Patented gap control system
Precision down to ±1 μm - even during rapid coating/no-coating transitions.
Calender Systems
Calendering System for Intermittent Coated Battery ElectrodesPrecision calendering for patterned electrode manufacturing
Patterned Electrode Performance
Performance meets patterned precision
Our intermittent calendering system brings intelligent synchronization and adaptable force control to every coated segment – while maintaining clean transitions at uncoated areas. This results in uniform compression, reduced edge defects, and better mechanical stability of your electrode coating.
Whether you’re running pulse coating, discrete patterns, or foil edge leave-outs, our calenders deliver the precision, control, and adaptability required for intermittent electrode processing.
Roller Synchronization
Independent direct drive for each roller ensures exact torque and gap management across patterned intervals – reducing stress at coating edges and maintaining dimensional accuracy.
Compact Footprint
Space-efficient design minimizes vibration and flexing under high load conditions – ideal for high-speed pattern-based production lines.
Electrode Uniformity
Thermal control and ultra-precise nip gap (±1 μm) enable repeatable densification of coated areas, while preserving foil integrity in uncoated sections.
Custom Configuration
Custom roller profiles, web widths, and automation logic tailored to your pattern geometry, foil width, and cycle time.
Digital Intelligence
Real-time process monitoring and IIoT-driven analytics support predictive diagnostics, recipe storage, and digital traceability – even across changing batch formats.
Technical Specifications
Optimized for intermittent electrode calendering
Intermittent calendering requires exceptional accuracy in pressure control and rapid mechanical adaptation. Our systems are calibrated to meet the specific requirements of stop-start patterns, coating gaps, and high-precision alignment.
Specs List Title
Web width
up to 1,500 mm
Production speed
up to 80 m/min
Roller diameter
up to 1,000 mm
Gap accuracy
±1 μm
Compression force
up to 200 tons
Roller temperature
+10 °C to +200 °C
Enhance performance with tailored add-ons
Our system architecture is modular – allowing seamless expansion for quality control, automation, and process safety specific to intermittent applications.
Control Engineering: Electro-Hydraulic
Delivers high-precision force regulation through an electro-hydraulic control loop – ensuring stable nip pressure across variable web loads for consistent compaction and minimal deviation.
Thickness Measurement (Non-Contact)
Inline, laser-based thickness measurement provides real-time calendering feedback without touching the material – improving quality assurance and enabling closed-loop process control.
Web Cleaning Device (Non-Contact)
Removes fine dust and particulate matter from electrode surfaces using ionized air or brushless systems – preventing contamination and defects before compression.
Preheating (IR-Field, S-Roll Design)
Infrared or S-Roll thermal modules elevate coating temperature before calendering, improving material flow, binder activation, and final electrode density uniformity.
Cutting Units
Integrated slitting or cross-cutting systems allow precise web dimensioning inline—ideal for converting wide master rolls into downstream-process-ready widths.
Splice System
Enables automatic or semi-automatic roll changes with minimal line interruption – maintaining continuous production and reducing material waste during transitions.
Remote Maintenance
Secure, cloud-enabled diagnostics and support access allow our engineers to troubleshoot, update, or optimize your system remotely – reducing downtime and service response time.
Inspection System
High-speed visual or sensor-based inspection detects surface defects, coating irregularities, or material inconsistencies – ensuring early quality intervention and batch traceability.
Marking System
Applies codes, batch numbers, or quality marks directly onto the web—enabling precise traceability and simplifying downstream logistics and compliance processes.
Engineered for your advantage
Intermittent coated battery electrodes require adaptive control, seamless transitions, and uncompromising repeatability. Every system is purpose-built to manage variable web conditions with precision, ensuring reliable performance, long-term durability, and production flexibility from pilot to scaled manufacturing. Discover how our proven features drive measurable value.
Very sturdy and compact design
Rigid structure ensures pressure consistency while minimizing required floor space.
Direct drive of each roller
Ensures torque precision and individual roller calibration—essential for variable coating zones.
Inline/offline applications
Easily integrated into new or existing intermittent coating lines.
Easily operated
User-friendly HMI and recipe handling streamline setup and reduce operator training time.
High automation level
Automated pressure, temperature, and speed adjustment improve consistency and output.
One-Stop-Shop
From engineering to after-sales service - Matthews Engineering is your partner for every project phase.
Key applications & industry sectors
From pilot-scale R&D to high-throughput production lines, our calender systems cover every step of the battery electrode and separator film manufacturing process. Discover how each solution is purpose-built to optimize specific applications - wet or dry, continuous or intermittent.
Calender for continuous coated battery electrodes
High-speed, precision calendering for roll-to-roll coated electrodes - ensuring uniform thickness, density, and mechanical integrity in large-scale lithium-ion production.
Coating Lines for battery separator film
Our coating systems enable ultra-thin, uniform coatings on separator films used in lithium-ion batteries - with integrated tension control, low-solvent operation, and inline inspection capabilities.
Laboratory Calender GK 300 L for battery electrodes
Compact, configurable calendering unit for R&D and pilot-scale applications - perfect for material testing, parameter optimization, and pre-production validation.
Laboratory Calender GK 300 L 6R for battery electrodes
A high-precision, six-roller calender system designed for R&D and small-batch production. Ideal for material validation, parameter optimization, and pilot-scale trials - offering full control over compaction, temperature, and web handling in a compact footprint.
Battery
Whether producing lithium-ion pouch cells or cylindrical solid-state batteries, our calender systems help you enhance electrode performance, energy density, and production yield.
Calender and Smoothing Rollers
Custom-engineered rollers for upgrading or retrofitting existing calender systems - available with specialized surfaces and thermal or mechanical enhancements.
Development Center
Test, validate, and refine your materials and processes in our dedicated development center - equipped for trials, scale-up, and next-gen prototyping.
Let’s talk about your needs
Ready to elevate precision and production control for your intermittent coated electrode line? Our team is here to help you explore how our calendering technology can be configured to meet your material requirements, pattern geometries, and performance targets. Let’s build the right solution - together.