Elevating Battery Production: The Essential Role of Powder Handling Expertise

by | May 8, 2024 | Extreme Lithium Battery Manufacturing, Monitoring line performance, Sustainable manufacturing | 0 comments

Partner contribution: Matcon; Expert: Richard Lockwood

The escalating demand for batteries exerts substantial pressure on manufacturers to amplify their operations. Although powder handling might not occupy a core position in the battery manufacturing process, its significance in augmenting the ultimate product’s efficiency, quality, and performance cannot be overstated.

Matcon, an expert in the domain of powder handling systems, collaborates intricately with an array of stakeholders across the battery manufacturing landscape to address various production challenges.

Addressing Powder Handling Challenges

In the high-stakes realm of battery manufacturing, the precision and quality of powder handling processes can significantly impact the efficiency, sustainability, and ultimate success of production operations. A nuanced understanding of the complexities associated with managing powders at varying states and temperatures is essential. This includes the adept handling of materials that may be extremely hot or require transport under diverse climatic conditions, emphasizing the critical nature of maintaining product integrity throughout the manufacturing cycle.

Picture credits: Matcon

Accurate dosing of materials is paramount, not merely for operational efficiency but also as a strategy to minimize the waste of valuable powders, thereby contributing to more sustainable manufacturing practices. This precision ensures that each component contributes optimally to the final product, laying the groundwork for batteries that meet the highest performance and reliability standards.

Contamination risks pose a significant challenge, threatening the purity and integrity of powders. Mitigating these risks is crucial, necessitating systems and protocols designed to protect against any compromise in material quality. Similarly, preventing moisture ingress is vital. Moisture can have adverse effects on powder quality, affecting texture and composition, which in turn can detract from the consistency and performance of the end product. Manufacturers must prioritize creating a controlled environment to shield powders from such detrimental influences.

Achieving homogeneity across powder batches is another critical objective, ensuring each production unit adheres to stringent quality and performance benchmarks. This consistency is key to fostering trust in the manufacturing process and, by extension, in the final battery products.

However, the challenge intensifies when dealing with large quantities of powders, especially when hundreds or thousands of kilograms are processed in a single container. It is here that Matcon’s specialized expertise becomes invaluable.

Matcon’s Solutions

With over 40 years of experience in powder handling across various industries, Matcon offers innovative solutions tailored to the unique needs of battery manufacturing.

Matcon’s Intermediate Bulk Containers (IBCs), equipped with the proprietary Cone Valve technology, offer an unparalleled solution for these challenges. The Cone Valve IBCs facilitate smooth, controlled discharge of powders, thereby preserving the quality of sensitive materials, ensuring accurate dosing and mitigating contamination risks. This technology allows for efficient and reliable material transfer during Cathode Active Material (CAM) or Anode Active Material (AAM) production, addressing the critical need for maintaining powder homogeneity and preventing moisture ingress.

Picture credits: Matcon

Furthermore, Matcon’s comprehensive process consultancy and expertise in blending technology, including their pilot-scale blenders with High Shear, provide battery manufacturers with the tools to achieve seamless scalability and precision in powder handling. These solutions are designed to integrate within current systems while supporting future expansions, thus enhancing process efficiency and yield.

Partnering with Manufacturers at Every Stage

Matcon has worked with a diverse portfolio of global clients, including battery material manufacturers, electrode producers, and other stakeholders in the supply chain. The company brings its wealth of experience acquired from collaborating on gigafactory developments with established battery cell manufacturers, emerging start-ups, and R&D entities.

At every stage, Matcon engages in conversations about scaling up wisely and ensuring that powder handling growth from lab to pilot to full-scale production does not become a bottleneck. As a trusted partner, Matcon provides solutions that meet today’s needs and can evolve organically with tomorrow’s demands.

Picture credits: Matcon


The battery manufacturing sector is experiencing rapid growth, yet the importance of powder handling in the production process often goes unnoticed. Matcon offers solutions and unparalleled expertise in powder handling, assisting battery manufacturers in scaling their operations both efficiently and safely. Through a partnership with Matcon, manufacturers can concentrate on their primary strengths and be secure in the knowledge that their powder-handling infrastructure supports their expansion plans and contributes to their success.

About the author

Richard Lockwood

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