Scale from Lab to Gigafactory

Feb 14, 2023

battery manufacturing battery

The battery manufacturing industry is growing rapidly to meet the increasing demand for batteries from around the world. Companies are investing heavily in research and development as well as adopting digitalisation solutions to scale up production processes and reduce costs. A common objective that exists throughout battery manufacturers of all levels of maturity is the “Gigafactory”, a hugely scaled production that produces thousands and thousands of batteries every single day.  

The scale of production that a company can achieve is critical to success in this industry. Scaling requires a well-aligned production system of equipment and process knowledge. To stay competitive, this alignment should be supported by digital technologies 

Find out more about some of the challenges in this process, and how battery manufacturers can scale from lab to gigafactory in a more effective and reliable manner. 

What is the issue?

Battery manufacturing companies and start-ups alike are driven by a commitment to advancing R&D activities, with the goal of developing products that will meet the evolving needs and demands of the market.  

Transitioning from a lab environment into a mass-market product can be a serious challenge, requiring a scalable and flexible digital backbone to support the company through this process. Simon Moores, CEO of Benchmark Mineral Intelligence, a London-based price-reporting agency and research firm specialising in battery materials, has stated regarding the Britishvolt situation: “Making lithium-ion batteries isn’t easy, especially at scale.” 

There are a number of challenges entrepreneurs hit at this stage, including:

battery in electric car
car battery manufacturing

Data handling difficulties

While a significant number of fledgling enterprises grasp the significance of data utilisation, executing it effectively remains a challenge. Traditional spreadsheet methods prove inadequate in meeting the demands, while implementing a comprehensive Manufacturing Execution System (MES), though desirable, may be financially and practically untenable during the initial stages of growth. 

Organisational silos

Forging robust links between product-centric and customer-centric teams poses a formidable challenge, as each group harbours distinct expectations and demands from the organisation and its processes. Additionally, the convergence of disparate engineering domains, particularly in the fields of chemical, physical, and engineering, may result in communication breakdowns, exacerbating the situation. 

Complex hardware transitions

A lab has an extremely small hardware capacity in comparison to a gigafactory, so companies require careful planning when scaling, or they risk a serious budgetary challenge. Additionally, lab equipment is operated differently than equipment that was engineered for series production purposes, and recipes may vary significantly, too. This highlights the importance of carefully planning and executing the hardware transition from lab-scale production to large-scale production to avoid any potential problems. 

Knowledge transfer

The main challenge in knowledge transfer in battery manufacturing is the technical complexity of the processes and technologies involved. Battery manufacturing involves a wide range of specialised techniques, including electrochemistry, materials science, and engineering. This complexity can make it difficult for employees to fully understand and replicate the production processes, which can impede the effective transfer of knowledge and lead to inefficiency, errors and lack of scalability. 

Tight budgets

The transition from laboratory to gigafactory represents a significant milestone in any production process. It represents the movement from small-scale experimentation to full-scale mass production. This shift requires a thorough reassessment of the resources required to achieve optimal results. The allocation of resources should be done with foresight and meticulous consideration to ensure that the transition is seamless and that the production process is optimised. 


What is the solution?

Over the past three decades, we have cultivated a highly-integrated software suite designed to optimise our clients’ operations, both in low and high-volume phases. Our clientele’s unwavering confidence in our capabilities has enabled us to not only develop software solutions but also accrue a wealth of operational expertise, which we can draw upon to further enhance our offerings. 

User-centric software

Our software solution was developed by engineers, with a deep understanding of the needs and challenges faced by engineers in their day-to-day operations. This user-centric approach taken in the development of our software ensures the high usability of our software and enables engineers to work more efficiently, saving valuable time and reducing the potential for errors. This, in turn, helps organisations to achieve greater operational efficiency and improve their overall competitiveness. 

battery production robots

High technical interoperability

We offer a specialized software suite catering to the unique needs of laboratory environments as well as series production requirements. Our solutions are designed to support the entire production process, from initial experimentation in the laboratory to full-scale mass production. Our specialised software suite ensures a seamless transition from laboratory software to our state-of-the-art MES, which helps to minimise downtime, reduce costs, and improve efficiency. 

One of the key benefits of our software suite is its compatibility with third-party software. Our MES modules are fully integrated with those from other software providers, providing a unified and seamless experience for our clients. This compatibility allows our clients to utilise their existing software while still taking advantage of our solutions. Our solution enables our clients to optimise their software landscape with pinpoint precision that fits like a glove. 

User-centric development

At the core of our philosophy is a commitment to customer-centricity, where we prioritise the needs of our clients and continuously evolve our offerings to ensure they derive maximum value. This customer-first approach guides every aspect of our development and ensures that our solutions are tailored to meet the unique requirements of each of our valued customers. 


We have been privileged to journey alongside our customers through the various stages of their operations, from laboratory environments to high-volume production. This has enabled us to gain a deep understanding of the different needs and challenges along the way, and to develop innovative solutions that deliver tangible benefits and support growth and success. 

Read more about the challenges, and how to approach them, during the battery manufacturing stages from lab to gigafactory in this whitepaper. Each stage, Plan, Scale and Stabilise, presents its own unique challenges and considerations. We will guide you through the stages and explore how the right digital software solutions can play a crucial role in navigating through each stage and beyond. Discover also insights in best practices and unlock unique tips and tricks.

battery manufacturing whitepaper