Lithium-ion battery

Lithium-ion batteries are at the heart of the energy transition, but their large-scale industrialization (EV and ESS) imposes extremely high requirements in terms of plant design and international regulatory compliance in process safety & machine safety.

ZEnergy Consulting supports industrial actors in the design, optimization and securing of lithium-ion battery manufacturing and recycling plants, integrating a global approach from the process to equipment certification.

Improved design of manufacturing and recycling plants

Our expertise covers the entire industrial chain:

Manufacturing of lithium-ion batteries (EV & ESS)

Review of the design of battery manufacturing equipment, meeting European and British regulatory requirements (mixing, coating, calendering, baking, TABLAMI, degas, charge-discharge, inspection, Module-Pack, etc.)
Design of the fire protection system for battery manufacturing equipment
Review of ATEX zone classification

Recycling of lithium-ion batteries

Analysis of dismantling and separation processes
Securing mechanical processing operations
Improvement of the treatment process
Managing the risks associated with end-of-life batteries

Industrial safety for lithium-ion battery manufacturing

Setting up a department Technical Safety & Compliance dedicated to process safety, machine safety and fire/explosion protection.

Machinery and process safety approach

Risk analysis according to ISO 12100
Calculation of safety performance levels according to ISO 13849
Functional analysis of industrial equipment
Reduction of risks of machine non-compliance

Optimization of equipment in operation

Mechanical and electrical modifications to existing machines
Updating control-command systems (industrial software)
On-site interventions and production support
Reduced downtime related to compliance issues

Equipment concerned: TABALMI, inspection, degas, CDC, mixing, calendering, coating, baking, etc.

Our industrial success

⚡ Optimization of TABLAMI Equipment (Gigafactory)

Compliance and optimization of a TABLAMI machine for the manufacture of lithium-ion batteries

The Challenge: The strict application of European safety standards caused repeated sudden cuts in electricity and compressed air each time a door was opened for maintenance or adjustment. This rigid approach led to cascading micro-stoppages, heavily penalizing the overall availability of the line (OEE) and degrading the production rate (pieces per minute – ppm).

The Impact: By rigorously applying our 7-step methodology, we orchestrated a surgical retrofit: risk analysis (ISO 12100) and safety recalculation (ISO 13849 PL_r), functional analysis, local modification of the electromechanical architecture and updating of the intelligence of the automation systems.

The Results: Untimely stoppages have been largely eliminated in favor of a smooth and secure production cycle. Capacity increased from 1,000 to 6,000 cells per day in just three weeks after return to service, with stabilized performance at more than 13 ppm during intensive load ramp tests.

Fire protection and safety studies

Fire protection of industrial equipment

Design of fire protection systems for a project in Spain
Integration of process and machine constraints
Definition of fire safety architectures

Industrial risk studies

Participation in security studies for new projects:

HAZID (hazard identification)
HAZOP/LOPA (operational analysis and deviations)
ATEX zone classification
Analysis of accident scenarios
Definition of safety barriers

Development of safety specifications for lithium-ion battery manufacturing equipment intended for:

Electric vehicles (EV)
Energy storage systems (ESS)

Content of specifications

Machinery and process safety
Fire and explosion protection
Multi-country regulatory requirements
Integration of lessons learned from France, United Kingdom, United States

Coordination and support for the certification of industrial equipment on international projects:

CE certification – Spain project
CE certification – X-ray equipment / scanners (UK & France)
- Compliance with PUWER 1998, IRR 2017 regulations
UL certification – South Carolina project (United States)

Added value

Global vision: Factory + Process + Safety
Lithium-Ion Battery Gigafactory Expertise
Deep knowledge of European and American standards
Integrated machinery safety and process safety
Experience in bringing existing equipment into compliance
Coordination of international CE / UL certifications
Reduction of downtime and improvement of line availability

Building safe and efficient battery factories

The success of lithium-ion projects relies on maintaining a precise balance between industrial performance and international regulatory compliance in process & machinery safety.

ZEnergy Consulting supports industry key players in the design and securing of robust, efficient factories tailored to the global standards of next-generation gigafactories.