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BMW, Dürr, BASF integrated paint process cuts 12 kt CO2 annually

The BMW Group saves 12,000 tons of CO2 annually during automotive production at its Munich plant by eliminating one step from the paint process. In other words, compared to a conventionally coated vehicle, a car coated with the shortened process can drive the first 420 kilometers with a net zero carbon footprint. In addition, the process saves as much energy as the amount needed by 250,000 Munich residents to wash one load of laundry every week.

These are the findings of a new TÜV-certified study conducted by the BMW Group together with the mechanical and plant engineering firm Dürr and BASF’s coatings experts.

The paint process is one of the most energy-intensive process steps involved in industrial automotive manufacturing, noted Dr. Hans Schumacher, head of Dürr’s Application Technology division.

The study specifically compared two primer-based coating processes to the integrated paint process without primer.

In conventional systems,the primer smooths surface irregularities and protects the cathodic e-coat—the undermost paint layer—from UV radiation. BASF was able to substitute the primer by integrating its protective properties into a newly developed waterborne basecoat layer.

In all categories included in the study, the “Integrated Process” proved to be the most beneficial. Compared to the current primer process, the Integrated Process reduces energy consumption and CO2 emissions by around 20% and saves costs.

The study was based on real-life data from 2014 evaluated with the Eco-Efficiency Analysis developed by BASF. The analysis will help BASF and its customers decide which products and processes are the best choice for a defined benefit, both ecologically and economically. The study has been validated by TÜV (German technical inspection and certification organization) and NSF (National Sanitation Foundation).

The Coatings division of BASF is a global expert in the development, production and marketing of innovative and sustainable automotive OEM and refinish coatings, industrial coatings and decorative paints.

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