On damage.news is a new report on the K&L Center Graf Hardenberg in Karlsruhe, written by Carina Hedderich, which we reproduce here with the kind permission of the editors:
Anyone standing in front of the Audi Center of the Graf Hardenberg Group in Gerwigstraße in Karlsruhe would never guess that one of the most modern body and paint centers in Germany is located under the parking garage next door. Between the parking garage levels and the AUDI and VW Commercial Vehicles Center on the first floor, up to 400 vehicles a month are repaired and overhauled on the second floor.
"There is always potential for optimization"
The body and paint center in Karlsruhe is one of four within the automotive group and started operations in 2021. "We act as an independent repair center within the Graf Hardenberg Group. All accident vehicles from the car dealerships in the Karlsruhe area are brought here by us using our own logistics and repaired here on 3,600 square meters," explains plant manager Markus Schuhmacher in an interview with schaden.news.
The body and paint center completes almost 40,000 repair hours per year. In order to guarantee this, an optimal process flow is required. Two painting lines were set up on the second floor for this purpose. The vehicles pass through the individual stations from masking to finishing via a 41-metre-long rail system with cross transfer.
Since last year, the airmatic painting technology from workshop supplier ensutec has also been providing additional efficiency. "There is always potential for optimization. Our trade partner Antony Autolack provided the impetus to put the application process itself to the test," explains Markus Schuhmacher.
Facts instead of building feeling: measurable process improvement
No sooner said than done: in July 2024, a system of the airmatic atomization technology installed - initially for a test run. By specifically optimizing and heating the air flow, the system ensures finer atomization, less overspray and a uniform painting result - properties that are also confirmed by the Graf Hardenberg site in Tuttlingen, which has been working with such a system since 2023.
According to the plant manager, the four-week trial operation quickly made an impact: "Our vehicle painters noticed the difference on the very first day and said to me, 'What's that air coming out?
But it didn't stop at subjective impressions. "We recorded and evaluated all data and consumption precisely during the test phase." The result:
Material savings in the double-digit percentage range. "The savings for the base coat are between 30 and 40 percent, and around 30 percent for the clear coat." In addition, according to the plant manager, the finishing work was noticeably reduced. And there was another side effect: "The reduced overspray has a positive effect on the replacement interval of the filter systems; overall, the service life of the filters has increased by around 20 percent," Markus Schuhmacher summarizes in the schaden.news interview.
The decision in favor of ensutec technology was made quickly, but not without careful consideration. Other systems were also tested in Karlsruhe. "The ensutec system impressed us both in terms of painting quality and handling. With comparable systems, for example, the painting hose was too heavy, which significantly impaired the application process."
"Technology has paid for itself in14 to 15 months"
Since October 2024, a total of four airmatic systems have been permanently installed in the Karlsruhe body and paint center - one per paint booth. In addition to a car and a commercial vehicle paint booth, the center has two multifunctional booths with infrared drying for minor and spot repair work. "Even though efficiency is naturally a high priority for our throughput, the quality of the paintwork is a clear focus for us. And this has improved significantly since we started using airmatic technology - both with the material from paint manufacturer PPG and with the paint system specified by VW," summarizes the plant manager.
The technology in Karlsruhe has also quickly paid for itself economically. "In terms of savings, the system paid for itself in 14 to 15 months - we're talking about savings in the five-figure range," says Markus Schuhmacher.
Focus on sustainable repair
Last but not least, the airmatic atomization optimization also contributes to the Group's sustainability strategy, according to the plant manager. According to the manufacturer, reducing the atomizer pressure by up to 20 percent means that less compressed air energy is required overall, which leads to further energy savings. This is another plus point for the body and paint center in Karlsruhe, as it was already clear during the construction of the new building that the center wanted to keep its CO2 footprint as low as possible. Two combined heat and power units, heat recovery, LED lighting and modern ventilation systems with floor extraction ensure energy-efficient repairs. Markus Schuhmacher believes that this puts him and his team in a good position for the coming years.
You can download the PDF with the report from schaden.news here download.