ABB’s latest RB1000i-S high-transfer efficiency paint atomisers have been installed at
Mazda’s Ujina plant in Japan, as the automotive manufacturer accelerates efforts to achieve carbon neutrality in its global production facilities by 2035.
The digitally-enabled atomisers, which began operation earlier this year, significantly reduce paint usage by increasing the paint transfer to the vehicle body through less overspray. Together with reductions in compressed air consumption and paint wastage during color changes, the new ABB atomisers are helping to reduce emissions in the paint process itself and in related paint booth equipment.
Joerg Reger, ABB Robotics’ automotive business line managing director, said: “Mazda states that 60% of CO
2 emissions during its manufacturing process is due to painting, making it a key target for optimisation as the company works to achieve carbon neutrality targets. Our new RB1000i-S atomisers achieve up to 95-99% efficiency, while reducing paint usage and costs, volatile organic compounds (VOC) and energy consumption for waste fluid treatment in the paint booth, all supporting CO
2 emission reduction.”
Improved transfer efficiencyMazda, which manufactures the CX-5 as well as the iconic MX-5 roadster as its Ujina plant No 1 in Hiroshima, reported a 17% reduction in paint usage due to the improved transfer efficiency of the RB1000i-S, equivalent to a saving of around 30,000 litres of paint annually.
Energy consumption and maintenance frequency, such as replacing the protective masking that prevents overspray from affecting the equipment, have also decreased. The company achieved additional cost reductions during the integration by deploying the RB1000i-S atomisers on existing robots, supporting carbon-neutral operations as well as the circular economy.
ABB’s RB1000i-S atomisers, which can be retrofitted to ABB and non-ABB robots, are an example of the company’s efforts to deliver smart and sustainable solutions to support the transition of the automotive industry.
An upgrade kit that enables existing RB1000i atomisers to take advantage of the enhanced RB1000i-S specification by replacing key parts such as the bell cup and air shaping nozzle, is just one of a range of upgrades available that are designed to elevate existing installations to the latest technology, maximising their performance and prolonging their lifetime while maintaining reliability and minimising downtime. ABB has committed to covering at least 80% of its product portfolio with its circularity approach by 2030.