further information on processes, system innovations, and complementary solutions can be found in the current Dürr catalog for industrial painting technology.

Drop-on-demand: Painting at the highest resolution
EcoNextJet is based on drop-on-demand technology. This involves attaching a printhead with 2,000 individually controllable nozzles to a painting robot. Each nozzle dispenses paint only when needed. Up to six drops can be dispensed per pixel. As the drops fly through the air, they merge into one larger drop before reaching the surface of the vehicle body. This technology allows size and speed to be controlled with a very high degree of precision. Pixel by pixel, a paper-thin image is produced, with approximately five micrometers of paint film thickness and resolution up to 720 dpi. The two-channel printhead can dispense two colors simultaneously. A software program, specially developed by Dürr, controls the robot’s path and calculates the point of impact for each drop – even on convex or vertical surfaces. Importantly, the same paint is used for all surfaces, simplifying the process and ensuring consistent finish quality.

Partnership as the key to innovation
EcoNextJet was developed through close partnerships: Dürr handled process integration, robotics, and software for the painting process; paint manufacturer Axalta developed the appropriate paints; and printhead manufacturer XAAR provided the printhead. “Our customers want their designers to have more freedom, especially when it comes to high-resolution graphics. The partnership with Axalta and XAAR significantly shortened the development time and made it possible to offer a complete system that meets the automotive industry’s requirements,” says Frank Herre, Director Automotive (Paint Shop) at Dürr.

Ready for practical use
EcoNextJet is available for initial testing in Dürr’s test centers in Bietigheim, Germany, and Southfield, Michigan, USA. At these facilities, manufacturers can observe how graphics and patterns are produced in an automated painting process that uses no films, reduces waste, and saves labor time. At the same time, the high resolution opens up new design possibilities. EcoNextJet is thus not only a technological innovation, but also a means of more efficient and more sustainable processes in vehicle production.

“The paint used is special—it serves multiple functions,” explains Fabian Schilt, Head of the European Industrial Sales Team at Dürr. “In addition to providing color, it provides the necessary conductivity. Since the chairs are used in cleanrooms and ESD areas, among other environments, it is essential that no static charge is generated.”

Compact paint supply with EcoSupply2 Core
In September 2025, Dürr supported PU plant specialist Hennecke with the installation of painting equipment on an existing robot at the Interstuhl site in Meßstetten-Tieringen. The system includes a painting robot equipped with the EcoGun AS AUTO pro spray gun, six EcoSupply2 Core stations for paint supply, and the EcoAUC 2K control unit. Interstuhl currently processes three colors, but the system is already designed to handle up to five colors.

The EcoSupply2 Core paint supply station is space-saving and user-friendly. It is ideal for industrial applications where painting occurs in confined spaces. At Interstuhl, the systems are additionally equipped with pumps from the EcoPump9 series, valves, and paint change blocks—components that have particularly impressed the company. This is due to the paint material used has special requirements: it is difficult to flush, hardens quickly, and tends to clog valves.

Ready for practical use
Extensive testing at the Dürr Test Center in Ledeč nad Sázavou, Czech Republic, proved that Dürr valves have no dead space – no material settles, ensuring reliable and clean processing. “We were convinced by Dürr right from the first demonstrations of the painting technology,” says Andreas Kunst from Interstuhl. “The technical team was always there to support us and led the project to success with a great deal of expertise and commitment.”

Efficient high-tech products benefit the environment
CEER relies on Dürr's new generation of ovens. The EcoInCure heats the body from the inside to reach massive body components more directly. This is particularly advantageous for electric vehicles, as they require – among other things – well reinforced rocker panels to protect their batteries in the event of a side impact while simultaneously preventing overheating in thinner parts of the body shell. This drying method is more environmentally friendly, reducing the required heating process time for the body is by up to 30% compared to conventional systems. An Oxi.X RV from Dürr CTS cleans exhaust air from the oven using the principle of regenerative thermal oxidation (RTO). The oxidation reactions, which purify the process exhaust, occur entirely within the heat exchange media. Since the system operates using electricity, there is no open flame and therefore none of the unwanted by-products of flame combustion.

