Made Perfect 2 – the painting of the Macan

The paint shop at the Porsche plant in Leipzig is one of the most modern in the world. A sophisticated system delivers immaculate and customised colours.

Like every Porsche, the Macan epitomizes the optimal interaction of man and machine. The intelligently controlled production process involves multiple locations and many suppliers, and culminates in state-of-the-art production at the Leipzig plant. In our series "Made perfect – the journey of the Macan" we accompany the entire production process of the compact SUV. The second part takes a look behind the scenes of the paint shop.

Leipzig plant, paint shop, infographics, 2014, Leipzig, Porsche AG
For infographics with better resolution, see left column (downloads)

With a fine spray, the painting process begins, inside and out. Additional gripper robots chivalrously open doors and open the hood. The robots work elegantly and efficiently, so that 85 percent of the paint actually reaches the body surface, reducing overspray to an absolute minimum. Using a dry paint droplet removal system, the excess paint particles in the air are bonded to a limestone­powder and disposed of. There is no waste. The pulverized limestone is completely recycled. “It goes to a cement-maker. Cement is fired to 2,000 degrees Celsius, so nothing is left of the paint,” says Töpfer.

The Porsche plant is an environmentally friendly plant

The Porsche plant is an environmentally friendly plant. The photovoltaic facility on the roof of the body construction area, for example, generates up to 800,000 kilowatt-hours of solar energy annually – roughly the annual energy consumption of over 150 average four-person households. The paint shop operates at up to 80 percent CO2-neutral. The required heat is supplied by a biomass power plant located right next to the plant. Sustainability as an expression of social responsibility, as board member Blume puts it.

The Ergo-Lux tunnel, a light tube outfitted with economical LED modules, is an equally good fit with the concept. The highly uniform reflected light is optimal for checking the paint job: two employees carefully inspect a hood and run their hands – without gloves –across its surface. This is the only way to detect the uneven spots that they then polish out. Now the Macan is ready for assembly.

In the next part the Porsche Newsroom accompanies the Macan at the assembly.

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