The rapid expansion of electromobility and stationary energy storage is driving an unprecedented scale-up of battery production worldwide. As giga-factories emerge across North America, Europe and Asia, manufacturers face a central challenge: how to maximize production efficiency while maintaining strict quality requirements.
A key performance indicator in this context is Overall Equipment Efficiency (OEE)—the metric that determines how effectively a production system converts planned production time into high-quality output. According to industry experts, systems reaching around 87% OEE are currently considered world-class, while new production lines during ramp-up may initially operate at 40% or less.
Slot-Die Coating: A Critical Step in Electrode Production
In lithium-ion battery manufacturing, the coating of copper and aluminium foils with electrode materials is one of the most demanding process steps. Modern coating lines typically run at web speeds of around 70 m/min with coating widths of approximately 1.2 m, while the full line length can reach 100 meters due to large drying sections.
Achieving consistent coating quality requires:
- highly precise slot-die manufacturing with sub-micron accuracy,
- stable coating delivery systems without flow pulsation,
- and extremely accurate basis-weight measurement systems.
In many cases, coating uniformity tolerances must remain below ±1%, placing significant demands on inline measurement technologies such as X-ray, beta-gauge or ultrasonic systems.
The Path to Faster Ramp-Up
For battery producers, shortening the ramp-up phase is essential. High material costs—particularly for cathode active materials—mean that low efficiency during commissioning can quickly lead to significant financial losses.
Industry specialists therefore emphasize close collaboration between equipment suppliers and cell manufacturers, combining machine technology with process expertise to accelerate stable production.
Key measures include:
- early process trials in technology centers,
- integrated project planning between supplier and customer,
- ongoing process engineering support during commissioning,
- rapid technical response in case of system issues,
- and centralized production data analysis.
Read the Full Technical Insight
The full article by Prof. Dr. Daniel Eggerath, Technical Director Energy Business Unit at Jagenberg Converting Solutions, explores the technical parameters influencing OEE in battery electrode production—from coating precision and measurement technology to system commissioning strategies.
Download the full article here
