Giga Factories

Typical Production Flow for 1 GWh LFP Cell Line

Raw Material Preparation

• Cathode Material: LFP powder (LiFePO₄) mixed with conductive carbon and binder.
• Anode Material: Graphite (natural or synthetic) mixed with binder
• Slurry Mixing: High-speed mixers create uniform cathode and anode slurries.

Electrode Manufacturing

• Coating: Slurries coated on aluminum (cathode) and copper (anode) foils.
• Drying: Continuous drying ovens remove solvents.
• Calendering: Rolls compress coated foils for uniform density and thickness.
• Slitting: Electrodes cut into precise widths for stacking or winding.

Cell Assembly

• Stacking / Winding: LFP cells can be prismatic or cylindrical, depending on design.
• Electrolyte Filling: Cells filled with LiPF₆-based electrolyte.
• Sealing: Pouch or prismatic cans sealed in controlled dry room conditions.

Formation & Aging

• Formation: Controlled charge-discharge cycles activate electrodes and form SEI layer.
• Aging: Cells rest for stability and performance verification.
• Testing & Grading: Cells sorted by voltage, capacity, and impedance.

Packing & Traceability

• PCells packed in vacuum-sealed trays under inert atmosphere.
• Data logged into MES (Manufacturing Execution System) for traceability.

Key Specifications for 1 GWh LFP Line

Parameter	Specification
Annual Output	1 GWh (~20 million 50 Ah cells)
Chemistry	Lithium Iron Phosphate (LiFePO₄)
Cell Format	Prismatic / Pouch
Production Area	~20,000–25,000 m² (cleanroom zones)
Automation Level	Semi or fully automated line
Power Consumption	~15–20 MW installed capacity
Workforce	200–300 (operators + engineers)
Dry Room Humidity	< 1% RH (dew point −40°C)