Europeʼs battery cell production is under pressure. Despite intensive research and investments worth billions, battery cell and plant manufacturers are facing high rejection rates, non-scalable processes, and unclear technology dependencies. Battery cell manufacturing combines chemical, physical, and technical processes in a highly complex production chain. New technologies present challenges, but they also open up opportunities. A recent analysis by EDAG shows how innovation potential can be systematically leveraged along the process chain – and why it is crucial to look at the entire process chain.
Early analysis of cause and effect
Many projects show that battery cell production is complex. Changes in cell chemistry require adjustments along the entire production chain – from material preparation and electrode production to cell assembly and finalization. New technologies have an impact on downstream production steps and may require adjustments or the replacement of existing equipment. Those who want to drive technological progress forward must consider the process chain as a whole. Early analysis of cause-and-effect relationships is crucial.
Technology integration brings millions in savings
As part of a study, EDAGʼs battery cell manufacturing team analyzed the impact of innovative technologies on the manufacturing process of lithium-ion batteries in pouch cell format, focusing on electrode manufacturing and cell assembly. The aim was to optimize manufacturing processes and identify interactions between state-of-the-art and innovative technologies, including feasibility studies. A comparison of a state-of-the-art layout with innovative concepts illustrates the potential for efficiency gains: One example shows that the use of a floating dryer with double-sided coating enables space savings of over 8,000 square meters. In the drying room alone, this can save more than 24 million euros in capital expenditure (CapEx) and over 2.8 million euros in operating costs (OpEx) annually. There is also further potential for savings in building, energy, and personnel costs.
Virtual battery cell production minimizes risks
Virtual manufacturing methods such as process simulations and so-called digital twins help identify weaknesses in production at an early stage and enable targeted optimization. Virtual battery cell production also offers an effective tool for evaluating technology options. It reveals interdependencies before investments have to be made. Combining real production data with simulation models makes it possible to identify cause-and-effect relationships at an early stage, minimize risks, and reduce scrap. This accelerates ramp-up, improves cost-effectiveness, and supports more economically sustainable battery cell production.
Technology database facilitates decision-making
In collaboration with cell manufacturers, plant manufacturers, and research institutions, EDAG has built up a database of 33 technologies for battery cell production as of October 2024 to enable systematic comparison and support suppliers and plant manufacturers in selecting technologies. EDAG is continuously expanding the database and integrating new findings from projects and research collaborations.
Digitalization and collaboration
The analysis results underscore the potential of innovative technologies – but technology alone will not make Europeʼs battery cell production future-proof. EDAG claims a holistic approach is needed that considers cell chemistry, recyclability, second-life concepts, and production processes. Research such as that conducted by EDAG shows how industrial maturity can be accelerated through simulation-supported analysis, data-based planning, and virtual process optimization. Long-term success also comes from close cooperation along the entire value chain. Collaboration of manufacturers, mechanical engineers, technology providers, and system integrators creates synergies and can strengthen Europeʼs competitive position. As an independent engineering service provider, EDAG supports market players in the early evaluation and implementation of technologies.
Free white paper download
In its current “Innovative Technologies and Process Chains for Sustainable European Battery Cell Production” white paper, EDAG provides a market overview and highlights challenges and opportunities for Europe, gives insights into innovative technologies and process chains, provides a practical comparison of conventional and innovative production layouts and provides information about its battery cell production technology database. The white paper is available as a free download.
