Dürr delivers cutting-edge paint shop for Volkswagen Puebla with electric drying and AI-driven systems to cut CO2 by 40 percent

Dürr delivers cutting-edge paint shop for Volkswagen Puebla with electric drying and AI-driven systems to cut CO2 by 40 percent

(IN BRIEF) Dürr has inaugurated a state-of-the-art paint shop at Volkswagen Group’s Puebla plant in Mexico, one of the automaker’s largest facilities worldwide. The project, awarded in 2022 and launched in January 2025, includes two parallel painting lines with advanced electrified equipment such as the EcoInCure electric drying system, which reduces CO2 emissions by 40 percent and shortens heating times by 30 percent. The site now paints up to 90 bodies per hour across multiple models, supported by Dürr’s DXQ software, high-bay warehouse, and EcoProFleet driverless transport system. Additional innovations include 170 robots, AI-driven surface cleaning technology, electric exhaust purification with Oxi.X.RV, and the EcoDryScrubber overspray separation system that reduces booth energy use by over 60 percent. Together, these technologies embody Dürr’s “Paint Shop of the Future” vision and position Volkswagen Puebla as a leader in sustainable, high-output vehicle manufacturing.

(PRESS RELEASE) BIETIGHEIM-BISSINGEN, 1-Sept-2025 — /EuropaWire/ — Dürr has completed the construction of an advanced paint shop at Volkswagen Group’s Puebla plant in Mexico, one of the automaker’s largest global production sites. Officially inaugurated in January 2025, the turnkey facility features two identical painting lines designed to significantly lower carbon emissions. A key highlight of the project is the use of electrified equipment such as the EcoInCure electric drying system, making the plant a benchmark for sustainable automotive manufacturing.

Dürr’s EcoRP painting robots will paint the Volkswagen bodies in Puebla in the future.

The Puebla site now paints 90 vehicle bodies per hour across multiple Volkswagen models. Awarded in 2022, the contract allowed Dürr to integrate core elements of its “Paint Shop of the Future” concept, including a high-bay warehouse and the EcoProFleet driverless transport system. This flexible production design, supported by Dürr’s DXQ software suite, breaks away from rigid line structures by optimizing cycle times for individual vehicles, thereby reducing both process length and CO2 output.

To support growing model diversity, Dürr installed 170 sealing and painting robots equipped with application technology capable of handling a wide variety of vehicle designs. The EcoRS Clean F system, combining a feather roller with robotic flexibility, ensures thorough cleaning for complex contours while preparing surfaces for coating. The scope of supply also included the entire paint and PVC systems along with AI-driven digital solutions from Dürr’s DXQ portfolio.

Reducing energy demand in body drying, the most energy-intensive step in painting, has been central to cutting emissions. Operating the ovens with green electricity slashes CO2 output by up to 40 percent compared to natural gas. According to Bruno Welsch, COO Automotive at Dürr, the EcoInCure system not only reduces heating times by 30 percent but also ensures more uniform temperature distribution by channeling hot air from the inside out to reach even solid structural areas such as rocker panels.

Dürr has gone further by pairing the electric drying ovens with its Oxi.X.RV exhaust air purification system. Unlike conventional gas-fired processes, this electric regenerative thermal oxidation (RTO) system eliminates volatile compounds without producing extra CO2. Its ability to operate autothermally makes it extremely energy efficient, maintaining its temperature using the heat generated during solvent oxidation.

EcoDryScrubber uses limestone powder as a natural binder to separate paint overspray.

The new facility also incorporates EcoDryScrubber overspray separation technology, which uses limestone powder to capture paint particles. Together with HEPA12 filters, the system ensures clean process air while automatically removing saturated material. By reducing the fresh air requirement to just 5 percent, the process recycles most of the booth’s air and lowers energy consumption by over 60 percent compared with traditional wet scrubbing methods.

With this project, Volkswagen Puebla gains a flexible, high-capacity, and environmentally advanced production line that sets new standards in sustainable vehicle painting while preparing the facility for future manufacturing requirements.

Media Contact:

Carina Lachnit
Marketing
Carina.Lachnit@durr.com

SOURCE: Dürr Systems AG