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The employee magazine
of the Volkswagen brand

Models and Technology

Two-Tone T-Roc

The new T-Roc is the first Volkswagen model that can be ordered in two colors. At the Palmela plant, a second paint shop has been opened just for this purpose.

Some 150 employees, including many young colleagues, work in the new paint shop in Palmela.

No other Volkswagen model can be made as individually as the new T-Roc. Customers can choose among four roof colors and 11 exterior colors in the “Style” line – with a total of 24 possible combinations.

In order to produce the “two-tone” design, a new, 400-meter-long paint shop has been built, and can be used alongside the one that was already in operation at the Palmela plant. A total of 150 employees paint approximately 300 roofs and A-pillars per day here for the two-tone T-Roc, which amounts to some 45 percent of total production. There are only four robots working at the new paint shop; all the other tasks are carried out manually by employees.

» It’s a fantastic experience to work here at the plant. We have to be very meticulous during the painting process in order to guarantee perfect quality. «

Mariana Alonso, technician

» After working in a normal paint shop for many years, I am very happy to be part of the two-tone project. «

Paulo Batista, supervisor

All the vehicle bodies for the T-Roc first go through the old paint shop, where they are painted completely in the exterior color ordered by the customer. Then, the bodies which will later leave the plant in the two-tone design enter the new paint shop. That’s where the roofs and A-pillars, the parts which will receive a different color, are sanded by the employees. Before robots apply the new paint, foil is affixed to the rest of the vehicle body to protect it from the spraying. “This type of work requires a lot of precision from the employees,” says João Camolas, head of the paint shop.

» We have mastered all the challenges, even the extremely detailed processes. We needed a lot of teamwork to avoid errors. «

Angelo Monteiro, technician

In order to meet the high quality standards, this special procedure was thoroughly tested in pre-production. Camolas says that he has deliberately given this difficult task to many of the younger employees. “They were extremely committed and eager to learn.”

Once the roof and A-pillars have been painted, the vehicle body is dried in an oven at 80 degrees Celsius. Then it goes into the oven for a second time after the protective clear coat of varnish has been applied. On the way to production, the two-tone vehicle bodies then rejoin the ranks of their monochrome “colleagues.”