Exploring the potential of utilizing high-performance thermal insulation in automotive paint ovens: energy and environmental perspectives

PurposeDue to economic, environmental and regulatory pressures to reduce vehicle emissions, the automotive sector continues to seek ways to make manufacturing processes more environmentally sustainable. Since automotive paint shop ovens in automobile manufacturing consume a significant amount of energy, simulating oven operations is essential, as it enables the appropriate selection of parameters that need to be adjusted to ensure a paint oven best meets its requirements. For these reasons, the ongoing use of advanced thermal insulation materials, such as flexible hierarchical superhydrophobic ceramic nanocomposites and scalable high-temperature thermal insulation materials with mechanical robustness, shows great promise for low energy consumption.Design/methodology/approachA mathematical model was developed to detail energy losses under various insulation scenarios, ranging from the operating temperature of the oven to ambient conditions and material thickness. This model was used to facilitate a comparison among several insulation configurations in terms of energy consumption, fuel savings and thermal uniformity of performance. Meanwhile, a cost-benefit analysis was carried out to consider the economic feasibility of applying high-performance insulation solutions.FindingsIncorporating next-generation thermal insulation materials, such as aerogels and ceramic fibers, into car paint ovens can lead to improved energy efficiency, reducing operating costs and pushing sustainability in the manufacturing process. Emerging thermal insulation materials, particularly aerogels, have a significant potential for great energy and environmental benefits through the integration of car paint ovens. In minimizing heat loss and energy use as well as enhancing thermal stability, these materials help to support sustainable production processes.Originality/valueThis study provides valuable insights into the performance, feasibility, and economic benefits of these materials, facilitating their integration into the automotive industry and beyond.