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.

Real-world impact: ABB's painting innovations in automotive manufacturing

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.

PixelPaint technology was recently deployed at the Mercedes-Benz Sindelfingen plant in Germany, where it complements the site's conventional painting processes by enabling the precise and efficient application of intricate paint designs. The implementation has enabled Mercedes-Benz to offer unprecedented customization options, with the Mercedes-Maybach SL 680 Monogram Series being the first model to receive exclusive and individual paint finishes enabled by PixelPaint.

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.