Wednesday, December 4, 2024
Dürr’s latest innovation allows mixed two-component (2C) paint systems to be directly integrated into the atomizer’s return system for the first time, eliminating VOC emissions during flushing processes and colour changes in the paint booth. This advanced solution has been successfully implemented in two top coat lines for over a year.
Traditionally, mixed 2C paint systems released significant amounts of volatile organic compounds (VOCs) into the paint booth air during flushing and colour change processes. In conventional methods, residual paint is flushed forward into a funnel or directly into the washout, causing VOC contamination in over 70% of the booth air. Dürr’s EcoBell PurgeBox, equipped with special filter mats, already reduces VOC emissions by up to 60%, setting a new standard in eco-friendly painting processes.
Dürr’s new development further reduces VOC load by enabling a return system for 2C clear coats, similar to the classic 1C process. Previously, this was unthinkable for mixed clear coat systems consisting of hardener and stock paint. Using a patented process sequence with precisely coordinated parameters, mixed 2C materials can be flushed back via a return system integrated in the atomiser without curing. This technology includes up to two main needles in the atomiser and the established diaphragm valve technology, which ensures high mixing quality with minimal mixing volume. Low VOC emissions of only 5 percent occur solely during the bell disk cleaning in the EcoBell Cleaner D2, with no VOC release during flushing or colour changes.
Effect finishes within normal cycle times
The return system for mixed 2C materials is not only environmentally friendly, but also saves time. During cleaning of the bell disk and atomiser surface in the EcoBell Cleaner D2, flushing and priming can occur parallel. These steps, previously performed sequentially, are now completed in parallel within just 15 seconds, reducing colour change time by half, increasing system capacity, and allowing more time for painting. Tinted clear coats can now be applied without any cycle time losses, enabling car manufacturers to make much broader use of effect finishes, which were previously limited to exclusive segments.
When combined with the EcoBell4 Pro, this setup delivers unparalleled flexibility. Each robot arm integrates two returns for 2C materials (2x2C), enabling simultaneous preparation of stock paint and hardener for the next body on a separate channel while the current body is being painted. This design ensures that even chemically incompatible paints and hardeners can be applied through dedicated channels. Dürr rigorously tests customer clear coat systems in its test center to ensure compatibility. To date, all 2C clear coats tested have proven compatible with this innovative technology, allowing for seamless return and collection via the atomisers.
Return system reduces costs for fixtures and fittings
The EcoBell4 Pro rotary atomiser is available with the return system in the 2x2C and 1x2C variants, while the EcoBell3 can be retrofitted with 1x2C. Another system using this new technology is currently being commissioned. Beyond eliminating VOC emissions during flushing and colour changes and significantly reducing flushing agent consumption, this solution also offers low investment costs by eliminating the need for funnels, EcoBell PurgeBox units, and other fixtures and fittings in the paint booth.
For over a year, the return system for mixed 2C material has demonstrated its effectiveness at a leading electric car manufacturer, operating in two top coat lines with 42 high-rotation atomisers.
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