Another notable feature is Dürr’s EcoPaintJet Pro, an award-winning overspray-free painting system. CEER can utilize this to offer its customers cars with a two-tone paint finish. The EcoPaintJet Pro technology marries customer-specific product design with automated production. Bodies can be painted with two contrasting colors simultaneously, reducing paint consumption and eliminating plastic waste since the EcoPaintJet Pro does not require masking with adhesive tape. The system can also paint complex patterns such as lettering and logos.

“Innovation is a key driver of performance and sustainability in vehicle production. The paint shop of the future will deliver great flexibility, energy and paint efficiency, and exciting premium vehicle paint finishes,” said Dr. Lars Friedrich, CEO of Dürr Systems AG. “We are pleased to have the opportunity to partner with CEER to create one of the most modern car production lines in the world.”

Flexible box concept instead of rigid painting lines
CEER can swiftly incorporate new models and easily scale production capacity with the paint shop of the future. The key lies in implementing a modular concept, where flexible EcoProBooth boxes replace traditional lines with their rigid cycle times. In the box concept, the robots paint the interior and exterior of the car bodies in just one box. The new universal atomizer from the EcoBell4 Pro series meets the highest painting quality standards. Dürr’s EcoProFleet AGVs are constantly in motion and flexibly transport bodies between workstations and the high-bay warehouse based on demand. DXQlogistics.control, Dürr’s tailored software solution for the AGVs’ control logic, controls material flow digitally following work deck utilization, equipment, and availability. 

Smart factory due to DXQ software
Digital solutions from Dürr's DXQ product family turn CEER's paint shop into an intelligent factory. The DXQcontrol modular solution is an innovative manufacturing operations management (MOM) system with a microservices architecture that delivers a high level of flexibility and consistency. The MOM comprises over 50 functionalities for manufacturing planning, execution, control, monitoring, optimization, and predictive analysis. DXQanalyze provides information based on specific systems and uses, enabling it, for example, to forecast the remaining service life of system components or to establish links between quality results and machining processes, taking transparency about the operating behavior of machines and systems to a whole new level.

“Our goal at CEER is to build a world-class manufacturing facility, setting new benchmark for efficiency and sustainability,” said James DeLuca, CEO of CEER. “This paint shop of the future will place CEER at the forefront of automotive manufacturing innovation, allowing us to offer our customers in Saudi Arabia and the wider region a level of customization they have never seen before. The result will be a more environmentally friendly manufacturing process and the ability to offer customization in car colors, finishing, and intricate details that will excite the public.”

In autumn 2024, Dürr opened its subsidiary Dürr Systems Arabia LLC in Jeddah, Saudi Arabia, to further strengthen its customer relations in the region.

Revised operating concept
Dürr has significantly improved the spray guns’ operation with larger adjustment elements and optimized haptics for easier control. A new ergonomically correct rotary knob replaces the previous lever for regulating the spray air. This prevents accidental adjustments and can be completely closed if necessary. The optimized air valve makes you reliably set the pressure right from the first trigger pressure point.

Fewer variants, greater reliability
The EcoGun ACE pro requires just four air cap variants. Two conventional and two low-volume, low-pressure air caps cover all diameters from 1.2 to 2.5 millimeters across seven different nozzles sizes. This simplifies storage and reduces the risk of mix-ups. Plus, to make handling easier and avoid loose parts, the air cap and union nut remain connected after removal.

New design as a visible change of generation
Visually, the EcoGun ACE pro stands out with a new bronze-colored housing and black controls. The design signals a new generation without changing the proven system principles. Dürr continues its line of low-pressure spray guns offering robust industrial quality, precise spray patterns, fast color changes, improved ergonomics, and cost-effectiveness.

A unified portfolio for enhanced customer value
The merger will not affect existing contract terms or services. On the contrary, customers will benefit from a broader service portfolio, innovative and sustainable solutions, and the convenience of a single point of contact for all production needs. Dürr Systems Italy will provide a unified portfolio including consulting, planning, and implementation of assembly processes, along with painting technology, pretreatment and electrocoating systems. Dürr’s high-performance technologies like the automated guided vehicles (AGVs) ProFleet are used at car manufacturers worldwide, enabling flexible, cost-effective manufacturing tailored to individual industrial requirements.  

