Bentley has begun operations at a new state-of-the-art paint facility at its Crewe headquarters, significantly expanding the range of exterior finishes available to customers while introducing a new Spectraflair paint technology through its Mulliner personalization program.
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The new 12,500-square-meter Paint Shop is now responsible for finishing the Continental GT, Continental GTC and Flying Spur ranges, with Bentley’s first battery-electric vehicle set to join production later this year. The Bentayga will be integrated into the facility in the coming years.
The building represents another step in Bentley’s ongoing “Dream Factory” transformation of its Crewe campus. Standing as the tallest structure on site, the facility was designed with future bespoke paint processes in mind and expands Bentley’s ability to offer increasingly individualized finishes. Customers can now choose from nearly 100 exterior colors, including specialized satin, ombré and Mulliner-developed finishes.
The opening of the facility coincides with the launch of a new Spectraflair finish known as Spectral Verdant. Developed from Bentley’s existing Verdant paint, the color incorporates microscopic light-reflecting elements that create a shifting spectrum effect beneath the green base coat when viewed in natural light.
To showcase the finish, Bentley created a one-off Continental GT S finished in Spectral Verdant and accented by a hand-sprayed Ghost White Pearlescent Union Flag racing stripe. The stripe required several days of manual paint work and serves as a demonstration of the bespoke capabilities now available through Bentley’s Mulliner division.
The new Paint Shop combines traditional craftsmanship with advanced manufacturing technology. Production is spread across two levels, with manual finishing and inspection processes concentrated on the ground floor and automated paint application systems located above.
A fleet of ten Automated Guided Vehicles (AGVs) transports vehicle bodies between workstations. Bentley says it is the first automotive paint facility in the world to utilize self-propelled carriers throughout the paint process. The system allows production routes to be adjusted as needed to accommodate highly customized customer specifications.
The facility also incorporates a number of environmental and efficiency improvements. A new water-based primer replaces the solvent-based solution previously used, while more accurate paint application and improved filtration systems are expected to reduce waste materials by up to 45 percent compared with the previous paint shop.
A Residual Thermal Oxidiser system treats paint-process emissions by burning volatile compounds at temperatures approaching 1,000 degrees Celsius before air is released back into the atmosphere. Bentley says the system can reduce paint-related volatile organic compound emissions by up to 98 percent.
Energy efficiency was also a focus during development. Waste heat generated by paint application systems is captured and redistributed throughout the building, allowing the facility to operate without additional heating for roughly two-thirds of the year.
The building itself serves as a showcase for Bentley’s paint expertise. Forty-five exterior display panels have been finished in colors from Bentley’s paint portfolio, each painted using the same techniques applied to customer vehicles.
As Bentley prepares to launch its first electric vehicle later this year, the new Paint Shop provides the company with expanded capacity for both production volumes and increasingly bespoke customer requests, while establishing a manufacturing platform intended to support future generations of Bentley vehicles.
