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Accelerating battery production: A key to the energy transition

  • Writer: Michel
    Michel
  • Jun 8
  • 3 min read

An abstract digital illustration of a glowing battery icon surrounded by circuit-like blue lines, symbolizing energy storage, battery technology, and smart manufacturing systems.

The shift to clean energy is transforming how industries, cities, and supply chains operate, and batteries are at the center of this transition. Once limited to electronics and electric cars, batteries are now critical for reducing carbon emissions across sectors. As a result, battery demand is rising rapidly, which means factories must scale up production quickly without losing quality or increasing costs.[1]


Why ramping up battery production is so challenging


Battery factories, also called gigafactories, are being built globally to meet this fast-growing demand, which is expected to exceed 3000 GWh in the coming years. However, setting up production is not as simple as turning on a machine, since new production lines often go through a long ramp-up phase, where output is low, processes are unstable, and efficiency is not yet optimal.


Low OEE in battery manufacturing means high costs


A visual breakdown of how to calculate Overall Equipment Effectiveness (OEE) using the formula: OEE = Availability × Performance × Quality. Availability is calculated as Run Time divided by Planned Production Time. Performance is Total Units times Ideal Cycle Time divided by Run Time. Quality is Good Units divided by Total Units.
Overall Equipment Effectiveness (OEE)

During ramp-up, Overall Equipment Effectiveness (OEE) is typically low, which leads to losses in time, energy, and costly materials like lithium and nickel. This inefficiency is made worse by poor process control, which causes rework and waste, and in some cases, entire batches must be discarded. In this context, where competition is intense and margins are tight, improving OEE becomes a strategic priority rather than just a technical concern.


Electrode coating: A critical process


Close-up view of a precision slot-die coating machine applying electrode material in a battery production line, with red lighting and aligned coating lanes visible.

One of the most sensitive steps in battery manufacturing is electrode coating, where extreme precision is required. If the coating is uneven by just a few micrometers, it can affect battery lifespan and safety. That’s why modern gigafactories use slot-die coaters in cleanroom environments, applying layers with accuracy better than 1 μm.[2]


To ensure quality, X-ray or beta gauge systems measure the coating’s weight with precision as fine as 0.1%, while confocal lasers and profilometers detect early-stage defects. Additionally, fluid dynamics at the strip edges can introduce variability, so smart sensors are used to correct these effects in real time. As lines get faster and wider, this level of control becomes even more critical to avoid large-scale scrap.[3]


Innovation must include production

Innovation in batteries is often focused on new materials or chemistries, but production processes also need to evolve. Manufacturers now require flexible, connected, and intelligent systems that can adapt in real time. This is where public-private partnerships, like those in Horizon Europe, come into play. They support integrated projects where technical experts, researchers, and manufacturers co-develop solutions, reducing the risks and costs of industrializing new battery technologies.

To accelerate ramp-up and reduce costly errors, the industry is adopting collaborative commissioning a model where equipment suppliers and manufacturers co-develop processes from the start. Instead of simply delivering machines, suppliers bring in their technical expertise early, leading to smoother integration and fewer startup delays. According to Fraunhofer IPA, this approach can cut time-to-stable-production by up to 30%, a major advantage in competitive markets. Beyond speed, it also builds trust, improves on-site problem-solving, and encourages suppliers to align their systems with the end user’s real-world production goals.[4]


Conclusion: Speed matters in the climate race

Scaling up battery production is not only about building more capacity, but also about activating that capacity quickly and reliably. Every delay in ramp-up pushes back clean energy goals, which is why collaboration across the supply chain is so important. The future belongs to those who combine smart engineering, transparent teamwork, and strategic ramp-up planning.


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References:

  1. International Energy Agency (IEA). (2023). Global EV Outlook 2023: Catching up with climate ambitions. Retrieved from https://www.iea.org/reports/global-ev-outlook-2023

  2. PFFC Online. (2025, May). Revolutionizing Lithium-Ion Battery Manufacturing: Advances in Slot-Die and Electrode Coating Technology. Retrieved from https://www.pffc-online.com/coat-lam/18505-revolutionizing-lithium-lon-battery-manufacturing-advances-in-slot-die-and-electrode-coating-technology

  3. PRO Flexconvert. (n.d.). Magazine for Converting Professionals. Retrieved from https://m2n-converting.com/

  4. Fraunhofer Institute for Manufacturing Engineering and Automation (IPA). (n.d.). Battery Manufacture. Retrieved from https://www.ipa.fraunhofer.de/en/about-us/guiding-themes/battery-manufacture.html



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