In this lesson, we will delve into the applied processes and techniques involved in the coating of vehicles, with a focus on environmental considerations.

  1. Coating of Vehicles – General
  • This section provides an overview of the current production process for coating vehicles, including cars, vans, trucks (truck chassis), truck cabins, and buses.
  • It outlines the main techniques employed to prevent and reduce emissions during the coating process.
  • While the primary focus is on cars, it acknowledges that coating processes for vans, trucks, and truck cabs share similarities but also exhibit differences due to variations in coating materials, processes, and application techniques.
  • Factors such as corrosion protection, production volumes, body designs, and customer criteria can significantly impact the coating process.

1.2 Overview of Paint Shop Investment, Design, and Operation

  • Vehicle manufacturers have unique priorities and targets related to quality, customer expectations, shareholder demands, and environmental compliance.
  • These factors influence how a paint shop is designed and operated, impacting technical layouts, corrosion protection methods, and paint systems.
  • The choice of paint systems and paint shop type plays a crucial role in reducing VOC emissions and energy consumption.
  • Vehicle paint shops fall into three distinct categories, and once a choice is made, it is challenging to change, making it a long-term commitment.
  • Large multinational companies with these paint shop installations employ advanced management systems to balance competing objectives.
  • Key aspects influencing consumption and emissions include capital planning, operational management, quality systems, and environmental management.

1.3 Paint Shop Layout and Operations

  • In passenger car paint shops, processes occur sequentially in separate sections along the production line.
  • Standard line capacities range from 30 to 60 units per hour, with adjustments made through shifts rather than changing line speeds.
  • Complex paint shops cover extensive areas, including workstations for body preparation, inspection sections, storage areas, ventilation equipment, overspray scrubbers, VOC abatement systems, staff and maintenance zones.
  • Large spray booths, the core of the paint shop, consist of multiple floors and require significant building height to accommodate essential components.
  • Investment costs for a new paint shop of this scale typically range from EUR 150 million to EUR 250 million (2018 values).
  • The processing time for a vehicle body in the paint shop ranges from 6 to 11 hours.


  • Coating vehicles involves complex processes and techniques with significant environmental implications.
  • The choice of paint systems and shop type is a long-term commitment, impacting emissions and energy usage.
  • Advanced management systems help balance various objectives in large multinational companies.
  • Paint shops are extensive installations with multiple components, and spray booths are central to the process.
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