Less space, lower energy use, and higher performance — that’s the vision behind the new concept factory for lithium-ion battery cells from engineering leaders Dürr and GROB. The two companies showcased their breakthrough technologies at The Battery Show India in Greater Noida, highlighting innovations that promise to redefine efficiency and sustainability in battery manufacturing. At the heart of this concept are dry electrode coating and advanced Z-folder technology for cell assembly, integrating notching and minimizing process complexity.
Global Partnership Driving Clean Mobility
Since forming the partnership in 2022, Dürr and GROB have worked together to become system suppliers for lithium-ion battery production across Europe, North America, and India. Their collaboration aims to localize cutting-edge technologies, strengthen ties with Indian battery manufacturers, and support the nation’s ‘Atmanirbhar Bharat’ initiative toward a self-reliant clean energy ecosystem.
“We are driving India’s clean mobility transition with world-class manufacturing systems for lithium-ion batteries that combine international engineering excellence with local manufacturing and service throughout the entire project and product life cycle,” said Aji Philip, Head of LiB at Dürr India.
German Wankmiller, CEO of the GROB Group, added, “With our expanded portfolio of highly available machines and systems, we now cover nearly the entire value chain for battery cell production with our own technologies.”
Concept Factory: Compact, Energy-Efficient, and Scalable
The new concept factory combines dry coating and Z-folder technology to achieve up to 50% less space and 70% lower energy consumption compared to conventional systems. This not only improves space efficiency and reduces operating costs but also enhances production performance and battery cell quality — setting new benchmarks for sustainable manufacturing.
Dry Coating: Efficient and Sustainable Innovation
At the core of this efficiency leap lies Dürr’s X.Cellify DC system, which implements the Activated Dry Electrode® process developed with LiCAP Technologies.
Instead of a liquid slurry, the process uses a dry-mixed active powder, pressed into a free-standing film using calender machines. The film is then laminated onto both sides of the collector foil, eliminating drying, solvent recovery, and treatment processes. The result: major savings in space, energy, and cost.
The process also improves material efficiency, as excess film material can be fully recycled back into production. A recent proof of concept confirmed that the Dürr machine delivers consistent, high-quality dry coating, and the company is now seeking industry partners to scale up pilot applications.
High-Speed, Compact Cell Assembly
GROB’s latest Z-folder generation, equipped with integrated notching, boosts system performance while minimizing space requirements. By guiding the separator over fewer deflection rollers with uniform, low web tension, the technology ensures greater process stability. A high-quality magazine buffer system for electrodes further enhances reliability, achieving up to 95% system availability — a key advantage for high-volume production environments.
Precise Electrolyte Filling with High Pressure
Dürr has also developed an innovative single-step electrolyte filling process that operates without residual gas. By injecting the electrolyte at pressures up to 30 bar — two to three times higher than industry norms — the process allows for precise dosing, faster filling, and quicker electrolyte penetration into active materials. The advancement significantly reduces cycle time and improves cell consistency and quality.
Digital Twin for Complete Production Transparency
The Dürr–GROB ecosystem is fully integrated with end-to-end digitalization. A digital twin of the entire factory allows simulation of every process before physical production begins — shortening commissioning times and improving planning accuracy. All simulation data feeds directly into Dürr subsidiary iTAC’s MES/MOM software, which manages production control, traceability, and quality analysis across the manufacturing process. This ensures maximum equipment effectiveness, minimizes downtime, and supports data-driven decision-making.
Powering the Future of Battery Manufacturing
Through this concept factory, Dürr and GROB are pioneering the next generation of battery production — one that combines German engineering excellence, digital innovation, and sustainability. With India emerging as a key hub in the global battery supply chain, their collaboration sets a strong foundation for a cleaner, smarter, and self-reliant future in energy storage technology.
