Dürr is a global engineering and manufacturing firm that develops technology and systems for efficient production processes, especially in the automotive industry. It provides automation, robotics, painting systems, final assembly solutions, and testing and filling tools for car manufacturers.
You studied computer science and automation before they became central to industry. Looking back, what's the most profound change AI and automation have brought to manufacturing and operations?
The biggest shift has been the explosion of data and the ability to use it meaningfully.
When I started programming in 1992, your focus was purely on getting a machine to run. Today, you're working with billions of data points—tracking quality, speed, and process anomalies—that feed directly into AI systems.
This has made operations far more efficient. Facilities can now be fine-tuned in real time, processes optimized, and both capital and operational costs reduced. Perhaps most significantly, Automation and AI enable manufacturers to maintain consistently high quality over long periods of time—something that simply wasn’t possible 30 years ago.
Paint shops are among the most resource-intensive parts of auto manufacturing. What are some of the key innovations Dürr has introduced to make it more efficient?
Over the past decade, we’ve focused our R&D on sustainable alternatives, mainly to reduce energy and material consumption in the process and to reduce the plant’s footprint. Traditional wet scrubbing systems that used water and chemicals to bind overspray in the spray booth have largely been replaced by dry separation using limestone. Once saturated, the limestone is filtered out and fully recycled—often reused in other industries like power plants or brickmaking. This change eliminated water usage entirely and reduced spray booth energy consumption by over 60%.
For car body painting, we also developed High Transfer Efficiency (HTE) systems with advanced paint applicators and service cubicles in the spray booth. In the service cubicles, applicators can be cleaned or automatically changed without stopping production. These features, along with 98% air recirculation, lead to additional energy savings of 45–60%.
You’ve partnered with Stellantis on a new energy-efficient paint shop. How do the energy and emissions savings compare to traditional gas-fired systems?
We call the system EcoInCure Electrified. It features an over 100-meter oven for car body curing, divided into sections for heat-up, treatment, curing, and cooling. For electric vehicles, which have larger structural elements, we’ve engineered targeted airflow and rotated the usual conveyor running direction for 90 degrees to optimize heat distribution from the inside out.
Instead of gas burners, the system uses electric heating, cutting energy use by up to 60%. Our EcoInCure system adds further savings in energy use and exhaust emissions by 60%. We also recover heat from the exhaust and use it to precondition other parts of the facility, creating a compound benefit across the entire plant.
Advanced sustainable technologies often face resistance due to cost. How do you help OEMs justify the investment?
There’s always a balance between capital and operational expenditures, and in regions where energy is cheap—like parts of the U.S.—the long-term value can be harder to sell. But the industry is shifting. Most capex optimization in automotive painting has already been done, so the next major savings are in operations.
With our technologies, customers can save, depending on the process and UPH, a high one-digit million € figure annually on materials and energy. That translates to a very fast ROI and over a 20-year plant lifecycle. The savings in an amount of an investment in a new paint shop. OEMs are starting to focus more on total cost of ownership, not just upfront cost, though regional disparities in adoption still exist.
What other industries or technologies are you expanding into, and how are you applying your core strengths there?
Automotive remains a major focus—especially as we rethink paint shops and assembly lines to handle the unique needs of electric vehicles. We also support battery production, electric motor and gearbox assembly, and testing systems as part of our evolving portfolio.
Beyond that, we’re pushing into areas like MedTech automation and sustainable vertical farming through our EcoY initiative. In aerospace, we currently automate painting for components like rudders and wings.
With Chinese EV makers like BYD entering Europe, what does your partnership in Hungary suggest about the evolving global market?
We’ve had a strong presence in China for over 30 years and built many joint venture paint facilities there. With their new plant in Hungary, BYD is emphasizing high-end application technologies, and our systems provide high transfer efficiency..
Overall, I can say that from our location in China and with our strong international Dürr organization, we are better positioned than anyone else to support Chinese OEMs in their global projects. We also work closely with numerous OEMs, who consider us a strategic partner. This shows that OEMs today want not just innovation, but reliable partners who can deliver sustainability at scale.
European regulations are accelerating the transition to electric and low-emissions manufacturing. How is this influencing your business, and is legislation helping or hindering progress?
Electrification is the biggest shift, and our products are well aligned with sustainability goals. But I believe industry could go even further if supported by more effective policy—especially in infrastructure. The current frameworks set penalties for emissions, which is clear, but they don't always enable the change they demand.
The technology exists, and the motivation is growing, but wider adoption requires help removing roadblocks. Governments need to invest in the infrastructure and incentives that allow industries to meet these ambitious environmental targets. That’s where real, scalable progress can happen.
