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Ford has introduced a high-solids-based system paint system applied in just three wet layers at its Avon Lake assembly plant in Ohio, US.

The formulation produces fewer volatile organic compounds and CO2 emissions than current water-borne and medium-solids-based paints.

Senior materials developer Timothy Weingartz said: “The high-solids-based paint is better because it contains more colour pigment – it takes less to paint a vehicle.”

Allowing three layers of wet paint to be applied one on top of another and baked once eliminates two paint ovens from the process, saving space.

It also saves energy, an important part of cutting plant costs and CO2 emissions. Not having water-borne paint also helps. In order to get a quality finish, the water must be removed from the paint by means of heavy-duty air-conditioning.

Ford worked with chemicals firm BASF on developing the system for three years. In-plant testing took a further year before the system was put into use on 400 Econoline vans for a US fleet customer.

Ford’s tests indicate the paint will improve long-term resistance to chips and scratches. The OEM will monitor the vans over the next 12 months, however.

“The Econoline is big; the amount of paint needed will let us confirm laboratory test results,” said Ford.