ELIMINATING LIQUID SOLVENTS
Instead of solvent-based mixing, our process utilizes a dry blend of active materials, binders, and conductive additives.
Calendering Systems
Multi-Roll CalenderThe future of dry battery electrode manufacturing starts with our patented Multi-Roll Calender system
Dry Battery Electrodes
Milestones – Our DBE Success Stories
Over the last decade of development and commercialization, Matthews Engineering has created various patented solutions for DBE production machines. In the first production lines for dry battery electrodes, developed as early as 2012, the individual units of the multi-roll calender and the laminating line were still set up separately, one after the other.
Today, the state-of-the-art process consists of a combined system that allows for powder processing and lamination in only one production step, enabling fast and efficient production.
1998 | First project in the battery area with advanced calendaring machines
Developed advanced calendaring solution for the field of magnetic tapes, with the machine concept later deployed for calendaring of lithium-ion battery electrodes.
2008 | A Strategic Acquisition for Future Growth
Saueressig Joins Matthews International Corporation
Saueressig becomes part of Matthews International, laying the foundation for expanding expertise in precision manufacturing and energy storage solutions.
2009 | Pioneering Large-Scale Lithium-Ion Battery Production
First Market Reference in Energy Storage
First large-scale production of lithium-ion batteries in Europe by “European Batteries OY”. We develop and supply two calender lines for compressing cathode and anode electrodes, thus establishing the first reference systems on the market for energy storage applications.
2010 | Breakthrough in Intermittent Coating Compression
Supporting Germany’s First Large-Scale Lithium-Ion Battery Plant
Matthews Engineering is awarded a contract for four calender lines by Evonik Litarion GmbH, driving innovation in electrode compaction with a new approach to processing intermittently coated electrodes.
2012 | Advancing Dry Electrode Manufacturing
Matthews Engineering is a pioneer in the world’s first production line for dry electrodes. Our calender Technology was developed and designed in-house and adapted to the requirements of the capacitor manufacturing market.
2014 | Innovation in Research & Development
Launch of the First Laboratory Calender
Leveraging expertise from industrial-scale production, we develop a laboratory calender tailored for R&D departments, universities, and research institutes, enabling early-stage battery development.
2015 | Driving Innovation
Advancements in Energy Storage
KontiFlex Project: We develop a continuous manufacturing process for flexible bipolar plates, further strengthening its reputation in energy storage innovation.
2017 | Establishing Research Leadership in Energy Storage
Participation in Public Research Projects (FesKaBat)
Matthews Engineering joins the FesKaBat energy storage research project, solidifying its role as a trusted partner in Germany’s battery research landscape.
2018 | Early Adopters of Dry Battery Electrode Technology
Applying Dry Capacitor Technology to Battery Production
We successfully transfer dry capacitor production technology to battery electrodes, positioning itself as an early global pioneer in solvent-free electrode manufacturing (First DryFilm Concept).
2019 | Leading the Dry Film Revolution
Development of the World’s First Industrial-Scale Dry Film Production Line
A significant industry milestone: During that time, we designed and constructed the first large-scale dry film production system for batteries.
2020 | Scaling Up Production Capacity
New Assembly Hall & Large-Scale DBE Plant Orders
- Completion of a new assembly hall in Vreden, expanding manufacturing capabilities.
- Major equipment orders drive the start of large-scale dry battery electrode production.
2021 | Infrastructure Expansion
Facility Upgrades
- Competence Center Expansion: Opening of a state-of-the-art multipurpose facility in Vreden, featuring a modern assembly area, storage, and advanced testing capabilities to bridge the gap between lab-scale research and industrial production.
2022 | Global Expansion & Strategic Acquisitions
New Service Facility in the USA & Portfolio Expansion
- Launch of a new service center in San Antonio, USA, dedicated to the reconditioning of multi-roll calender rollers for battery manufacturing.
- Acquisition of OLBRICH and Polytype Converting®: Matthews International expands its energy solutions portfolio, incorporating expertise in hydrogen fuel cells and battery production, including wet & dry electrode processing, separator films, and battery wrapping lines.
2023 | Strengthening Production & Energy Industry Support
Ramp-Up of Vreden Production for Energy Sector
The Vreden site increases capacity for roller refurbishment and precision manufacturing, directly supporting the energy industry’s growing demands.
2024 | A Landmark Achievement in DBE Technology
Patent Issued for Dry Electrode Manufacturing
We officially protect our innovative dry electrode manufacturing process, reinforcing its leadership in solvent-free battery electrode production.
Outlook 2025 | Advancing DBE Research & Industrialization
Launch of a Dedicated DBE Competence Center
Matthews Engineering will establish a Development Center launching an innovative dry electrode battery solution, setting a new industry standard for R&D, testing, and industrial-scale DBE innovation.
ELECTRODE MANUFACTURING ON A NEW LEVEL
From Lab to Production
Key Advantages
Engineered to meet the demands of gigafactories and high-volume battery manufacturers, this system ensures consistent electrode quality, optimized energy density, and maximum production throughput while significantly reducing production costs and environmental impact.
ENHANCING PRODUCTION EFFICIENCY
By removing the need for drying and solvent recovery, the process streamlines electrode fabrication, reducing production time and energy consumption.
IMPROVING ENVIRONMENTAL SUSTAINABILITY
The elimination of hazardous solvents like NMP significantly reduces the environmental impact, aligning with global efforts to create greener and more sustainable battery technologies.
Higher Battery Performance
Advanced gap control enables precise electrode thickness and density adjustments, ensuring uniform compression, optimized porosity, and mechanical integrity for improved battery performance.
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.
Battery
Whether producing lithium-ion or solid-state batteries, our calender systems help you enhance electrode performance and energy density.
Conductive Powders
We provide advanced conductive powder testing services to help battery manufacturers and innovators unlock optimal electrode performance in dry processes.
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.
Coating Line 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.