While headlines around the Volkswagen Group have not been particularly encouraging - with possible factory closures and job cuts being discussed - the German brand’s operation in Portugal continues to gather pace.
Work to modernise the plant ahead of production of the new Volkswagen T-ROC in 2025 is under way and is now moving towards its final stages. One of the most critical areas at the Palmela site is a key focus: the press shop.
In an interview with Automotive Manufacturing Solutions, Thomas Hegel Gunther, Managing Director of Autoeuropa, says the Palmela plant “is one of the most productive within the brand”. He adds that the aim is to raise output and efficiency without “reducing jobs”, while also “preparing the future” of this facility.
This is one of several investments announced in 2021 to modernise what remains, to this day, the largest private investment in Portugal. The new press shop area (pictured in the lead image) is expected to boost both production and efficiency at the Portuguese factory. Below, we explain what this investment changes in practice.
What is at stake
After 30 years in service, Autoeuropa is upgrading its mechanical press line - a service life that is not especially high for machinery of this type. Even so, plant management has made improving productivity in this area a priority.
The press shop has long been one of Volkswagen Autoeuropa’s core strengths. This division produces components not only for models built in Palmela, but also for other plants across the group.
Volkswagen Autoeuropa press shop: why it matters
Because of its scale and capacity, the new line is known as Press Extra Large (PXL). The equipment is being built by Schuler Pressen to Volkswagen Group standards, and it will enable tooling to be transferred directly from other factories to Palmela - and from Palmela to them.
“By comparison, the current Tandem Line runs at a rate of six strokes per minute, while the new PXL reaches 15 strokes per minute.”
The existing press line will nevertheless remain in operation. It will act as support capacity, helping to meet periods of higher demand, whether for models produced at Autoeuropa or for other plants within the German group.
The PXL press line numbers
The line consists of six mechanical presses installed in sequence, in other words in tandem. The first press will apply a maximum force of 2,100 t, while the remaining five presses will each apply 1,200 t. In total, the PXL delivers 81,000 kN of force.
Automation, monitoring and faster changeovers
Beyond higher output, the new PXL press line is designed to be more efficient to run. It includes machine-vision systems for identifying and centring parts, along with monitoring systems that can, for instance, anticipate adjustments and repairs, helping to avoid unplanned stoppages.
Product changeovers - or tool swaps - are also streamlined and fully automated. On the Tandem Line the process is manual and takes 20 minutes. On the PXL, the fully automatic changeover is completed in five minutes.
According to Autoeuropa, in a direct comparison, the current Tandem Line operates at six strokes per minute, while the new PXL will reach 15 strokes per minute.
Autoeuropa also states that “all systems in the new PXL are built with the highest energy efficiency in mind, as well as compliance with all environmental protection requirements”.
According to Palmela plant management, construction of the new PXL press line is expected to be completed in February 2025.
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