Battery Electrode Mixing & Integrated Material Handling Solution

The Eirich Battery Electrode Mixing & Integrated Material Handling Solution is a fully automated system designed for wet and dry mixing processes in electrode production. The system manages the process sequence from raw material intake and automated dosing to the discharge of processed intermediates. It is configured to support both traditional wet slurry preparation and solvent-free dry electrode manufacturing.

Flexible Architecture

The solution allows a flexible architecture. A vertical design is the preferred architecture as it enables gravity-fed material flow. Raw materials move from silo storage and big-bag discharging units through dosing and mixing stages to the final discharge point. This vertical orientation reduces the total horizontal floor space required for the mixing installation compared to horizontal line configurations, making it more space-efficient and reducing mechanical stress and potential contamination compared to traditional horizontal line configurations. However, horizontal configurations are available to accommodate specific building height restrictions or existing facility layouts.

Core Mixing Technology

At the center of the solution is a batch-based intensive mixer, Eirich MixSolver®, featuring a horizontal, rotating mixing pan and an eccentric high-speed rotor. This specific configuration separates material transport from energy input, allowing for precise control over the process parameters:

• Wet Mixing: Applies controlled shear to coat carbon particles and homogenize NMP or water-based slurries without destroying delicate active materials.
• Dry Mixing & DBE: Provides the high-energy impact required to fibrillate binders (PTFE) for solvent-free workflows.
• Solid-State (ASSB): The hardware supports moisture-sensitive All-Solid-State Battery materials through a vacuum-tight design and integrated nitrogen or argon gas inerting.

Process Monitoring and Quality Control

Eirich offers the QualiMaster® LiB inline process control system. Within the mixer, the system monitors energy consumption, motor power, temperature, pressure, and viscosity. In the downstream slurry and buffer tanks, additional parameters are recorded via the PLC system — including density, grain size distribution, solids content, and pH. To further enhance quality assurance, the system also includes QualiMaster Rheology. This module enables the inline verification of viscosity directly via the mixing tool using a defined measuring sequence. This allows for precise, real-time monitoring of rheological properties without the need for manual sampling or external lab tests. All data is collected in a single database and supports data mining, AI applications, and process analysis.

Batch traceability is guaranteed across the entire process chain. The ProView® web-based visualization tool enables time-saving comparison of different batches and simplified analysis of all recorded data flows. Communication between systems uses the OPC UA protocol, ensuring standardized data transfer even between equipment from different manufacturers.

Scale-Up & Process Validation in Eirich Test Centers

Eirich provides a validated path from R&D to mass production through dedicated industrial-scale Test Centers. This infrastructure allows customers to verify process parameters on full-scale equipment before investing in laboratory hardware or committing to factory commissioning.

• Linear Scale-Up: Due to consistent mixing geometry, results from the EL1nano (0.1 L) or Intensive Lab Mixer EL5 (5 L) transfer linearly to production-scale volumes.
• Verification Trials: Customers can perform 500 L trials using the Intensive Mixer RV12 to confirm product quality and cycle times under real-world industrial conditions at Eirich Test Center in Germany or at a dedicated partner like UKBIC.
• Full-System Trials: For integrated trials that extend beyond mixing to the full process chain, Eirich collaborates with specialized partners such as UKBIC or Battery NY, who possess the required downstream equipment.