„Next Generation Paintshop“.

Through this venture, Mercedes-Benz continues to consistently implement its sustainable business strategy in Germany. This major project in Sindelfingen is part of a long-term strategic partnership with Dürr Systems.

With the new hall, Mercedes-Benz is setting the course for further transformation of its traditional site, which celebrates its 110th anniversary this year. In the future, the “Next Generation Paintshop” will operate without fossil fuels and cover its energy requirements with green electricity. The sustainable paint shop is scheduled to go into operation in the spring of 2028.

The sustainable paint shop is being built in the centre of the plant premises on the site of the former Assembly Hall 36. Once completed, the “Next Generation Paintshop” will be located in the immediate vicinity of Factory 56, where the Mercedes-Benz S-Class, the Mercedes-Maybach S-Class and the all-electric EQS are produced, as well as Hall 46, where the E-Class and the GLC are built. The new paint shop, covering approximately 170,000 m², is being built on a footprint of approximately 60,000 m² at the centre of the plant (a so-called “brownfield” project) and is designed in line with Mercedes-Benz’s holistic approach to sustainability. The subsoil consists of recycled concrete and base course material from the demolition of the old assembly hall, which previously stood on the site. This not only conserves resources but also directly recycles waste products.

An environmentally friendly building concept and the intelligent use of state-of-the-art paint technologies will reduce overall energy consumption by 50 percent compared to the previous facility. The aim is to significantly reduce energy consumption per painted car body, which is a considerable amount. Two factors will help to achieve this goal: software applications from the strategic partner Dürr for energy management and energy-efficient technologies that enable the paint booths and dryers to be operated economically and intelligently.

An intelligent heating network is used to save additional primary energy by pooling heat surpluses and requirements, supported by highly efficient heat pumps. As a result, up to 50 percent of production operations can be supplied in house. Around 20,000 m² of the roof area will be equipped with photovoltaic systems. In addition to a green roof outside, a further 7,000 m² of green space and a 1,200 m² park around the building will be created. These areas promote biodiversity and improve air quality. Furthermore, the plant concept ensures comprehensive exhaust-air purification and reduces emissions by around 60 percent. The use of state-of-the-art technology makes it possible to reduce water consumption by more than half compared to the existing paint shop. In addition, the wastewater produced is completely recycled.

With the help of a digital twin and virtual commissioning, the construction time and ramp-up of the “Next Generation Paintshop” can be significantly accelerated. All paint booths, dryers and around 250 robots are integrated into MO360 Data Platform, the innovative digital production ecosystem used by Mercedes-Benz. This means that all production data can be accessed and analysed by all employees in real time via the cloud.

The “Next Generation Paintshop” will cover all special and large-scale painting processes – from the high-tech cleaning immersion baths to corrosion protection, sealing using the drop-on-demand process and surface finishing in the painting process. Following a successful pilot project at the Rastatt plant, the building technology will also be monitored using generative AI.