26 August 1998
PAINT EMISSIONS HAVE BEEN SLASHED; POWDER PAINT PROVIDES HOPE FOR EVEN GREATER GAINS WIXOM, Mich. - Over the past 20 years, U.S. automakers have reduced hydrocarbon emissions from automotive paint facilities by 80 percent. The further use of near zero emission powder paint technology will improve air quality even more.Rather than reducing emissions by adding expensive controls that add no value to the vehicle, engineers agreed it would be better to change the paint materials and eliminate polluting at the source. They determined the lowest emitting paint materials would be powder paints.
Powder paints for primers and chip protection had been implemented in some automotive painting facilities and used extensively in the appliance industry but powder clear coat, the final paint layer, offered even more challenges. The appearance of the final paint layer is critical and, short of repainting the vehicle, no opportunity exists to repair imperfections with powder clear coat after the vehicle has left the factory.
Chrysler, Ford, and GM formed the Low Emissions Paint Consortium, one of 12 consortia under USCAR’s umbrella, in 1993 to tackle the technical challenge of researching, developing and ultimately implementing paint-related technologies to reduce or eliminate emissions from automotive paint systems. USCAR aims to accelerate the availability of low emissions painting technology to create a cleaner environment, while remaining competitive in world markets.
"Rather than having three independent but duplicate programs working on the same thing, we each realized it would be more efficient to work together," said USCAR’s Ernie McLaughlin. "We’re moving faster and getting more done for less money."
Before work began in the $20 million powder paint facility in Wixom, Mich.,engineers from Ford and Chrysler worked in GM’s Moraine, Ohio plant to launch powder primer surfacer. Ford and GM engineers then assisted in the launch of full body powder anti-chip paint at Chrysler’s Sterling Heights, Mich., and St. Louis, Mo. plants. This unique approach to working together in each other’s plants allowed the three companies to quickly obtain vast experience in powder paint.
Based upon its experience, the team of engineers who had worked on the launch of powder primer and anti-chip developed a "Powder Prime Launch Manual," which helps member companies design and launch new powder primer systems. USCAR also established a library of knowledge gained by the consortium on powder painting materials, processes, equipment and facilities.