Battery Manufacturing

Every system we install is backed by our pass-or-free compliance guarantee. If your dust collection, solvent recovery, or cleanroom system doesn’t pass regulatory inspection, we fix it at no cost.

Pyrophoric & Reactive Metal Dust

Lithium metal dust is pyrophoric — it can ignite spontaneously in air and reacts violently with water. Cathode materials (NMC, LFP) and anode materials (graphite, silicon) are also combustible. Standard dust collection approaches don’t work here. These dusts require nitrogen-inert collectors, explosion-proof electrical systems, continuous oxygen monitoring, and specialized discharge handling to prevent ignition during collection and disposal.

NMP Solvent Vapor

N-Methyl-2-pyrrolidone (NMP) is the primary solvent used in cathode slurry coating. It’s a reproductive toxin with an OSHA PEL of just 10 ppm (8-hour TWA). NMP vapors are released during electrode coating, drying, and calendering. Capture and recovery systems are needed for worker protection, to meet EPA VOC emission limits, and to recover NMP with significant economic value for reuse or resale.

Cleanroom Particle Control

Cell assembly — electrode stacking or winding, electrolyte filling, and sealing — typically requires ISO Class 6 or 7 cleanroom environments per ISO 14644-1. Metallic particles in the cell can cause internal short circuits and field failures. Maintaining cleanroom classification requires HEPA or ULPA filtration, controlled pressurization, and careful management of material flow between dirty and clean zones.

Formation Off-Gassing

During the initial charge (formation), lithium-ion cells generate gases, including CO, CO₂, ethylene, and hydrogen fluoride (HF), from electrolyte decomposition and SEI layer formation. Formation rooms need exhaust ventilation designed for these specific gases, with monitoring and controls to maintain safe concentrations for operators working in or near the formation area.

Multiple Material Streams

Electrode production handles cathode active materials (lithium compounds, nickel, cobalt, manganese), anode materials (graphite, silicon), binders (PVDF), conductive additives (carbon black), and current collector foils (aluminum, copper). Each material has different combustibility characteristics, exposure limits, and collection requirements. Cross-contamination between cathode and anode dust streams must be prevented.

Dry Room & Humidity Control

Many battery production steps—particularly electrolyte filling and cell sealing—require ultra-low-humidity environments (dew points below -40°F). Dust collection and ventilation systems serving dry rooms must be designed to prevent moisture intrusion and maintain a controlled atmosphere. Ductwork penetrations through dry room envelopes need proper sealing to prevent humidity migration.

Inerted Dust Collectors

Nitrogen-blanketed cartridge dust collectors with continuous oxygen monitoring, explosion-proof electrical components, and inerted discharge systems. Designed for pyrophoric lithium dust and reactive cathode/anode materials. Oxygen concentration is maintained below the limiting oxygen concentration (LOC) of the specific dust being collected.

NMP Solvent Recovery

Dedicated solvent vapor capture and condensation/adsorption recovery systems for NMP from electrode coating and drying. Recovers NMP for reuse or resale — the value of recovered solvent typically provides a meaningful return on the system investment. Exhaust concentrations are designed to meet EPA VOC limits and OSHA worker exposure requirements.

Cleanroom HEPA Systems

HEPA and ULPA filtration for cell assembly cleanrooms operating at ISO Class 6–7. Fan filter units, ceiling grid systems, and air handling configurations are designed to maintain classification under production conditions. Individually scan-tested filters with ISO 29463 certification and full validation documentation.

Formation Exhaust Systems

Ventilation and exhaust systems for formation and aging rooms where cells off-gas during initial charge cycles. Designed for the specific gas mixtures generated (CO, CO₂, ethylene, HF traces) with appropriate materials of construction, monitoring, and exhaust treatment to protect operators and meet emission requirements.

Process Enclosures & Source Capture

Engineered enclosures and source-capture hoods for electrode mixing, slitting, die-cutting, and material handling operations. Designed to contain and capture dust at the point of generation before it enters the workspace. Critical for maintaining both exposure limits and product quality — dust that escapes capture can contaminate downstream processes.

