Lithium-ion battery film calendering line BREYER IONDry

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Overview
BREYER IONDry is a solvent-free dry electrode production system designed for continuous roll-to-roll processing of lithium-ion battery electrodes. The technology converts dry electrode materials into homogeneous, laminated electrode films with controlled thickness, density and compression, suitable for R&D, material development and pilot production.

Process description
The process starts with dry mixing of active materials, conductive additives and binders. The premixed powder is continuously dosed and fed into a calender module where multiple roll gaps compact and form homogeneous electrode films. Thickness and compression are adjusted in-line. In the final stage, the films are laminated onto both sides of the current collector foil (aluminium for cathodes, copper for anodes) to produce finished electrode structures. Forming, thickness control and lamination are integrated into a single continuous roll-to-roll workflow.

Systems and scale
BREYER provides scalable configurations for laboratory and pilot needs:

• IONDry 400 core — compact laboratory and development system for material screening and process optimization.
• IONDry 600 pilot — pilot-scale line for process development, scale-up and initial production runs enabling continuous dry electrode manufacturing.

Key process elements

• Synchronized dosing and conveying system for controlled material distribution and continuous feeding.
• Multiple precisely controlled calender gaps allowing simultaneous top/bottom film formation and subsequent lamination.
• Electro-hydraulic roll gap control for accurate adjustment by distance and force.
• Inline sensors for continuous monitoring of thickness, pressure and key process parameters to ensure reproducibility.

Advantages

• Solvent-free electrode production — eliminates solvents and associated handling.
• No energy-intensive drying step — reduces process energy consumption and operating costs.
• Integrated continuous roll-to-roll workflow (feeding, film formation, thickness control, lamination).
• High-precision calender gap control via electro-hydraulic actuation.
• Automated material handling synchronized with calender for stable continuous feeding.
• Inline process monitoring for reproducible and stable production.
• Designed for scale-up from laboratory to pilot production.

Applications
Dry coating and calendering technology for lithium-ion battery electrode manufacturing. Suitable for research institutes, material developers, pilot production and initial industrialization for market segments such as e-mobility and stationary energy storage.

Technical specifications

• Product family: BREYER IONDry
• Available configurations: IONDry 400 core (laboratory/development), IONDry 600 pilot (pilot-scale)
• Process type: Dry mixing, compaction in calender roll gaps, roll-to-roll lamination onto current collector foil
• Current collector compatibility: Aluminium (cathodes), Copper (anodes)
• Material handling: Synchronized dosing and conveying system
• Control technology: Electro-hydraulic roll gap control (distance and force)
• Monitoring: Integrated inline sensors for thickness, pressure and key process parameters
• Environmental/operational benefits: Solvent-free process, eliminates drying step, reduced energy consumption and operational costs
• Experience: Development activity in dry electrode processing since 2009