High-performance intensive mixer for maximum efficiency

The FM high-performance intensive mixers from Zeppelin Systems are characterized by their ability to disperse and homogenize raw materials highly efficiently. This makes them the ideal choice for the resource-saving and safe production of battery masses, both in dry and semi-dry mixing processes. They can implement individual shear rates and temperature profiles in various process steps in order to effectively disperse nanoparticulate conductive additives, activate binder materials in a targeted manner and fibrillate them. This not only achieves an even distribution of the raw materials, but also changes the particle structure in a targeted manner, which leads to an increase in bulk density and energy density. The mixers also offer customizable wear protection, which ensures a long service life even with abrasive materials. ‘Our intensive mixers have already proven themselves with international battery manufacturers, and we are convinced that we can further expand our involvement in this future market,’ says Ralf Boschert, CFO of Zeppelin Systems GmbH. He adds: ‘Thanks to our many years of experience in the industry, we are able to react quickly and flexibly to our customers’ requirements in battery mass production.’

Comprehensive expertise in raw materials handling

The handling of raw materials plays a decisive role in the production of dry-coated electrodes. Zeppelin Systems has many years of expertise in this area. This includes not only the rapid emptying of a wide variety of containers, but also particularly gentle pneumatic conveying, which prevents segregation of the end product. In addition, the company's sophisticated containment technology ensures the safe handling of toxic materials. Precise dosing of the individual components into the mixer and reliable discharge - even with raw materials that are difficult to fluidize thanks to special discharge aids – are key elements of process reliability. The Zeppelin Batch Management System also ensures complete batch traceability.

Calender dosing innovation

To ensure continuous and precise dosing of the calender rollers, Zeppelin Systems engineers developed their own calender dosing system. “The dosing unit for the calender has a continuous material supply with level monitoring in the hopper, which means that the calender rollers cannot run empty. The special geometry of the hopper prevents any bridging effect, and the development of dust from the hopper and vibration channel is also not an issue”, explains Hubert Stojanovic, Vice President for Performance Materials at Zeppelin Systems GmbH.

Testing and optimizing processes – in Zeppelin Systems’ technical department

Zeppelin Systems operates three test centers where process-critical processing steps can be tested and improved. One example is the Test Center for Mixing Technology in Kassel, where processes are developed and tested on individually configurable mixers at laboratory and production scale. For various AAMs (anode active materials) and CAMs (cathode active materials), such as LFP, NCA, NCM or graphite, test series have been carried out recently with various customers and research institutions. The various products’ behavior with regard to fluidizability, caking, discharge behavior, product destruction, etc. are investigated at the test center in Friedrichshafen. A separate test setup is currently being created here to enable calender dosing testing for various AAMs and CAMs for Zeppelin Systems customers. In addition, a very wide range of product analyses are carried out in the company’s own bulk material laboratory; these include moisture measurement, particle size and distribution, bulk density determination, and shear tests.

Projects with more than 150 gigawatts implemented to date

Zeppelin Systems’ battery-mass expertise is valued worldwide. Customer projects of over 150 GWh have been implemented to date in Germany, Sweden, the USA, India and South Korea. In addition, Zeppelin Systems is playing a key role in national and international research and development projects. Notable examples are the EU-funded GIGABAT project and the German GUTBatt project. GUTBatt involves process development of scalable material structuring as well as dry mixing and calendered dry electrode production for lithium-ion batteries with liquid and solid electrolytes. We Create Solutions!

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