Achieving Successful Scalability

Innovative Production: Reducing Complexity to Reach Volume

It is well known that the challenges inherent in complex manufacturing environments can lead to decreased productivity, inefficiencies, quality issues, and increased costs, all of which significantly impact production output and hinder business growth. At Enerpoly, we have prioritized leveraging and optimizing existing manufacturing technologies, and in 2024, we acquired equipment that has been proven in lithium-ion and nickel-metal hydride production. Our innovative approach to minimizing complexity in both production and product design, combined with the inherent safe nature of zinc-ion chemistry, has allowed us to create a simpler manufacturing environment that supports effective scaling.

In production, Enerpoly has significantly streamlined the manufacturing process for zinc-ion batteries compared to what is required for lithium-ion battery production, including the shortening of steps like formation times. This approach reduces risks in the manufacturing process and boosts productivity. Additionally, zinc-ion manufacturing has minimal production constraints—such as not requiring clean or dry rooms due to the safe nature of zinc-ion chemistry—which reduces energy consumption and operational costs.

Enerpoly has transitioned from producing individual battery cells to battery cell modules, simplifying the integration of cells into battery packs and making the overall assembly process more efficient. Creating the electrodes—one of the most challenging and complex aspects of battery manufacturing fue to factors like maintaining stringent quality control and ensuring consistent quality across larger volumes—is straightforward and efficient in our design. This emphasis on simplicity results in more consistent and efficient production, with shorter lead times.

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Dry electrode manufacturing: a game-changer for sustainability

Enerpoly’s innovative dry electrode manufacturing process for zinc-ion batteries is setting a new industry standard and encouraging other battery manufacturers to adopt this method due to its lower energy consumption and reduced environmental footprint⁵. This approach not only offers significant economic advantages but also facilitates the production of high-energy-density electrodes⁶.

In contrast, traditional wet, slurry-based electrode processes are energy-intensive and environmentally burdensome, requiring liquid slurries that must be dried and managed through complex solvent systems. Moreover, these solvents can be toxic, which is harmful to workers and requires careful disposal processes. Our dry electrode technology addresses these challenges by utilizing dry materials, which eliminate the drying phase and results in substantial energy savings.

The key benefits of our process include:

• Reduced energy consumption: by eliminating solvents, we remove the need for drying and solvent recycling, which decreases energy use, lowers production costs, and reduces our carbon footprint.
• Lower environmental impact: the absence of solvents leads to less waste generation, promoting a more sustainable manufacturing approach.
• Increased energy density: our dry processes can apply thicker coatings, enhancing energy density in comparison to the wet process.

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100% European supply chain: a strategic advantage

In today’s market, the battery supply chain for materials is heavily concentrated, with nearly 90% of global installed cathode active material manufacturing capacity and over 97% of anode active material manufacturing capacity  for lithium-ion batteries being sourced from a single region⁷. This is similar for manufacturing equipment sourcing as well. Enerpoly stands out by sourcing 100% of our materials and manufacturing equipment from Europe. This collaboration with European industry not only insulates Enerpoly from potential supply chain instability, but also leverages the innovation and quality standards for which the region is known.

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Skilled Workforce: Our Greatest Asset

Enerpolys approach to industrial-scale production is built on a strong foundation of technology and talent. We have developed our own patented zinc-ion battery technology, with the inventors actively involved in our operations. Our team brings over a decade of experience in battery manufacturing, along with a strong drive and commitment to innovation and sustainability.

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A vision for a sustainable energy in a thriving world

At Enerpoly, we are determined to reduce the cost of energy storage to below $50 per kilowatt-hour within the next five years, a milestone that could result in a reduction of global carbon emissions by 50 megatons of CO₂ equivalent over the next decade. By delivering the world’s safest, most sustainable, and most cost-effective energy storage solutions, we are transforming the stationary energy storage market and accelerating the transition to a cleaner, greener future.

To learn more about how our innovative, scalable, and sustainable solutions are driving the future of energy storage, get in touch with us today.

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Footnotes

1. Ramirez, R. "These Dirty Power Plants Cost Billions and Only Operate in Summer. Can They Be Replaced?" Grist, May 8, 2020.

2. Zoltek, G. "NV Energy Aims to Reduce Customer Costs, Save Energy with New Solar Battery Storage Facility." KTNV, April 26, 2024.

3. Hevia-Koch, P., D. Morris, and A. Rawlins Bilbao. "The Clean Energy Economy Demands Massive Integration Investments Now." International Energy Agency (IEA), January 25, 2024.

4. European Association for Storage of Energy (EASE). "Policy Priorities." EASE. Accessed November 7, 2024.

5. Benchmark Source. "Revolutionising Battery Production: How Dry Electrode Manufacturing Promises to Cut Costs." November 1, 2024.

6. Jin, W., G. Song, J. Yoo, S. Jung, T. Kim, and T. Kim. "Advancements in Dry Electrode Technologies: Towards Sustainable and Efficient Battery Manufacturing." June 12, 2024.

7. International Energy Agency (IEA). "Trends in Electric Vehicle Batteries." Global EV Outlook 2024.