All models manufactured at the Neckarsulm site from 2025 will be net carbon-neutral
EDITOR ’ S CHOICE GEARED UP FOR SUSTAINABILITY
AUDI
All models manufactured at the Neckarsulm site from 2025 will be net carbon-neutral
With the new Audi A5 family , the first models based on the Premium Platform Combustion ( PPC ) with partially electrified drive systems and new electronic architecture are rolling off the production line in Neckarsulm . The brand with the four rings is consistently gearing vehicle production towards sustainability . The goal : In line with the “ 360factory ” production strategy , all models manufactured at the Neckarsulm site from 2025 will be net carbon-neutral . To achieve this , Audi is relying on more efficient production lines , a higher degree of automation , and innovative technologies . From 2025 , the renovated paint shop will be one of the most modern in the automotive industry .
As production of the new Audi A5 in Neckarsulm commences , the largest start-up phase in the plant ’ s history has begun . “ Thanks to many years of experience in the production of vehicles with combustion engines and expertise in complex ramp-ups , the Neckarsulm team has the ideal prerequisites ,” says Board Member for Production Gerd Walker . Fred Schulze , Plant Manager of Audi Neckarsulm , adds : “ For the new Audi A5 family , the Neckarsulm workforce has acquired further qualifications for new systems and automotive production technologies . At the same time , we have created a future-proof production plant infrastructure .” Rainer Schirmer , Chairman of the Works Council at Audi Neckarsulm , is also confident : “ Neckarsulm employees can handle complexity and are flexible . With these skills , we will contribute to the success of the Audi A5 for our site and Audi .
The company is modernizing , digitalizing , and transforming its plants to manufacture sustainably .
The four Rings ’ vision for the production of the future is thus continuing to take shape : The company is modernizing , digitalizing , and transforming its plants to manufacture sustainably . By 2025 , Neckarsulm , like all Audi sites worldwide , is set to achieve CO2- neutral production .
Significantly lower energy consumption in renovated paint shop
When it is completed in 2025 , the renovated paint shop at the Neckarsulm site will be among the most modern in the automotive industry . Numerous processes have already been optimized , and environmentally friendly procedures have been introduced for the launch of the Audi A5 . While sustainable water-based paints have long been standard at Audi , the latest models also undergo a new painting process . The filler is replaced by a pre-zone paint that can be applied wet-on-wet . The previous separate drying of the filler is no longer necessary , allowing the four rings to reduce energy consumption significantly : Up to 140 kWh can be saved per vehicle .
In Neckarsulm , Audi relies on modern and effective methods to prevent corrosion . Cathodic dip painting , for example , includes dipping and rotating the body upside down in the tank using a rotation process . This is more spacesaving and thorough , as it avoids minimal air bubble formation and dirt deposits . A new , more energy-efficient process is also used for drying the cathodic dip coating . Instead of the previous external drying process , a so-called transverse drying process is now used . Air is blown into the interior , and the body is heated from the inside . In addition to being more energy efficient , the transverse dryer is better suited to future electric and hybrid vehicles and their strengthened floor assemblies .
Audi achieves a further energy saving of around 50 kWh per vehicle thanks to a new paint separation process . Previously , the paint mist was collected in water with 100 percent fresh air and disposed of . In the new dry separation process , it is captured by state-of-the-art filters instead . This process allows more than 90 percent of the filtered air to be reused , largely eliminating the need for energy-intensive fresh air conditioning . At the same time , in contrast to conventional wet separation , the use of fresh water and chemicals is eliminated .
6 PECM Issue 71