Development of the unique Three Layer Wet Paint System
Coating has always been the process that creates the greatest environmental burden during automobile production.
The volatile organic compounds (VOC) generated during a vehicles coating procedures account for about 95% of total emissions for the entire production process. Additionally, each coat requires its own baking and drying process and these are responsible for roughly 60% of all CO2 emissions.
Various coating processes have recently been adopted by many automobile manufacturers around the world that reduce VOC emissions. The variety of these processes, however, actually leads to an increase in the CO2 emissions of between 5% and 60%. In this current age, when the emphasis is on the urgent issue of preventing global warming, these methods are no longer appropriate.
Mazda has developed the unique Three Layer Wet Paint System, the first technology in the world to reduce VOC and CO2 emissions simultaneously.
Getting closer to solving all the problems of vehicle coating
As its name implies, the Three Layer Wet Paint System is a one-step baking and drying coating method that applies three layers in succession-primer coat, base coat and clear coat-while still wet, without drying in between. By eliminating the drying process formerly required after applying the primer coat, CO2 emissions are reduced 15%. In addition, a new low solvent content paint jointly developed with paint manufacturers, applied with high-precision coating equipment enables gains in coating efficiency leading to reductions of 50% in VOC emissions.
Until recently, it was thought that using a wet paint system would lead to problems of paints mixing between the successive layers. For this reason other companies' coating techniques require a drying stage following the intermediate coat. Mazda overcame this issue through innovations such as the newly developed interface control resin that was added to the paint. The Three Layer Wet Paint System also displays a deep tone finish that is unique to this method.
Mazda commenced development of this technology in 1994. The perfected Three Layer Wet Paint System was introduced after four years of experimental verification and has been adopted across all Mazda's production facilities in Japan.
This pioneering technological development has been awarded the Japanese Environment Minister's Prize, the METI (Ministry of Economy, Trade and Industry) Minister's Prize and various other awards.
Mazda has developed a state-of-the-art technology that may well become the international standard for vehicle coating; the process which is currently the greatest obstacle to environmentally friendly automobile production. We will continue to pursue the ideal of a single solution to all the issues facing the coating process.
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