Powder processing solutions for battery manufacturing
Driven by strong growth in electric vehicles and consumer electronics, the global battery market continues to expand rapidly. Battery manufacturers are simultaneously expected to deliver higher performance—such as faster charging, longer lifetime and higher energy density—while reducing costs. As part of the Hosokawa Group, Hosokawa Micron supports battery producers worldwide with proven powder processing solutions that address these challenges.
Together with its sister companies, Hosokawa Micron supplies equipment covering key stages of battery production, from drying and milling to classification, spheroidising, mixing and coating. These technologies are available for both large-scale manufacturing and research & development.
Flexible and efficient drying
Drying and pre-milling of cathode precursor materials such as nickel, manganese and cobalt oxides is a critical first step. Hosokawa Micron offers continuous solutions like the DMR flash dryer, which handles slurries as well as filter cakes and achieves residual moisture levels below 1%. Integrated classification ensures only correctly dried particles are discharged, while internal dispersion improves evaporation efficiency and reduces energy consumption.
For applications requiring extremely low moisture levels or smaller batch sizes, alternatives such as vacuum dryers or conical paddle dryers are available, capable of combining high temperatures with deep vacuum.
Ultra‑fine milling and graphite shaping
Precise particle size distribution is essential for battery performance. Ultra‑fine milling increases surface area, improving capacity, charging speed and service life. Hosokawa Micron provides air classifier mills and fluidised bed jet mills suitable for both cathode and anode materials, including graphite and silicon, delivering very fine and narrow particle size distributions.
To enhance the properties of graphite anodes, Hosokawa also offers spheroidising technologies. Rounding flaky graphite particles increases bulk density and wettability, allowing higher energy density. Dedicated systems are available for both natural and synthetic graphite, with optional ceramic wear protection to ensure maximum product purity.
Mixing, coating and testing expertise
Fine powders often require controlled high‑shear mixing to avoid adhesion and ensure homogeneous coating with carbon black or binders. Batch and continuous high‑intensity mixers enable precise coating and improved conductivity, while lower‑shear solutions such as conical mixers are used where gentle homogenisation is sufficient. All systems can be fitted with wear‑resistant linings to minimise contamination.
To support process development, Hosokawa operates large test centres in Germany and the Netherlands, allowing extensive trials under realistic conditions. The company also offers comprehensive containment solutions and certified equipment to meet safety, purity and dry‑room requirements, including those for solid‑state battery production.
Recommend article