The Renault-Nissan Alliance redefines the way its cars are built - the Nissan Resende plant example

The Renault-Nissan Alliance’s commitment to reducing its CO2 footprint extends not only to its vehicles but also to how they are built. Nissan’s Resende plant in Rio de Janeiro, Brazil, is a benchmark for Nissan in this regard.

 

By starting from scratch, Nissan has been able to ensure its new plant in Resende, which began operations in 2014, has the lowest environmental impact of any plant in the entire Nissan group. Full of green innovations, the factory builds the Nissan March (Micra) for the rapidly expanding Brazilian market.

Limiting the impact of the plant on its environment was a key focus for Nissan when it developed plans for Resende. As a result, cutting-edge techniques have been adopted that drastically reduce CO2 emissions during the manufacturing process.

 

A key element is the adoption of a new three-wet paint process.  Rather than baking the car twice during the paint process – once after applying the primer to an electro coated body-in-white, and again after the top coat had been applied – the new process eliminates the need to put the vehicle into an oven between the primer and top coat stages.

 

Eliminating a baking stage brings about a reduction in CO2 emissions of about 30 percent while further environmental gains are made by the use of paint cartridges which reduce wasted paint and solvents and reduce the emission of volatile organic components (VOC).

 

Further environmental considerations include the careful separation of waste products with the ultimate aim of correct destination for 100% of the materials, including recycling and reuse, as well as strict management of water usage during the production process. The plant is already one of the most efficient users of energy in the business, with up to 80 percent of its electricity consumption coming from Brazil’s extensive hydropower.

 

The buildings showcase natural illumination and ventilation systems which further reduce energy consumption and have a low environmental impact. 

But it’s the final element that really sets the factory apart from others. Completely surrounding the entire facility is a deep ‘Green Belt’. More than 4,000 plants have been planted around the factory, helping to neutralise CO2 emissions and, at the same time, reducing noise levels for the surrounding environment. The Belt reflects the region’s natural habitat and covers an area of more than 12 acres. 

 

Once established, wetlands will be created within the Green Belt to help maintain the balance of the local ecosystem and ensure the survival of more than 150 species of birds.