The streamlined structure simplifies project coordination, reduces administrative complexity, and ensures continuity in customer relationships and service quality. Customers can count on long-term support through preventive maintenance, technical assistance, and plant modernization. “We can offer our customers in the automotive and industry sectors a unique combination of expertise, comprehensive manufacturing solutions and reliability throughout the entire production cycle,” Hohmann summarizes.  

Dürr also operates another subsidiary in Italy: Verind S.p.A., based in Milan, manages robotic and application technologies. The company will continue to operate as an independent entity and brand within the Dürr Group. Verind specializes in the production of industrial systems for application, ultrafiltration and waste water treatment for customers in automotive and general industry. In addition, Verind is Dürr’s Center of Excellence for electronic dosing machines. The company offers expertise, engineering, laboratories, and technologies dedicated to the application of painting and coating products, e.g. on metal, aluminum wheels, plastic, wood, ceramic, marble, composite and glass.

New standards for the painting process in Indonesia
The RoDip® E is being used in Indonesia for the first time, marking a significant milestone. With its high flexibility, it sets new standards in pre-treatment and electrocoating. Thanks to a controllable carriage, it enables individual, vehicle-specific dip curves. The recirculation system positioned at the side of the tank helps reduce the height of the system, saving space. With its modular design, the painting system is scalable and prepared for future production increases. Capacity can be increased from five up to fifteen car bodies per hour.

In addition to the RoDip® E, Dürr is supplying proven dryers and the EcoDry X dry separation system for the paint shop. This system is especially sustainable, using cardboard and disposable filters, and requiring neither water nor chemicals. The new plant is controlled and managed using the latest Industry 4.0 IoT concept to meet the requirements of digitalization. DXQequipment.operation enables operating processes and production data to be visualized in real time. This increases both efficiency and productivity.

Efficiently planned and quickly implemented
The project has been implemented in an exceptionally short time frame: construction began in December 2024, and production is scheduled to start in fall 2025.

Indonesia - an emerging location in the automotive industry
With the new paint shop, PT Handal Indonesia Motor is strengthening its position as a growing car manufacturer in the region. Innovative technologies are expected to facilitate international car brands in local production. At the same time, the project plays a key role in establishing Indonesia as an emerging and sustainable location in the Asian automotive industry. As a partner, Dürr is contributing extensive technical expertise - backed by decades of experience working with automobile manufacturers worldwide.

Efficient Execution Despite Challenges
Despite global supply chain interruptions through sheet metal processing and electrical components constraints, fluctuations in maritime transport, and extreme weather events like Super Typhoon, Dürr completed the project within 18 months. From contract signing in November 2023 to final acceptance in July 2025, the project was delivered on time and to specifications. 

Recognition for Excellence
In recognition of its outstanding performance, TC Motors recently awarded Dürr China the “Excellent Supplier” title. This award highlights the collaborative spirit and technical excellence that characterized the project. “A key factor in this achievement was the effective collaboration between the teams of Dürr China and Dürr Vietnam with the TC Group, working together to ensure the project's success,” said Wang Shuo, Project Manager at Dürr Paint shop systems Engineering (Shanghai) Co., Ltd. “We are extremely proud to receive this award. It reflects the dedication and professionalism of our team, who overcame considerable challenges to deliver an advanced modern factory.” 

Dürr’s technological contribution
Dürr played a key role in equipping the paint shop with advanced technology. The highlight is the electrically driven RoDip® E for pretreatment and electrocoating, using freely programmable trolleys. Each trolley has a conveying drive and a rotating drive, which enable horizontal and rotating movements to be controlled independently of each other for each body.
Benefiting from this, the system can set different dip curves according to vehicle models, thereby enhancing coating quality, improving energy efficiency, and reducing unit costs. Another special feature of the paint shop is that the primer and clear coat are applied in the same spray booth. This saves investment costs. The scope of delivery also includes sealing lines, seven painting robots, ovens, and a hot wax line.

In addition to a classic production layout with wet coating, the partners have developed a concept factory with dry coating and the new Z-folder technology that represents the next generation of battery cell production. Thanks to powerful and innovative technologies, production requires 50 percent less space and 70 percent less energy, resulting in significantly higher space efficiency and lower operating costs.