Material Recovery Systems

Battery electrode materials — lithium compounds, nickel, cobalt, manganese, graphite — have significant value. Dust collection systems designed for material recovery capture and segregate these materials for recycling or reprocessing rather than treating them as waste. Segregated collection streams prevent cross-contamination between cathode and anode materials.

Electrode Mixing

Cathode and anode slurry preparation — weighing, dispensing, and mixing active materials, binders, and conductive additives. Primary hazards: reactive dust from powder handling and NMP vapor from slurry preparation. Requires inerted collection and local exhaust ventilation.

Coating & Drying

Electrode slurry applied to current collector foils (aluminum for cathode, copper for anode) and dried in ovens. The primary NMP emission source in the plant. Requires high-volume vapor capture with NMP recovery or oxidation. Coating dust from edge trimming also needs collection.

Calendering & Slitting

Coated electrodes are compressed (calendered) for density and slit to final width. Both operations generate fine electrode dust from the coated surfaces and foil edges. Source-capture hoods with dedicated dust collection prevent both operator exposure and product contamination.

Cell Assembly

Electrode stacking or winding, tab welding, electrolyte filling, and cell sealing — typically in ISO 6–7 cleanroom and dry room environments. HEPA/ULPA filtration maintains particle classification. Ultra-low-humidity dry rooms require a moisture-controlled ventilation design.

Formation & Aging

Cells undergo initial charge/discharge cycles to form the SEI layer. Off-gassing produces CO, CO₂, ethylene, and trace HF. Formation rooms need exhaust ventilation with gas monitoring and appropriate treatment. Some facilities use vacuum degassing, which generates concentrated exhaust streams.

Module & Pack Assembly

Cells assembled into modules and packs with welding (laser and ultrasonic), adhesive application, and thermal interface material dispensing. Fume extraction for welding and adhesive operations, plus general ventilation for the assembly area.

Testing & Quality Control

End-of-line testing, cycling, and quality inspection. Some test protocols involve abuse testing (overcharge, nail penetration, crush) that can trigger thermal runaway with toxic gas release. Dedicated ventilation and containment for abuse testing areas.

Scrap & Material Recovery

Electrode scrap from slitting, die-cutting, and rejected cells contains valuable active materials. Dust collection systems designed for material segregation and recovery capture lithium, nickel, cobalt, manganese, and graphite dust for recycling rather than landfill disposal.

OSHA 29 CFR 1910.1000

Permissible exposure limits for all airborne contaminants in battery manufacturing: NMP (10 ppm TWA), lithium compounds, nickel (1 mg/m³), cobalt (0.02 mg/m³ — one of the strictest PELs), manganese (5 mg/m³ ceiling), carbon monoxide (50 ppm), and hydrogen fluoride (3 ppm ceiling). System design must ensure exposure levels remain below these limits at all operator positions.

NFPA 660 & Combustible Dust

NFPA 660 (effective January 2026) requires dust hazard analysis for all combustible dust operations. Lithium, graphite, and many cathode materials are combustible or pyrophoric. DHA testing determines Kst, Pmax, and minimum ignition energy to drive the design of explosion protection, inerting systems, and housekeeping requirements. Pyrophoric dusts may require additional controls beyond those specified in NFPA 660.

EPA VOC Emission Limits

NMP is a regulated VOC. Battery manufacturing facilities that release NMP above threshold quantities must comply with EPA emission limits, which may require New Source Review permits, best available control technology (BACT), and continuous emission monitoring, depending on the facility’s total VOC emissions and location. Solvent recovery or thermal oxidation systems address both worker exposure and environmental requirements.

ISO 14644 Cleanroom Classification

Cell assembly typically requires ISO Class 6 or 7 environments per ISO 14644-1, with particle concentration limits measured at 0.5 μm and larger. Maintaining classification requires validated HEPA/ULPA filtration, positive pressurization, gowning protocols, and particle monitoring. System design includes qualification testing (IQ/OQ/PQ) documentation for validation.