Cathodic electrocoating (KTL) is not only a reliable method of corrosion protection, but also makes a significant contribution to reducing the environmental footprint of manufacturing. Automotive manufacturers and their suppliers are facing increasingly stringent ESG requirements. As a result, modern KTL processes focus not only on coating quality, but also on energy efficiency, material savings and overall production circularity. This makes KTL an ideal technology for customers with strict environmental requirements.
Automotive Painting Partners (APP) is among the largest job coaters specialising in cathodic electrocoating in Europe. We operate two identical KTL lines that use water-based coatings, a highly stable process and exceptional material utilisation. This enables us to reliably coat even complex-shaped components with consistent quality and a minimal environmental footprint. Below are the key aspects that make this method a sustainable and technologically advanced choice.
Low material consumption thanks to precise process control
Cathodic electrocoating is inherently a highly efficient method. Thanks to the electrochemical principle, the coating is deposited evenly exactly where it is needed. This results in exceptionally high paint utilisation with minimal losses. In practice, this means not only stable corrosion protection, but also lower paint consumption and a reduced environmental burden across the entire process.
Water recycling and closed-loop systems
Rinsing stages are traditionally among the largest consumers of water in surface treatment processes. Our lines therefore operate with multi-stage systems that allow both water and coating material to be continuously returned to the process.
At APP, all processes run within closed-loop systems that enable the reuse of both paint and water. These are continuously filtered, replenished and monitored. This minimises waste generation while reducing the need for fresh input materials. The result is lower emissions and less waste. Compared to other coating methods, cathodic electrocoating places a significantly lower burden on the environment.
Energy efficiency: when the oven works smartly
The curing oven is one of the largest sources of energy consumption in the entire process, which is why its intelligent control is critical. We use A-shaped ovens that operate on the siphon effect principle – heat has nowhere to escape and is retained within the system.
Thanks to uniform airflow, high-quality thermal insulation and precise temperature control, energy losses are minimised. This leads to lower energy and resource consumption, while also ensuring higher stability and quality of the cured coating. For customers monitoring their carbon footprint and ESG performance, oven energy optimisation is often one of the most important evaluation criteria.
Low TOC emissions: a key advantage of water-based systems
The water-based coatings we use contain significantly lower levels of total organic carbon (TOC) than conventional solvent-based paints. In practice, this represents one of the greatest environmental benefits of the process and provides assurance of compliance with increasingly strict EU legislative limits. Lower TOC levels have a positive impact on the entire product life cycle as well as on customers’ overall emissions reported within their sustainability reporting.
Minimising emissions and waste
From an emissions perspective, cathodic electrocoating is a clean technology – provided it is managed with sufficient precision. At APP, we therefore carefully monitor all process baths to maintain long-term stability and consistent quality.
TOC emissions are generated primarily during the curing phase. For their safe treatment, we use a catalytic afterburning unit. Using a platinum oxide catalyst, exhaust gases are heated to over 400 °C, where TOC compounds are effectively eliminated. The result is a significant reduction in emissions and waste, as well as a stable process that meets even the most stringent internal customer audits.
High-quality surface treatment aligned with sustainability and ESG goals
At Automotive Painting Partners, we combine the technical precision of KTL with the principles of sustainable manufacturing. Closed-loop systems, water and material recycling, energy-efficient ovens and water-based coatings allow us to deliver premium quality with a minimal environmental footprint. This makes us a reliable partner for automotive manufacturers and suppliers seeking a combination of technological excellence, environmental responsibility and easily auditable processes.
Would you like to learn how our KTL lines can support your ESG objectives? Contact us for a detailed consultation.
