BASF Coatings' overspray-free two-tone process achieves 100% transfer efficiency
Last update on Jun 2, 2026
Coatings formulators and automotive OEM engineers evaluating two-tone application processes can now assess the operational and sustainability profile of BASF Coatings' Overspray-Free Application (OFLA) process, which has entered serial production at Renault's Maubeuge plant and received the Sustainability Award in Automotive 2026 in the Technology: Operations & Supply Chain category.
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The award is organized by the ATZ/MTZ Group (Springer Nature) and Arthur D. Little, and recognizes technological and process innovations that deliver measurable contributions to sustainability in industrial operations.
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Offers tailored rheology, optimized flow and leveling behavior
OFLA is a wet-on-wet process for two-tone vehicles. The contrast color is applied using digitally controlled paint jets, producing a defined paint edge without masking. The process relies on BASF Coatings' ColorSharp decor coat paint technology, engineered specifically for overspray-free jet application.
According to BASF Coatings, the paint formulation features tailored rheology and optimized flow and leveling behavior, designed to support sharply defined jet-applied paint lines and to limit defects typically associated with conventional spray basecoats. Because paint is deposited only at the target location, the process achieves 100% transfer efficiency and eliminates overspray entirely.
“The award underlines how process innovation, enabled by advanced paint technology, can fundamentally change the sustainability profile of automotive two tone painting without the efficiency and resource penalties of conventional approaches,” said Alvin Lao, head of global sustainability, automotive OEM coatings at BASF Coatings. “The jury’s recognition highlights OFLA as a technology driven solution that delivers measurable environmental and operational value for automotive manufacturing.”
OFLA is the result of a collaborative development between BASF Coatings (paint innovation), Renault (OEM manufacturing), and Dürr (application and automation technology). Serial production data from Renault's Maubeuge plant, as reported by BASF Coatings, indicates the following outcomes:
- Approximately 25% reduction in energy consumption, equivalent to roughly 1.7 GWh per year
- Approximately 300 tons of CO₂ reduction per year
- Elimination of approximately 300 g of masking-related, paint-contaminated waste per vehicle
- Approximately 200 g of process-level paint savings per vehicle, by avoiding the second basecoat and clearcoat run required in conventional masking-based two-tone processes