ABB's digitally enabled RB1000i-S spray atomizer has been put into use at Mazda's Ujina No. 1 plant in Japan to support its ambitious sustainability goals
Mazda estimates that 60% of carbon dioxide emissions during the manufacturing process come from the spraying process, which highlights the importance of optimizing the spraying process to achieve carbon neutrality
The spraying efficiency of the new RB1000i-S atomizer is as high as 95-99%, reducing the usage and loss of paint, reducing energy consumption and emissions
ABB's latest RB1000i-S high-paint rate spray atomizer has been installed at Mazda's Ujina plant in Japan as the automaker accelerates its goal of becoming carbon neutral at global manufacturing plants by 2035. The digital high paint rate atomizer, which was put into operation at the beginning of this year, improves the paint rate of the car body by reducing paint overspray, significantly reducing the amount of paint used. ABB's new atomizer reduces compressed air consumption and paint waste when changing colors, helping to reduce exhaust emissions during the spraying process and related equipment in the spraying workshop.
"Mazda estimates that 60% of CO2 emissions from manufacturing come from painting, making painting a key optimization metric as the company strives to achieve its carbon neutrality goal," said Joerg Reger, head of ABB's Robotics Automotive business unit. "Our new RB1000i-S atomizers deliver a paint coverage rate of 95-99%, while reducing paint usage and costs, reducing volatile organic compound (VOC) emissions in the paint shop and energy consumption for waste treatment, all of which contribute to reducing CO2 emissions."
Mazda produces the CX-5 and the iconic MX-5 roadster at its Ujina Plant No. 1 in Hiroshima. Mazda reports that the RB1000i-S atomizers have improved paint coverage and reduced paint usage by 17%, equivalent to approximately 30,000 liters of paint saved per year*. Energy consumption and maintenance frequency (such as replacing protective covers to prevent overspray contamination) have also been reduced. By integrating the RB1000i-S atomizers on existing robots, Mazda has further reduced costs to support carbon neutral operations and the development of a circular economy.
ABB's RB1000i-S atomizer can be retrofitted for ABB Robotics and other robots, which is one of the examples of ABB's commitment to providing sustainable and intelligent solutions to support the transformation and upgrading of the automotive industry. The upgrade kit enables the new performance of the RB1000i-S on existing RB1000i atomizers by replacing key components (such as the bell and the forming air ring). This is just one of a series of upgrade options designed to upgrade existing equipment to the latest technology level, thereby maximizing performance and extending service life while maintaining reliability and minimizing downtime. ABB is committed to achieving a full life cycle approach for 80% of its products and solutions by 2030.