Increased productivity and up to 40% lower energy consumption for high production volumes
For this new body shop, the objective was clear: to increase production capacity whilst reducing processing times, energy consumption and operating costs.
Requirement
The client required a system designed to handle high production volumes with a fast, continuous and efficient workflow. The priorities were:
- to optimise the operational layout
- to reduce vehicle movement
- to eliminate downtime and unnecessary manoeuvres
- to increase productivity per vehicle
- to minimise energy consumption and operating costs
Solution
The facility was developed with a linear and rational layout, designed to speed up the flow of vehicles and maximise productivity.
The preparation area incorporates six Genius preparation zones, two of which feature front extraction, dedicated to sanding, masking and high-speed Smart Repair.
On the opposite side, two Extra paint booths are installed, connected to each other and served by the Lean Car Mover handling system with dedicated tracks and trolleys, which drastically reduces handling times.
Each booth is equipped with a touchscreen PLC for precise control of painting and drying parameters, ensuring consistent quality and optimised cycle management.
Energy efficiency is ensured by inverter-controlled fan-coil units with heat recovery, capable of automatically adjusting consumption based on the actual workload.
The system is complemented by a paint mixing unit, designed to ensure order, safety and operational continuity.
Result: increased productivity, reduced waste and a continuous workflow
The new system enables:
- workflows up to 25% faster
- a 35–40% reduction in energy consumption
- greater production continuity
- shorter handling times
- low running costs
A comprehensive, sustainable and high-productivity solution, designed for bodyshops that need to handle high volumes whilst maintaining quality, competitiveness and energy efficiency.
