GIGABAT and the European challenge: gigafactories to lead the electrification of the future
Electrification is already a reality in European industry. Sectors such as the automotive industry are racing towards more sustainable models, driven by technological innovation and the need to become more competitive in an increasingly demanding global market. But this transformation presents a major challenge. Without the capacity to produce batteries on a large scale itself, Europe will continue to rely on third parties.
In response to this strategic challenge and to narrow the gap with Asian dominance in battery manufacturing, GIGABAT has been launched – a project funded by the European Commission’s Horizon Europe programme. Izertis is taking part in the project, alongside 15 other partners from five countries, with a clear objective: to drive the development of gigafactories that strengthen Europe’s industrial autonomy and ensure a truly sustainable model of electrification.
Gigafactories: the cornerstone of European autonomy
European industrial autonomy necessarily depends on developing its own technology and having the infrastructure in place to support it on a large scale. Against this backdrop, gigafactories are establishing themselves as a strategic option for reducing reliance on foreign imports, strengthening global competitiveness and moving towards a more efficient and sustainable energy model.
These large-scale electric battery manufacturing plants enable us to meet the growing demand for energy storage solutions, both for electric mobility and for a wide range of industrial applications. They are the silent driving force behind electrification.
Gigafactories are the silent driving force behind electrification
But its true potential lies not solely in its size or its production capacity. There is another decisive factor: the extent to which it has been digitised.
Only through smart, connected and optimised processes will it be possible to ensure long-term efficiency, sustainability and competitiveness.
Digitise to optimise
In a gigafactory, every battery is the result of a highly complex industrial process. Its operation is based on the flow of current between two electrodes of opposite polarity (the so-called ‘poles’ of a battery), which makes the internal design and the precision of the manufacturing process key factors in determining the final energy output.
The manufacture of these electrodes, which consist of materials such as graphite or lithium in sheet form, involves a series of critical stages: mixing of materials, continuous lamination, coating, pressing, drying and cutting. The resulting plates are then stacked, encapsulated in a conductive electrolyte, sealed, and subjected to controlled charge and discharge cycles (the formation process) until the battery is fully operational.
Digitalisation makes all the difference with connected factory environments
In high-capacity production facilities, this macro-process can involve more than ten stages, each requiring specific equipment and offering significant scope for improvement in terms of efficiency and control. This is where digitalisation makes all the difference.
Connected factory environments enable the virtual modelling of processes, the evaluation of scenarios and the optimisation of performance in such complex industrial facilities, thereby reducing costs, energy consumption and lead times without compromising quality.
Digital twins and batteries with digital passports
In a context where the scale and operational complexity of gigafactories demand maximum efficiency and the optimal use of time and resources, Izertis is leading two key contributions within the GIGABAT project.
On the one hand, it designs and implements a digital twin of the plant, supported by artificial intelligence. This virtual replica of production processes makes it possible to identify critical points, anticipate incidents and optimise the use of resources. Furthermore, the system is capable of progressively integrating real-world experimental data, analysing it and using it to design and evaluate new production scenarios before putting them into practice.
On the other hand, Izertis is developing a digital product passport– an immutable record based on blockchain technology – which accompanies each battery throughout its lifecycle. This passport ensures full product traceability, including key information, parameters and characteristics, and serves as an essential tool for ensuring quality, regulatory compliance and competitiveness in the European market.
Thanks to these solutions implemented by Izertis, GIGABAT has established itself as a flagship project in the development of sustainable, digitalised and innovative gigafactories, set to play a strategic role in the future of the European battery industry.