Efficient and sustainable dry coating
Dürr’s dry coating system X.Cellify DC product family implements the so called “Activated Dry Electrode^®“ process from LiCAP Technologies. Dürr has been cooperating with the U.S. coating expert specifically in the field of dry coating since 2023. The Dürr machine uses a dry-mixed active material instead of conventional slurry. This powder mixture is pressed into a free-standing film using calender machines, which is then laminated onto both sides of the collector foil. Compared to wet coating, this eliminates the drying process as well as the recovery and treatment of solvents – saving space, energy, and costs. The free-standing film also offers advantages in terms of material efficiency, as excess film material can be completely returned to the production process before lamination onto the collector foil. 

The recently achieved successful proof of concept demonstrates that the Dürr machine is capable of performing the dry coating process with consistently high quality. It can be scaled up, and Dürr is actively seeking pilot partners in the industry.

High-speed cell assembly
With the new generation of Z-folders, which integrate the notching process, GROB achieves higher performance with less space. For particularly stable and reliable system technology, the separator is guided over a few deflection rollers with very even and low web tension. Thanks to a high-quality magazine buffer system for the electrodes, the system achieves 95 percent availability.

Precise electrolyte filling with high pressure
A process developed by Dürr enables battery cells to be filled in a single step without residual gas. Unlike the conventional process, the electrolyte is filled directly into the cells at up to 30 bar. The filling pressure is thus two to three times higher than the current industry standard. The process design enables precise dosing and shortens both the filling process and the subsequent penetration of the electrolyte into the active material.

End-to-end digitalization
The equipment technology from Dürr and GROB is complemented by end-to-end digital mapping of the production process. Even in the planning phase before production starts, a digital twin enables simulation of the entire factory and speeds up implementation on site. The data from the simulation flows into the MES/MOM software of Dürr’s subsidiary iTAC, which can be used to control and plan all production steps in battery manufacturing. Important functions here are traceability and quality analysis to avoid errors in production. This results in high overall equipment effectiveness.

Innovations in wet coating
Dürr has also further optimized its technologies in terms of performance and energy efficiency in the classic wet coating process. One example is the automation of the coating station and the slot dies, which form a closed control loop for the layer thickness – resulting in faster production start-up and reduced scrap rate. “Adding automated slot die profile control provides our customers with the ability to not only reduce the machine startup time, but it also ensures quality throughout the production process by maintaining the coating uniformity.”  explains Adam Shambeau, Senior Director of Dürr Lithium-Ion Batteries Americas, “Scrap reduction and machine up-time are critical to our customer’s success, so enhancing our products through automation or innovating our offerings with dual-side coating technology to reduce the total cost of ownership are two great examples where our products bring value to our customers.”

In the subsequent drying process, battery manufacturers can use laser dryers to achieve a 50 percent faster web speed and particularly energy-efficient drying. After drying, the electrode coating is densified using calendering machines. The machines from Dürr work with particular precision using “Dynamic Gap Control”: two sensors measure the distance between the two rollers with an accuracy of 0.5 µm. This results in a very uniform layer thickness, with no more force being applied than necessary. Dürr's calenders are used for both wet coating and dry coating to compress the film.

At the Battery Show North America 2025 from October 6 to 9, Dürr and GROB will be presenting their concept factory as a physical 3D model at their joint booth 3822 at Detroit’s Huntington Place Convention Center.

Dürr will be introducing a new naming concept. The company is bringing together its products for electrode coating and electrolyte filling under the new name “X.Cellify.”

Less energy, less production space
Dry coating offers clear advantages over conventional wet coating in electrode production: it reduces space requirements by up to 65% and lowers energy consumption by up to 70%. These savings are mainly due to the elimination of dryers and solvent recovery. "The successful proof of concept is a major step forward for us. We have demonstrated that the new kind of dry coating with free-standing film works reliably and delivers consistently good quality. It can be scaled up, making it the basis for initial pilot projects in industry," explains Bernhard Bruhn, Vice President of Dürr's Global Business Unit LIB. The process is suitable for today's lithium-ion batteries and also for solid-state batteries.

