Author: Luca Schneider – Leclanché

Within BATMACHINE, several machine suppliers for cell manufacturing are collaborating to develop new machines for specific process steps. Specifically within the project, the unique advantage lies in the connectivity and efficiency of the mixer (Netzsch), coating/drying machine (FOM Technologies, TEKNIKER), thickness measurements (SKZ), and the calendering unit (FOM Technologies).
All these machinery are integrated to create an intelligent machinery plant based on software from SINTEF. As a result, this high level of digitalisation can enable new features. For instance, it allows to reduce overall energy consumption, in conjunction with renewable energies.

To obtain rapid feedback from practical use, Leclanché is testing the mixer and calendering machinery. Leclanché is a lithium-ion battery manufacturer located in the southwest of Germany. Because of the shorter distance, machinery trials for mixer and calendering units were tested at Leclanché first. Leclanché is testing the machines with high-nickel content NMCs for cathode active material as well as high-energy anodes.

Subsequently, POMEGA will set up the entire pilot plant, including mixing, coating/drying, and calendering.

Mixer Machinery Trials

The activities related to the mixing trials began with Netzsch, SKZ, and Leclanché at the start of the project.
Initially, the specific needs of the industry were gathered, influencing machine development. The formulations for the anode were investigated and optimised at SKZ based on Leclanché’s initial suggestions. In March 2025, a week of testing different recipes with the mixer and Leclanché’s anode materials took place at Netzsch. This testing week was very successful and will continue in June 2025 at Leclanché’s site for anode slurries as well as water-based, PFAS-free cathode slurries. In the video below, conductive additive is added to the water/binder solution. 

Calendering Machinery Experiments

The calendering unit, developed by FOM Technologies, can be used as a standalone unit or integrated into the coating and drying line. The standalone calendering unit was shipped to Leclanché in October 2024 and tested until March 2025 (see Fig. 1). Electrodes produced at industrial scale with high precision in thickness and mass loading were used to investigate FOM calendering unit machine-material interaction. Optimal machine parameters were identified to maximise the C-rate capability and ensure long cycle life in electrochemical tests of the electrodes. High-energy cathodes and anodes were tested. Following the experiments at Leclanché, the calendering unit will be integrated into the production line.

Fig.1: Calendering unit from FOM technologies installed at Leclanché R&D laboratory.