Five challenges in the paint shop

Traditional automotive paint application has long faced challenges that impact cost, efficiency, and environmental performance. One of the biggest issues is low transfer efficiency, where much of the paint sprayed never reaches the vehicle, resulting in high material waste and increased costs.

Solvent-based paints also release volatile organic compounds (VOCs), contributing to air pollution and requiring expensive treatment systems to meet strict environmental regulations. As these regulations tighten, traditional methods are becoming harder to sustain.

Maintaining a consistent, high-quality finish is another hurdle. Variables like temperature, humidity, and equipment wear can affect coating uniformity, often resulting in defects and costly rework.

Additionally, traditional systems are labor-intensive and energy-heavy, with manual processes and multiple curing stages slowing down production and increasing operational expenses.

Linked to this is a growing shortage of skilled paint shop workers. With expert operators retiring and a shortage of new operators caused by lack of training and apprenticeships, many companies are finding it harder to find people who can deliver the consistent levels of quality demanded by customers.

Together, these challenges highlight the need for more efficient, precise, and sustainable painting technologies to meet the demands of today’s automotive industry.

Traditional paint application challenges

Skills shortages

The cost of paint waste

Emissions regulations

Inefficient paint transfer

Rising customer expectations

*Source:
PPG Industries Inc

Rising customer expectations

Today’s car buyers expect more than just a shiny finish. They want vehicles that look great and stay that way for years. Paintwork needs to do more than turn heads in the showroom. It must resist scratches, fading, weather damage, and everyday wear and tear. On top of that, people want more choices: unique colors, special finishes like matte or pearlescent, and custom styling that reflects their personality.

These rising expectations are putting real pressure on automotive manufacturers. Delivering flawless, high-quality finishes across different models and complex shapes isn’t easy, especially when production schedules are tight. Customers now expect perfection straight from the factory, with no room for imperfections or costly rework.

To keep up, manufacturers are turning to smarter paint systems, precision robots, and real-time quality checks. Advanced technology helps ensure every vehicle leaves the line with a consistent, high-end finish – no matter the color or design.

In short, customers are raising the bar, and automotive painting must rise with it. That means better performance, more options, and absolutely no compromises on quality.

Source:
PPG Industries

Next challenge: Inefficient paint transfer >>

Did you know?

Over 60% of car buyers say color and finish are key factors influencing their vehicle purchase decision.

*Source:
United States Environmental Protection Agency

Inefficient paint transfer

Inefficient paint transfer is a common challenge in automotive painting and can significantly affect both quality and cost. Transfer efficiency refers to how much paint reaches the vehicle surface compared to how much is sprayed. In many traditional systems, a large portion of paint is lost as overspray, especially when using older atomizers, poor spray patterns, or suboptimal settings.

Several factors can cause low transfer efficiency, including incorrect spray angles, inconsistent air pressure, improper nozzle selection, and variations in robot or operator movement. Environmental conditions like temperature and humidity can also affect how well the paint adheres.

The consequences are serious. Poor transfer means more paint is needed to achieve full coverage, driving up material costs. It also increases the amount of waste that must be collected and treated, adding to environmental and regulatory concerns.

Additionally, uneven coating can lead to defects such as runs, thin spots, or inconsistent color, which often result in costly rework or scrapped parts.

Improving transfer efficiency not only reduces waste and saves money, but also helps ensure a higher-quality, more consistent finish, making it a key focus area for manufacturers aiming to improve both sustainability and performance.

Next challenge: Emissions regulations >>

*Source:
United States Environmental Protection Agency

Did you know?

Around 34,000 tons of wet paint sludge is produced by US car plants every year*. This sludge needs to be collected, treated and disposed of.

Emissions regulations

Environmental impact is a big concern in automotive painting, and it’s something manufacturers can’t afford to ignore. One of the main issues is the release of volatile organic compounds (VOCs), which are found in many traditional solvent-based paints. These VOCs contribute to air pollution and smog, and as a result, regulations around them are getting stricter.

In the U.S., the Environmental Protection Agency (EPA) has set clear limits through rules like the National Emission Standards for Hazardous Air Pollutants (NESHAP), which directly affect how paint is applied in automotive plants.

The Clean Air Act also plays a major role in setting national air quality standards. Some states, like California, go even further. The California Air Resources Board (CARB) has some of the toughest VOC regulations in the country, often requiring the use of low-VOC or water-based paints.

To keep up, manufacturers are shifting to cleaner technologies like water-based coatings, high-efficiency application systems, and better filtration. These changes help the environment, but they can also mean extra costs and major updates to equipment and processes.

With regulations only getting tighter, the pressure is on. The automotive industry is being pushed to innovate, not just to stay compliant, but to build a more sustainable future.

Next challenge: Cost of paint waste >>

The cost of paint waste

Paint waste is one of those hidden costs in automotive manufacturing that adds up fast. In many traditional paint systems, only 30 to 60% of the paint actually sticks to the vehicle. The rest becomes overspray that settles in booths or gets filtered out and discarded.

Considering that automotive paint can cost anywhere from $30 to upwards of $100 per gallon, and that each vehicle needs multiple coats, the waste per car can quickly accumulate, potentially adding up to millions of dollars every year for high-volume manufacturers.

But it’s not just the cost of wasted paint. There are added expenses for collecting and disposing of overspray, maintaining equipment, cleaning spray booths, and staying compliant with environmental regulations. All this eats into margins and lowers overall efficiency.

The good news is that small improvements can make a big difference. Boosting transfer efficiency by even 10% can save hundreds of thousands of dollars annually. That’s why more manufacturers are turning to advanced paint systems and smarter automation to cut waste, save money, and still deliver the flawless finishes that customers expect.

Next challenge: Skills shortages >>

Did you know?

Boosting transfer efficiency by even 10% can potentially save thousands of dollars per year in paint and disposal costs.

Skills shortages

Automotive spraying is a skilled task requiring operators to learn the skills needed to achieve consistent high-quality finishes. Operators must have a thorough knowledge of not only how to apply the paint, but also the many different types of paint, primers and other coatings used in the spraying process, all of which have different properties and behaviors that can impact on finish quality.

The many hours needed to manually prepare and paint a vehicle also demand high levels of physical stamina and attention to detail, as well as the ability to identify and rectify problems such as runs or poor adhesion. Workers must also be prepared to operate in conditions involving long-term exposure to fumes and chemicals.

In recent years, a combination of factors, including the COVID-19 pandemic, reduced training opportunities, and retirement of skilled aging workers has led to a growing shortage of automotive paint operators, with people leaving the industry faster than they can be replaced.

For automotive manufacturers, failing to resolve this situation will have an impact on production capacity, potentially delaying the availability of new vehicles as units take longer to pass through the painting stage.

Why automate? >>

*Source:
2025 Seraph Automotive Manufacturing Report