Free-standing film reduces scrap
The proof-of-concept plant is located in Chassieu in southern France, in a dry room environment at Ingecal, a Dürr Group company specializing in calender technology. Calenders are machines with rollers that compress materials into an even layer. Dry coating starts with film formation: A horizontal calender forms the dry powder into a film. It is referred to as “free-standing” because it runs through the machine without a carrier foil. In the second step, additional calenders compress the film to the desired layer thickness, density, and porosity. Finally, one film is laminated onto the collector foil from each side – thus producing the electrode. “Since we don't need a carrier foil until the final step, we can return the film to the process in its entirety if it does not meet the desired specifications. Thanks to the closed loop, no valuable active material is lost and we significantly reduce waste – an important point in battery production,” explains Bruhn.

Improved further processing 
The special characteristic of X.Cellify DC lies in its web guidance: the system transports the free-standing film in a self-supporting manner and compresses the film before it is applied to the current collector. The subsequent lamination onto the current collector requires less force than calendering in the wet coating process, which means that the foil does not deform – improving its processability for the downstream process steps of notching and stacking.

Combined strengths
The new approach to dry coating combines Dürr's expertise in electrode manufacturing and system integration, Dürr Ingecal's high-precision calenders, and LiCAP's patented Activated Dry Electrode^® technology. “To take the next step, we are actively seeking pilot partners in the industry for gigawatt-scale projects. This will enable us to bring the technology into real production environments – whether for electric cars, stationary storage or other applications,” says Bernhard Bruhn. Dürr is thus ready to partner in the next generation of battery production – with solutions for wet and dry coating.

Painting technology for high model variance
The two identical painting lines feature 170 sealing and painting robots, with the corresponding application technology for sealing and coating the different Volkswagen models in the future. This encompasses EcoRS Clean F, a prime example of Dürr’s efforts to bolster system technology to equip it for growing model diversity. It combines the thorough, gentle cleaning prowess of a feather roller system with the high flexibility inherent to a robotic setup. This makes it perfect for lines that paint many body variations with complex contours. The contract scope also includes the complete paint and PVC supply and software solutions with AI applications from Dürr’s proprietary DXQ product family.

Substantial reduction in CO₂ emissions
A central factor in CO₂ emissions reduction is body drying since it consumes the most energy in the painting process. Operating the ovens with regenerative energy, like green electricity, reduces the CO₂ emissions from the overall system by around 40 percent compared to a paint shop using natural gas. “This was one of the reasons why Volkswagen opted for the EcoInCure electric drying system,” explains Bruno Welsch, COO Automotive at Dürr. “Another is its special air duct system that heats the bodies from the inside out. This technology results in more uniform heating and cooling behavior and reaches solid body components like the rocker panels more directly than conventional systems, cutting the body heating times by 30 percent.”

Electric package concept for oven and exhaust air purification
Another cornerstone for minimizing CO₂ emissions is linking the electric oven to an electric air pollution control system. Dürr is the only provider on the market with an overall blended concept of this kind. It combines the EcoInCure with an Oxi.X.RV, an electric exhaust air aftertreatment system that purifies the polluted exhaust air using the principle of regenerative thermal oxidation (RTO) – with no open flame. Unlike conventional combustion processes, no additional CO₂ is produced by the operation. The system is also extremely energy efficient and achieves autothermal operation even with small quantities of solvent, i.e., it maintains its operating temperature by itself. It uses the significant energy produced during oxidation of the solvents to keep its process going.

Dürr has also installed an energy-saving, environmentally-friendly system for overspray separation. EcoDryScrubber uses limestone powder as a natural binder to separate paint overspray. Highly efficient HEPA12 filters remove all particles from the process air. The saturated limestone powder is disposed of fully automatically via a piping system – with no process interruption. The dry separation system at Volkswagen Puebla minimizes the required fresh air supply to 5 percent maximizing the proportion of recirculated air. This reduces the paint booth’s energy consumption by well over 60 percent compared with wet scrubbing. 

Innovation driver for industrial change 
Dürr innovations always focused on high functionality, quality, operating cost savings, and, in recent years, increasingly on sustainability.

