Dürr expands portfolio with enhanced simultaneous two-sided coating machine

• Introducing the GigaCoater™: Elevating efficiency in battery electrode production

Chennai. 30 September 2024 . Dürr presents its latest innovation in simultaneous two-sided coating technology set to revolutionize the battery manufacturing industry. The new GigaCoater™, designed for battery cell OEMs, combines wider substrate capabilities with faster coating speeds, promising significant manufacturing cost reductions while maintaining automotive-grade quality across widths up to 1,200 mm.

Since 2006, Dürr has led the way in simultaneous two-sided coating technology for battery electrode production, constantly refining and enhancing its offerings. This latest iteration, developed through substantial research and development investment, showcases Dürr’s commitment to providing cutting-edge solutions that drive efficiency and cost-effectiveness in manufacturing.

Streamlined configuration for maximum efficiency

The GigaCoater™ features a straight-path product flow with two coating stations combined in a single location, complemented by a non-contact flotation drying system. This streamlined configuration results in a more compact manufacturing footprint, reduces energy consumption, and eliminates edge curl after drying. The innovative coating process uses a slot-die against a backing roll, followed by a tensioned-web-over-slot-die (TWOSD), enabling simultaneous two-sided coating of the foil in a single pass. The air flotation dryer ensures even, non-contact drying on both sides, further improving electrode quality.

Significant reduction in operating costs

The simplified layout of the GigaCoater™ results in substantial operational cost savings. These savings come from reduced energy consumption thanks to the single-dryer system, reduced coil handling, fewer personnel needs thanks to the one-level design, lower material waste, and a smaller space requirement. Together, these efficiencies offer enormous annual savings.

In addition to cost savings, the GigaCoater™ enhances product quality by eliminating edge curl, ensuring uniform drying on both sides, and improving top-to-bottom alignment.

Extension of simultaneous two-sided coating product family

With the GigaCoater™, Dürr expands its portfolio of simultaneous two-sided coating machines, which previously consisted of the PilotCoater and ProCoater. The PilotCoater which can handle foils up to 350mm with coating speeds of up to 10 meters/minute, making it ideal for production, as well as ongoing process and product development. The ProCoater, a larger scale coating line, accommodates web widths from 350 to 700mm and coating speeds up to 50 m/min, supporting large-scale lithium-ion battery production. Both products are already in use by leading battery manufacturers worldwide.