ANDRITZ Schuler has commissioned a 1.5 GW battery cell formation line at a German premium electric vehicle manufacturer’s facility. This marks one of Europe’s largest installations dedicated to booster cell production. The line produces cylindrical cells engineered for high C-rate charging and discharging, an emerging approach as automakers separate power delivery from energy storage in next-generation EV architectures.​

Booster cells serve as dedicated power buffers for transient acceleration loads and ultra-fast charging events. They allow the main traction battery to optimize for energy density and range rather than peak power capability. Select premium manufacturers pursue this two-battery strategy to boost charging speeds and performance without shortening primary pack life.​

The formation line integrates more than 50,000 channels across 200 chambers, each with power electronics for gigawatt-scale throughput. During formation, where cells complete initial charge-discharge cycles, the system captures over two million data points per second. This enables precise grading and an electrochemical fingerprint for every unit.​

ANDRITZ Sovema technology powers the automation, including a Track and Trace system linking production history to performance data. Traceability supports quality control, pack design, field diagnostics, and safety analysis over time.​

Measuring 22 meters long, 10 meters wide, and 10 meters tall, the setup uses energy-efficient power electronics to cut losses in extended cycles that span days. Modular design and service strategies sustain uptime as European production grows.​

Commissioning aligns with automakers’ push for domestic cell manufacturing amid Asian supply cuts and EU sourcing rules. The unnamed customer’s booster focus points to performance-driven tech over mass-market cost competition.

Click here to read the latest issue of E-Mobility Engineering.