The BMW paint shop in Debrecen is a state-of-the-art facility where cars receive their color through a fully automated process capable of painting thirty car bodies per hour. The paint is applied in multiple environmentally friendly layers that provide color, shine, and protection against external damage. The plant operates without fossil fuels by using electric power for all heating processes (power-to-heat), significantly reducing CO2 emissions with energy sourced exclusively from renewables.
Innovative technologies such as the Heat Grid system recover waste heat from compressed air, drying ovens, and cooling systems, enabling an additional 10% energy saving. The ventilation system is supplied with preheated water at a low temperature of 65°C, maintaining stable conditions in the spray booths. Exhaust air is purified using cutting-edge eRTO technology, which electrically oxidizes solvent residues at high temperatures with high energy efficiency.
Digitalization enhances efficiency through automated guided vehicles (AGVs) transporting car bodies and AI-based automated surface inspection (AOI) ensuring premium paint quality. The paint overspray is captured by a dry separation system using limestone powder, reducing water consumption and enabling up to 90% air recirculation in the spray booths. The facility was virtually designed and staff were trained in virtual environments, reflecting BMW’s commitment to innovation and sustainability.
