In recent years, with the ongoing implementation of China’s “dual carbon” (carbon peak and carbon neutrality) strategy, green transformation in manufacturing is no longer a voluntary upgrade but a mandatory direction. As a key visual and functional component of automotive exteriors, headlamps not only provide illumination and signaling but also play a crucial role in brand identity and design language. Simultaneously, surface treatment processes for these parts have become focal points for environmental audits and energy management.
The core challenge facing automotive lighting manufacturers today is how to achieve optical functionality and aesthetic performance while reducing environmental impact and resource consumption.
No.1 Environmental Bottlenecks in Traditional Headlamp Production
1. Coating-Related VOC Emissions Pose Serious Risks
Conventional surface treatments for headlamp components typically rely on multi-layer spray coating processes, including primer and topcoat layers that contain volatile organic compounds (VOCs) such as benzene, toluene, and xylene. These materials are strictly regulated due to their environmental and health hazards. Even with VOC abatement systems in place, it is difficult to achieve source-level elimination of emissions.
Non-compliance with emission standards can trigger regulatory penalties, forced production halts, or even re-evaluation of environmental impact assessments (EIAs), creating operational uncertainty.
2. Complex, Energy-Intensive Process Chains
Traditional coating lines involve multiple stages including spraying, leveling, baking, cooling, and cleaning—usually requiring five to seven sequential steps. This lengthy process flow consumes significant amounts of thermal energy, compressed air, and cooling water, making it one of the largest contributors to operational overhead in manufacturing facilities.
Under the constraints of carbon intensity control, such resource-heavy production models are increasingly unsustainable. For manufacturers, failing to transition may mean hitting the ceiling of energy quotas, limiting further growth.
3. Low Environmental Robustness and Inconsistent Quality
Spray coating is highly sensitive to fluctuations in temperature and humidity. Minor environmental variations can lead to defects such as non-uniform film thickness, pinholes, and poor adhesion. Moreover, heavy dependence on manual operations results in inconsistent product quality and increased defect rates.
No.2 A New Sustainable Approach: System-Level Equipment Innovation
Amid growing environmental and regulatory pressure, upstream equipment providers are rethinking the fundamentals: How can surface treatment for headlamp components be redefined at the source to enable a truly green alternative?
Zhenhua Vacuum addresses this question with the launch of its ZBM1819 auto lamp vacuum coating machine, purpose-built for headlamp applications. The system integrates thermal resistance evaporation with chemical vapor deposition (CVD) in a hybrid process that eliminates traditional spray coating, offering a high-performance and eco-conscious solution:
Zero Spray, Zero VOC Emissions: The process fully replaces primer and topcoat spray layers with dry film deposition, eliminating the use of solvent-based materials and associated emissions.
All-in-One Deposition + Protection System: Cleaning and drying stages are no longer necessary, significantly shortening the overall process chain, reducing energy consumption, and optimizing space utilization on the shop floor.
High-Performance, Reliable Coating Output:
Adhesion: Cross-cut tape test shows <5% area loss, with no delamination under direct 3M tape application.
Surface Modification (Silicone Layer Performance): Water-based marker lines demonstrate expected spreading behavior indicative of hydrophobic surface properties.
Corrosion Resistance: 1% NaOH drop test for 10 minutes results in no observable corrosion on the coating surface.
Water Immersion Resistance: No delamination after 24-hour immersion in 50°C water bath.
No.3 Green Is Not Just Subtraction—It’s a Leap in Manufacturing Capability
As OEM demand higher standards for both environmental compliance and product durability, green manufacturing has become a key differentiator for Tier 1 and Tier 2 suppliers. With its ZBM1819 system, Zhenhua Vacuum offers more than just an equipment upgrade—it provides a blueprint for next-generation manufacturing processes.
The value of green manufacturing lies not only in reducing emissions, but also in improving production stability, optimizing resource efficiency, and enhancing the overall resilience of the manufacturing system. As the automotive industry enters a phase of concurrent green transition and value chain restructuring, ZBM1819 auto lamp vacuum coating machine represents a strategic leap—from regulatory compliance to green competitiveness.
Post time: Apr-30-2025