Phil
31-07-2002, 11:30 AM
-To Reduce Volatile Organic Compounds and CO2 Emissions-
Mazda has successfully developed a new environmentally friendly coating technology. It reduces the emission of volatile organic compounds (VOC) to the same level of VOC regulation in Europe where waterborne paints are mainly used, while achieving reduction of CO2 discharge and better coating quality. This significant technology has been launched at its Hofu Plant 1 in Yamaguchi Prefecture. The new technology is called "Three Layer Wet Paint System." Primer coating process is combined into the top coating process aiming to reduce environmental impact comprehensively.
The introduction of the new technology has achieved the following benefits:
1. Integrated process: Primer coating process is combined into the top coating process. This has contributed to a reduction in energy consumption by 15% CO2 discharge.
2. Emission reduction: Newly-developed low-solvent paint and reduced paint consumption through an introduction of high-efficiency coating robots have enabled Mazda to reduce emissions of VOC, such as toluene and xylene from the paint shop by approximately 45%.
3. Standard quality: Equal to that of current coating technology, through all-new interface control resin.
[Summary of new technology]
1. World's first Three Layer Wet Paint System
The Three Layer Wet Paint System is a system that primer coating process is combined into the top coating process. Primer, base coat and clear coat are applied continuously and baked all layers at once in the top coating process. The Three Layer Wet Paint System has been applied for the bottom of two-tone body, but not for the full body. Mazda is the world's first manufacturer that applies this new technology to the full body. The integrated process enables energy reduction, which was consumed in large scale within the paint booth and oven.
2. Newly developed paint to make Three Layer Wet Paint System possible
Mazda jointly developed new low solvent paint with lower VOC emission levels in cooperation with paint makers for the application of primer, base coat, and clear coat. Previously the surface of the primer and the base coat paints was separated by baking. In this new technology, a newly developed interface control resin separates the two coats. This resin is uniformly dispersed in the primer. Soon after the primer is applied, the resin moves to the surface of the primer, due to different surface tension, creating a high-viscosity barrier between the primer and the base coats.
3. Development of a highly-integrated/highly-efficient new coating system
Mazda has developed its own unique coating system that maximizes coating efficiency. Introducing more enhanced robots than the previous one, Mazda developed a system to control paint flow and air pressure with high accuracy. As a result, the number of coating robots required for each body has been reduced by 25%, and the primer application process has been integrated into the top coating process without extending the topcoat process. In addition, the robots have improved coating efficiency to reduce paint consumption, realizing homogeneous paint thickness and more uniformed quality.
In an effort to comply with the PRTR,* manufacturers are striving to develop environmentally sound technology. For example, with the aim of reducing VOC emissions, an increasing number of manufacturers are introducing a special coating process employing waterborne paints. Mazda, still using solvent paint, has achieved to meet the VOC regulation (35g/m2) of European countries where many companies employ waterborne paints. Furthermore, Mazda has drastically reduced CO2 emissions, as well as cutting down coating cost. This technology is expected as a comprehensive environmentally friendly measure.
Mazda is planning to introduce this technology at other plants, developing a further advanced method to employ waterborne paints to this system, aiming to further reduce CO2 and VOC.
*The PRTR (Pollutants Release and Transfer Register) is the system consists of "an arrangement for the registration and publication of the volume of harmful chemical substances released into the environment and the volume of such substances transferred as components of waste." Based on "The Law Concerning Reporting, etc. of Releases to the Environment of Specific Chemical Substances and Promoting Improvements in Their Management," it requires reports and publication of figures regarding chemical substances released into the atmosphere, water, and soil, and the volume transferred as components of waste.
Mazda has successfully developed a new environmentally friendly coating technology. It reduces the emission of volatile organic compounds (VOC) to the same level of VOC regulation in Europe where waterborne paints are mainly used, while achieving reduction of CO2 discharge and better coating quality. This significant technology has been launched at its Hofu Plant 1 in Yamaguchi Prefecture. The new technology is called "Three Layer Wet Paint System." Primer coating process is combined into the top coating process aiming to reduce environmental impact comprehensively.
The introduction of the new technology has achieved the following benefits:
1. Integrated process: Primer coating process is combined into the top coating process. This has contributed to a reduction in energy consumption by 15% CO2 discharge.
2. Emission reduction: Newly-developed low-solvent paint and reduced paint consumption through an introduction of high-efficiency coating robots have enabled Mazda to reduce emissions of VOC, such as toluene and xylene from the paint shop by approximately 45%.
3. Standard quality: Equal to that of current coating technology, through all-new interface control resin.
[Summary of new technology]
1. World's first Three Layer Wet Paint System
The Three Layer Wet Paint System is a system that primer coating process is combined into the top coating process. Primer, base coat and clear coat are applied continuously and baked all layers at once in the top coating process. The Three Layer Wet Paint System has been applied for the bottom of two-tone body, but not for the full body. Mazda is the world's first manufacturer that applies this new technology to the full body. The integrated process enables energy reduction, which was consumed in large scale within the paint booth and oven.
2. Newly developed paint to make Three Layer Wet Paint System possible
Mazda jointly developed new low solvent paint with lower VOC emission levels in cooperation with paint makers for the application of primer, base coat, and clear coat. Previously the surface of the primer and the base coat paints was separated by baking. In this new technology, a newly developed interface control resin separates the two coats. This resin is uniformly dispersed in the primer. Soon after the primer is applied, the resin moves to the surface of the primer, due to different surface tension, creating a high-viscosity barrier between the primer and the base coats.
3. Development of a highly-integrated/highly-efficient new coating system
Mazda has developed its own unique coating system that maximizes coating efficiency. Introducing more enhanced robots than the previous one, Mazda developed a system to control paint flow and air pressure with high accuracy. As a result, the number of coating robots required for each body has been reduced by 25%, and the primer application process has been integrated into the top coating process without extending the topcoat process. In addition, the robots have improved coating efficiency to reduce paint consumption, realizing homogeneous paint thickness and more uniformed quality.
In an effort to comply with the PRTR,* manufacturers are striving to develop environmentally sound technology. For example, with the aim of reducing VOC emissions, an increasing number of manufacturers are introducing a special coating process employing waterborne paints. Mazda, still using solvent paint, has achieved to meet the VOC regulation (35g/m2) of European countries where many companies employ waterborne paints. Furthermore, Mazda has drastically reduced CO2 emissions, as well as cutting down coating cost. This technology is expected as a comprehensive environmentally friendly measure.
Mazda is planning to introduce this technology at other plants, developing a further advanced method to employ waterborne paints to this system, aiming to further reduce CO2 and VOC.
*The PRTR (Pollutants Release and Transfer Register) is the system consists of "an arrangement for the registration and publication of the volume of harmful chemical substances released into the environment and the volume of such substances transferred as components of waste." Based on "The Law Concerning Reporting, etc. of Releases to the Environment of Specific Chemical Substances and Promoting Improvements in Their Management," it requires reports and publication of figures regarding chemical substances released into the atmosphere, water, and soil, and the volume transferred as components of waste.