High-capacity formation line boosts European battery production

ANDRITZ Schuler has supplied a high-performance battery cell formation line with an installed capacity of 1.5 gigawatts to a battery manufacturer in southern Germany. The system has been in operation since the beginning of the year and is producing cells for a premium German automotive original equipment manufacturer. The financial value of the order has not been disclosed.

Formation technology for fast-charging EV batteries
The delivered line is designed for the mass formation of innovative cylindrical “booster” cells. These cells are optimized for rapid charging and discharging cycles, making them suitable for use as auxiliary energy buffers in electric vehicles, where high power density and efficiency are critical.

Formation represents the final and chemically decisive step in battery cell manufacturing. After electrode fabrication and cell assembly, controlled charging and discharging cycles activate the electrochemical properties of the cell. Precision, repeatability, and energy efficiency during this phase directly influence cell quality, lifetime, and performance consistency.

High channel density and data-intensive operation
The formation line is based on technology from ANDRITZ Sovema, which was acquired by ANDRITZ Schuler. It incorporates more than 50,000 formation channels and 200 formation chambers, enabling parallel processing at industrial scale. Integrated power electronics manage the energy flows required for formation, while a full Track & Trace system ensures continuous traceability at cell level.

During operation, the system collects more than two million data points per second from the batteries. This data density supports process optimization, quality assurance, and downstream analytics, aligning with automotive requirements for transparency and reproducibility across the battery supply chain.

Automation, footprint, and energy efficiency
The fully automated line includes automated loading and unloading and occupies a footprint of approximately 22 meters in length and 10 meters in width and height. It is designed to minimize energy losses during formation, a process traditionally associated with high power consumption. An integrated service and maintenance concept supports high availability and predictable lifecycle costs.

Strengthening European battery manufacturing capabilities
According to ANDRITZ Schuler, the project reflects a fully European industrial collaboration, combining equipment engineering, digital solutions, and power electronics expertise. Installation, commissioning, and lifecycle support were part of the scope, positioning the company as a systems supplier rather than a standalone equipment provider.

The deployment highlights the increasing industrialization of battery cell manufacturing in Europe and the growing demand for high-throughput, data-driven formation systems capable of meeting automotive performance and traceability standards.