The topics of artificial intelligence (AI), automation and sustainability are crucial for the future of the surface industry. This is illustrated by the lecture program of the DFO Automotive & Plastic Coating Conference 2024. More than ever, the aim is to increase efficiency, reduce costs and introduce more sustainable processes at the same time. The competitive pressure within the automotive industry continues to increase in the face of difficult markets, especially on a global level. Therefore, the tools mentioned above are necessary to remain competitive in the surface treatment industry.
Artificial intelligence and automation - the future of surface technology
AI and automation have established themselves as key technologies in surface treatment. They offer far more than just efficiency gains and have the potential to revolutionize production processes in many phases - from material selection and paint formulation development to automated quality control. One notable example of this is the "Na Logisch" project, which presents the use of AI-supported methods to develop environmentally friendly paint formulations. High-throughput screening and adaptive test planning have shown that it is possible to develop paint formulations more quickly and with fewer resources. This saves valuable time and reduces the consumption of fossil raw materials.
PPG's digital platform AIM Automate was also presented at the conference. This platform automates the monitoring of electrocoating processes and uses cloud-based data analysis and machine learning to detect process deviations at an early stage and resolve problems automatically. This improves process stability while reducing costs at the same time.
Sustainability as a competitive advantage in surface treatment
Sustainability is no longer just a trend, but a decisive factor for the surface treatment industry. Car manufacturers such as Audi and Mercedes are using innovative technologies to make their production processes more environmentally friendly. Audi, for example, presented a new top coat line that uses electrically heated dryers and an air circulation system to significantly reduce energy consumption and CO₂ emissions. Mercedes, on the other hand, relies on thin-film pre-treatment, firstly to significantly reduce energy and material consumption, but also because the very high proportion of aluminum in the premium class is increasingly posing problems for conventional pre-treatment processes such as phosphating.
High-rotation atomizer technologies - efficiency and precision redefined
A new high-rotation atomizer technology from Dürr shows that even at a high level, improvements in paint application, reduction of rinsing losses and color change times as well as improvements in application efficiency are still possible. At the conference, Dr. Pavel Svejda from Dürr Systems presented the latest generation of EcoBell high-rotation atomizers, which enable further savings in paint and rinsing agents thanks to optimized geometry and flexible control. This means that it is still possible to further reduce production costs and significantly reduce material consumption, even in the area of application.
Smart Paint Factory - The digital future of painting processes
The future of the surface industry will be shaped by the concept of the Smart Paint Factory, in which data-driven processes optimize efficiency, flexibility and sustainability. At the conference, Ralf Wörheide from Orontec presented the vision of a fully automated paint factory in which algorithms analyze production data in real time and dynamically adapt paint formulations. This intelligent process optimization offers the prerequisite for taking the maximization of quality and minimization of resource usage and thus sustainability to a whole new level. Last but not least, the increased use of AI is expected to significantly reduce development times.
Conclusion: Innovation as a driver for efficiency, sustainability and automation
The surface industry is at a crossroads. Artificial intelligence, automation and sustainable production processes are no longer optional, but have become essential in order to meet global requirements. The innovations presented at the DFO Conference 2024 - from AI-supported paint formulations to the Smart Paint Factory and new high-speed rotary atomizers - impressively demonstrate how important technological advances are for a successful future of the surface industry.
Companies that implement these technologies today will not only optimize their production processes, but also set the course for a sustainable and competitive future.
A detailed report including video and interviews can be found here!