A variety of market-changing developments have shaped the industry. The RoDip^® rotation dip coating system was the first to enable 360° body immersion, improving coating uniformity. Continuous improvements to Dürr’s atomizers have increased clear coat transfer efficiency to over 90%. The groundbreaking EcoDryScrubber system replaces conventional wet separation, eliminating the need for water and chemicals, and setting new standards in energy efficiency. The EcoInCure oven uses cross-flow to reduce line length and gradually incorporates green energy for efficient, zero-carbon production. EcoPaintJet Pro technology enables fully automatic, overspray-free color spraying for the first time.

The rapid progress of digitalization in recent years has led to more advantages in plants: Combined with the DXQ digital platform Dürr’s "paint shop of the future" replaces linear manufacturing processes with flexible, dynamic systems for the mixed production of various car body shapes and a comparatively easy quick adaptation to changing production quantities. But Dürr offers more than paint shops. With its “NEXT.assembly” product line, Dürr provides a complete portfolio for final assembly, along with end-to-end solutions that reimagine conventional final assembly layouts.

Local expertise, global impact
From the initial introduction of foreign technologies to independent local implementation, Dürr China has built a nationwide service network, integrated itself deeply into the local industrial ecosystem, and established a strong service base. In line with its customer-first philosophy, the company has completed over 100 turnkey painting and assembly projects for both traditional automotive manufacturers and new energy vehicle brands. Dürr provides comprehensive professional support throughout the entire product life cycle, including system analysis, production capacity optimization, and more.

Thanks to its local experience, Dürr China has become a global systems center, coordinating the Southeast Asian market and actively exporting expertise developed in China. In recent years, the company has executed more than 50 multinational projects across over 20 countries and regions—including the Stellantis plant in Morocco and the BYD factory in Europe—efficiently supporting global industrial modernization.

Deepening local innovation for the future
Looking ahead, Dürr will further strengthen its localization strategy, make better use of global resources, and support both Chinese and international automotive manufacturers in their global growth. The company will invest further in talent development and build high-performance teams to enhance service quality.

Michael Baitinger, CEO of Dürr China, said: “Over the past thirty years of our partnership with customers in China, we have been honored to witness—and be part of—the automotive industry’s transformation. In the future, we will open a new chapter of localization, making more progress in R&D, production, and open collaboration, so that we can drive the sustainable development of the industry together with our partners.”

Alongside Dürr, a company recognized for its performance in the automotive sector, Cetec will now support a range of industrial segments. Dürr’s liquid and electrostatic painting technologies meet the demands of various industries with excellence, delivering quality, precision, and efficiency to different production types.

“Cetec has a consolidated history of operating in technical-industrial supply and a deep knowledge of the national market. This expertise, combined with Dürr's global know-how, creates a strategic partnership that offers cutting-edge technology, competitive pricing, and close customer service,” highlights Tiago Cardoso, Dürr's director of services. He adds that the synergy between the companies will enable Dürr to expand its presence in Brazil and offer even more complete and customized solutions.

Products available through this partnership include manual and automatic liquid spray guns, electrostatic liquid spray equipment, double diaphragm pumps, piston pumps (horizontal and vertical), dispensers, and spare parts.

Dürr painting solutions for various industries
The German company's portfolio includes all products required for transporting and applying fluids. The ready2integrate solution brings these products together in optimized sets, reducing implementation time, minimizing project risks, and simplifying integration with existing systems.

Solutions in the ready2integrate line include paint recovery systems, ring piping supply, and application sets compatible with robots from various suppliers. Although pre-designed, these components are delivered individually, offering flexibility for assembly according to each customer's specific needs.

“The combination of exceptional quality equipment, extreme efficiency, high reliability and durability—combined with Dürr’s global reputation and Cetec’s expertise in the Brazilian industrial market—has generated concrete, positive results for our customers,” says Eduardo Cernic, CEO of Cetec.

Partnership enhances quality
With a flexible and modular approach, Dürr’s solutions can be adapted to different production scales and processes, making them ideal for a wide variety of applications. With this pioneering partnership, Dürr and Cetec are beginning a new phase in Brazil: a specialized channel to bring the same level of automotive painting to other industries.

“We are very pleased with this partnership. Cetec has in-depth market knowledge and shares our values of innovation, excellence, and customer service,” explains Cardoso.