Revolutionizing the automotive paint industry: one drop of paint at a time

The automotive industry, a cornerstone of global manufacturing, is also one of the most resource-intensive, particularly in terms of energy use. Auto-makers’ paint shops stand out within numerous manufacturing processes for using up to 73% [2] of the total energy consumption in a typical vehicle factory. But that high energy use also makes paint shops ripe for sustainability improvements.

Our latest innovation, the RB 1000i-S paint atomizer, can lead this transformation, by helping manufacturers to make meaningful reductions to energy consumption, waste, and emissions.

Decoding VOCs and CO₂ emissions in automotive painting

The automotive painting operation is complex, involving high use of energy and materials. In Germany, the automotive industry accounted for 28.5% of final energy consumption in 2020 – painting being one of the highest contributors to this figure [3].

Painting also generates a substantial amount of volatile organic compounds (VOCs) from paint solvents, which are released into the atmosphere. VOCs, and CO₂ emissions from energy-intensive spray booths, contribute significantly to the industry's environmental impact.

Cutting waste, boosting efficiency

The RB 1000i-S paint atomizer, mounted on top of the ABB robot, can achieve a transfer efficiency of up to 95-99%, and reduce paint waste by a minimum of 30%, along with Co2 emissions. The digitally enabled atomizers, which began operation earlier this year, increase paint transfer to the vehicle, while reducing overspray and paint usage.

This means that a manufacturer producing 200,000 cars per year will save around 50,000 liters of paint and $500,000.

From PixelPaint to the Atomizer: ABB's technology at work

Our innovations go beyond improving paint atomization. PixelPaint technology, for example, is 50% faster than traditional methods and offers a more sustainable approach to custom paint designs. Using an inkjet-like head, PixelPaint applies two-tone paint and custom designs in one pass without the need for time-consuming masking and de-masking. This enhances the efficiency of paint shops and allows manufacturers to offer consumers unique designs with reduced environmental impact.

A case study: Mazda and ABB’s collaborative efforts for sustainability

In Japan, Mazda’s Ujina plant No. 1 provides a real-world example of our impact on sustainability in the automotive industry. Recognizing that roughly 60% of their production CO₂ emissions come from the painting process, Mazda partnered with ABB to install RB 1000i-S paint atomizers at their Hiroshima plant. 

The collaboration reduced paint usage by 17% – equivalent to 30,000 liters of paint saved annually. This efficiency translates into significant financial savings and a reduction in VOC and CO₂ emissions.

The future of sustainable automotive manufacturing

Our innovations show that companies do not need to choose between environmental responsibility and profitability. Our work with Mazda helps to create a roadmap for a leaner and cleaner automotive industry – one drop of paint at a time.

Footnotes

1. Automotive Paint Market Size, Share | Global Report, 2032

2. Approach for Design of Low Carbon Footprint Paint Shops in the Automotive Industry | SpringerLink

3. Umweltbundesamt: Energieverbrauch nach Energieträgern und Sektoren (2022)