Using Energy More Wisely: WellColl Takes the Lead in a Traditional Industry

WellColl has been a familiar sight in South Limburg for 75 years. With six locations and a wide range of services, the auto body repair company has grown into a pioneer in mobility. But behind that strong reputation lies a quiet revolution: a systematic quest to reduce waste and increase energy efficiency.

“In our industry, innovation isn’t a given,” says Managing Director Vital Verheggen. “Still, we want to make a difference by leading the way in sustainability—not because we have to, but because we believe in it.”

WellColl is a Limburg-based company that specializes in collision repair, auto bodywork, leasing, and RV repair. The company operates in a traditional market with many small players. “That makes large-scale investments difficult. But if we take the future seriously, we can’t just sit back and do nothing,” says Verheggen.

Compressed air as a hidden energy consumer

One of the biggest eye-openers for the company was the energy consumption of compressed air systems, a “silent energy guzzler” in the workshop. “Compressed air is crucial to our process,” explains Geert Hauman, Process and Engineering Coordinator. “We use it to control spray booths, for the spraying process itself, and for the lift bridges. But it’s also the most expensive form of energy.”

WellColl replaced the outdated system with frequency-controlled compressors that are more energy-efficient. In addition, the entire air network was inspected for leaks. “That may seem like a minor detail, but it has a major impact. By optimizing everything, we’ve significantly reduced our compressed air consumption.”

40% less gas consumption thanks to smart innovations
 

It wasn’t just compressed air that got an upgrade. WellColl is also working on significant savings in gas consumption, particularly in the spray booths. “Those are energy guzzlers,” says Geert. “That’s why we’ve switched to air-drying paints that cure at lower temperatures. That results in a 40% reduction in gas consumption.”

In addition, the workshop doors were replaced with quick-closing gates to limit heat loss. All lighting has been converted to LED. And the company is exploring alternative heat sources, such as connecting to a regional biomass power plant. “As soon as we can purchase hot water from there, we’ll be able to make another big leap in savings.”

Data as a Management Tool
 

What stands out at WellColl is the level of insight. Each branch is continuously monitored for energy consumption. Geert: “We know exactly how many spray booth hours there are per location and how consumption relates to that. This allows us to detect deviations and optimize processes.”

Planning is also important. “By scheduling cars more intelligently in the queue, we can prevent booths from having to be reheated repeatedly. That also saves energy. It’s not about one major change, but about dozens of small steps that together make a difference.”

Bumps in the Road

Still, becoming more sustainable isn’t always easy. For example, at the newest location in Maastricht, it turned out to be practically impossible to install an energy-efficient spray booth. “Electrification sounded good, but the necessary grid connection simply wasn’t available,” Geert explains. “That’s why we had to fall back on gas, but in combination with smarter planning and optimal utilization.”

Vital adds: “Obstacles like these show that sustainability is not just a technical challenge, but also a logistical and political one. Sometimes you run into roadblocks due to regulations or infrastructure.”

Future-Oriented Entrepreneurship

In the coming years, WellColl will continue to focus on sustainability. “It’s a continuous improvement process,” says Geert. “We want to reduce gas consumption even further, continue testing new technologies, and plan more efficiently. Every percentage point counts.”

Verheggen concludes: “Sustainability requires both vision and courage. Thanks to our scale, we are now able to invest. At the same time, we also want to inspire others. Ultimately, we’re not doing this just for ourselves, but for an industry that needs to become future-proof.”