High-voltage batteries have been repaired at the competence center for batteries in Hoyerswerda since 2022. This is much more cost-effective than a new battery and more sustainable. This expertise can also be used for other services. In focus: battery dismantling.
"It makes no difference whether we open a battery and then repair it or dismantle it in order to prepare it for alternative uses or recycling. The safety requirements are the same. By dismantling batteries, we can offer our customers a complete package covering the entire life cycle of a battery," explains Gunnar Grohmann, Team Leader Battery Technology at Leadec in Hoyerswerda. So far, several hundred batteries have already been dismantled there.
In general, there are three options for high-voltage batteries that can no longer be installed in vehicles. They can be reused in another area, recycled or remanufactured.
Batteries that have been carefully tested and are in a good state of health (SOH) are suitable for second-life applications. This means that the battery modules can be used in energy storage systems to compensate for voltage fluctuations in renewable energies such as photovoltaics.
For recycling, the batteries are dismantled down to module level. The removed modules are collected and shredded by specialized companies. The aim is to recover valuable ingredients such as lithium from the so-called black mass and return them to the material cycle.
"We really live the circular economy and it includes all materials. All components such as circuit boards, power rails etc. are recycled separately," adds Gunnar Grohmann.
At present, it is mainly used batteries that are recycled. Gunnar Grohmann sees great potential in new batteries that are never used due to faults in production: "There are 30-50 percent of new batteries that are out of production. These could be repaired, which is not (yet) being done for warranty reasons, or they could be dismantled to be reintroduced into the cycle."
Battery remanufacturing (ReMan) is currently on the rise. In remanufacturing, for example, modules are removed from three less powerful batteries and recombined to create a battery that reaches at least 90% of its charging capacity.
"I am convinced that ReMan will be one of the key topics in battery technology in the coming years. Because remanufactured batteries are interesting for used e-vehicles. The battery accounts for around a third of the cost of a new car. That is far too expensive for a used car. Here, remanufactured batteries can be a real alternative and we can significantly expand our services," says Gunnar Grohmann.
Leadec UK and plastic recycler Jayplas have developed a solution to recycle and reuse plastic packaging waste. The results are encouraging: A 81-ton carbon reduction from the 30,5 metric tons of bags purchased annually at the Halewood site.
The accelerated ramp-up of battery factories – especially gigafactories – is a key factor in covering global demand for powerful batteries. But how can this ramp-up be done efficiently and sustainably?
In this interview, Markus Bölke, Global Head of Green Factory Solutions, Sustainability & HSE at Leadec gives an insight into how the company has anchored the EU Green Deal in its strategy and how Leadec supports its customers with special services to make their own production more climate-neutral.
In the interview with Bernard Sextus, Director Operations of Leadec India, you can learn more about how every little contribution to climate protection counts, how data can be used to improve awareness and what Leadec colleagues in India actively do.
With “Green Factory Solutions” (GFS), Leadec offers its customers a green service portfolio along the entire factory life cycle. How does it actually work? Let us step into the shoes of a plant manager, accompany him during a working day, and see the many touchpoints after initiating a GFS project with Leadec.
Leadec CEO Markus Glaser-Gallion talks in the "Automobilwoche" about the lack of skilled workers, current business developments and strategic topics like e-mobility, integrated facility management and automation at Leadec.
The new sustainability report is available – and for the first time it is based on the new requirements of the European Sustainability Reporting Standards (ESRS). At the same time, it provides a comprehensive overview of projects and activities relating to sustainability at Leadec.
As the world’s leading service specialist for the entire life cycle of a factory, Leadec prioritizes ESG principles for a sustainable future. Our target is to lead our industry by example. The sustainability report 2023 was prepared according to the requirements of the Corporate Sustainability Reporting Directive (CSRD)/ European Sustainability Reporting Standards (ESRS).
Packaging plays a central role in logistics and the supply chain. How can innovative solutions be developed to switch from disposable to reusable packaging? The Leadec team in India has developed flexible reusable containers and an entire supply chain system for this purpose.
Leadec has been operating in Hungary for 30 years. Managing Director Ferenc Dákai has been with the company for almost as long. In this interview, he provides an insight into the Hungarian market, talks about current challenges, and draws his own personal conclusions.
More and more electric vehicles are on Germany’s roads. And they are hungry for electricity! Preferably available quickly and everywhere. As a technical specialist, Leadec is also on the road, installing, monitoring, and maintaining charging stations for a major car manufacturer to meet the demand.
Tracking waste and material flows in production facilities is crucial for improving recycling rates. This saves money and increases environmental sustainability. Leadec has gained experience in a comprehensive pilot project at an automotive manufacturer and is now implementing it in regular operation.
What influence do new production methods and technologies, increasing digitalization and incentive systems have on occupational safety? Find out in episode 7 of our Factory Talks.
The “Global Cleanup Week” at Leadec was born out of a small project idea. The aim was to offer employees an opportunity to get actively involved in the area of sustainability. And this happened with great success.
Waste management is no longer just about the disposal of waste. It has evolved from just dumping and burning waste to separate collection, sorting, and recycling to the circular economy, which sees waste as a resource. Find out more in episode 6 of our Factory Talks.
Manufacturers are working to make the transition to electric vehicles. Leadec is right in the middle of it. In this interview, Alexander Doebelin, Vice President E-Mobility in Global Business Development, provides insights into the business and explains where Leadec’s strengths lie in this area.
The semiconductor industry is growing strongly. Manufacturers have their sights firmly set on Europe. And technical services for the fab have a special role to play. In this interview, Dana Nikolaj, Business Director Semiconductor, provides insights into the business and the opportunities for Leadec.
Since the company’s beginnings more than 60 years ago, Leadec has been a people business. Placing sustainability at the heart of operations, and ensuring this reaches every person and every process, we again took steps and measures in 2022.
Waste separation is one of the biggest challenges in recycling plants. Due to the variety and mixture of different materials, it is often difficult to sort and process the waste efficiently. Automation solutions from Leadec help.
It may sound unusual, but factory sites are increasingly being used to create biodiversity. But what does it take to turn a conventional company site into a near-natural one?
Ulrich Haas is the managing director of Leadec’s newest subsidiary in France. In this interview, he talks about the opportunities and challenges of the market and where the company’s focus lies.
They are large, they are flat, and they are empty: factory roofs are ideal for mounting photovoltaic systems. For sustainable and independent energy generation. But what are the challenges and what needs to be considered?
Do you know our interview series “Factory Talks”? Leadec experts around the world talk about topics that are affecting factories and production (plants).
The battery is the heart of an electric vehicle: not only is it the most important component, but also the most expensive, raw material-intensive one. An intelligent battery management system usually ensures a long life. Nevertheless, a defect cannot be ruled out. In such a case, however, the battery does not have to be recycled directly – the alternative is to repair it.
