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São Carlos.

Employees of Volkswagen do Brasil (4 factories): around 24,000
Produced: 48 types of engines
Inauguration date: October 12, 1996
Build area: 74,500 m2
Total area: 730,332.30m2

Launched in October 12, 1996, the Volkswagen do Brasil engine factory in São Carlos reached a record volume of 7.5 million engines since the beginning of its activities. It is the third largest engine plant of Volkswagen Group worldwide. The São Carlos plant is responsible for producing an average of 77 thousand engines per month in 48 different models, 1.0, 1.4 and 1.6 liter, which equips the models New Gol, Fox, New Voyage, CrossFox, SpaceFox, Saveiro, Polo , Polo Sedan, Kombi, Gol G4 and Golf.

While investments of € 126 million, the São Carlos factory is accelerated regarding the works for the new productive building: now in equipment testing phase. Start of operations scheduled to be in 2013 when the production capacity will increase from 3,800 engines/day to 4,800 engines/day.

With modern technology and following the strictest safety and environmental standards, the new building will have a total area of 27,100 m2 and will house three production lines, two lines of machining and one assembly line.

With a focus on sustainability and efficiency, the new building was designed to avail the use of natural lighting that will be provided by greater spacing between support columns that provide increased clearance between each of them.

The unit is currently working in eleven lines of machining / assembly of high technological level, containing 18 robots and 77 automatic stations, which ensures the production of motors with high efficiency, quality and performance.

For the Brazilian market, 100% of the engines receive Total Flex biofuel technology. For the external market gasoline engines are produced that are mounted on vehicles for exportation and partial engines are also exported to Argentina.

Sustainability

São Carlos unit was the first unit of the Volkswagen Group outside Europe to conquer the ISO 14001 environmental certificate in 1997 and became a reference in environmental management for the remaining units in South America.


São Carlos factory has 18.6 hectares of legal reserve area, with preservation of the Cerrado, with the reforestation of the native forest as one of the permanent sustainable practices aiming at the environmental preservation.

In 1998, the São Carlos factory began performing in cold engine test series, called Kalt Test, an innovative technology performed in 100% of the engines and evaluates more than 300 distinct features in the motor by monitoring timing, noise, ignition, aspiration, exhaust, torque and lubrication. This equipment ensures the strictest dynamics and qualitative approval criteria of the engine.

Moreover, the non-utilization of fuel for testing stands out (used at Kalt Test, but 10% of the engines are still tested with fuel for quality purposes), which ensures greater environmental efficiency. The unit has four machines responsible for the tests, which take an average of forty five seconds for evaluation. The adoption of this technology allowed a 73% reduction in emissions of greenhouse gases compared to traditional testing processes.

In 2012, the unit has achieved another breakthrough in the area with the installation of a new industrial effluent treatment station, even more efficient and sustainable. The change in the system is pioneer in Volkswagen Brazil and doubled the capacity of industrial effluent treatment, as well as providing a 40% reduction in operating costs of the process.

The entire logistics process was designed to reduce costs, minimize traffic on the roads and increase environmental efficiency, through the use of "road train". Before being deployed, the process had its life cycle modeled in GaBi software for environmental analyzes. This evaluation was part of the decision-making process showing environmental efficiency increase of over 40% compared to the previous process. The same type of analysis was performed for the new machining technology. This process, known as MQL was developed for not using the emulsion of traditional water/oil, but a small amount of oil, increasing the environmental efficiency on water sources of at least 20% and enhancing the recycling of waste.

Another important project is the Composting Central, began in 2007 as a pilot project that yielded the São Carlos factory the AutoData Award in Environmental Responsibility. In 2009, the Center began to function effectively.

In the Composting Central, which has the ability to perform composting 10 tons/year, part of organic waste generated in the restaurant of the factory are treated, in order to turn it into fertilizer, used in the green area of the unit itself. In the year 2012, the plant recycled 98.3% of all waste generated.

To part 2

Volkswagen do Brasil

Rod. Luis Augusto Oliveira Km 148,8