Electrifying the Future
#1 Product Transformation
Electricity is an integral part of our daily routine and also makes many aspects of our lives more sustainable. On roads, rail, and in the air, electric drive systems are continuing to gain traction worldwide as a means of achieving climate-neutral mobility of the future. ElringKlinger’s commitment to alternative drive concepts spans a period of two decades. As such, it was an early mover in positioning itself as a specialist in e-mobility. Thus, rather than having to find its feet as it embraces the process of transformation, it can draw on long-standing expertise and a proven track record as a series manufacturer of cutting-edge products.
Shaping electric mobility
The demand for shorter charging times and longer ranges means that battery technology is the key to the successful electrification of the drivetrain. In this segment, ElringKlinger benefits from the requisite expertise in development, industrialization, and manufacturing to be able to offer the market technically mature, series-ready products. Customers can choose from customized or standardized designs, modular solutions, or individual components, ensuring maximum flexibility.
An electrifying product range
The ElringKlinger Group’s e-mobility portfolio comprises a wide range of solutions for battery modules based on prismatic or cylindrical cells in the low- and high-voltage range as well as complete battery storage systems. This modular approach accommodates different storage capacities depending on the application. These range from standard applications, e.g., 5 kWh to 20 kWh for a forklift, to high-performance automotive applications requiring 100 kWh and more. At the component level, ElringKlinger offers cell contacting systems that meet the most stringent technological and quality requirements. The associated development services include theoretical design with CAD, simulation, prototyping, and validation. The subsequent production processes for the cell contacting systems are based on the Group’s long-standing core competencies (plastic injection molding, punching, and the assembly of complex modules) and therefore enable a high proportion of added value across the entire manufacturing process. Several fully automated production lines for cell contacting systems are currently being ramped up. In this context, for example, ElringKlinger will soon be supplying the BMW Group with cell contacting systems for the new EV series from its “New Class” platform.
Expertise and flexibility
Thanks to its development expertise in simulation, validation, and testing, ElringKlinger as a technology group has the capabilities to address development issues for customer applications, such as battery cell aging, using a wide variety of approaches centered around simulation and real-world testing at cell, module, and system level. The major advantage for customers is that, from development and prototyping to testing and serial production, everything at ElringKlinger comes from a single source.
Customer focus
ElringKlinger is continuing to take this approach and is building on its expertise in battery technology, by (a) expanding the Neuffen site and ramping up production there and (b) establishing a new battery development center and adjacent production facility in South Carolina, USA. The objective is to further develop the product range with a focus on adding value for customers. To this end, ElringKlinger aims to extend its customer base for existing and new products and applications. To achieve this, the Group has developed an integrated strategic approach that interconnects product groups, market strategy, and site strategy.
13500 m²
The existing production area in Neuffen was expanded by a logistics center with around 4.500 m² to a total of 13.500 m².
Looking to the United States
The Group company ElringKlinger South Carolina, LLC. established in Easley, South Carolina, USA, in June 2024 is the Group’s next step in implementing the SHAPE30 transformation strategy announced in March 2024. It is envisaged that, from 2025, this facility will primarily manufacture battery technology products and will be developed into a center of excellence for batteries for the American market. The US is particularly important for the German auto industry, with renowned manufacturers operating large production facilities there. These plants not only serve the US market; as key production sites, they also export worldwide. Many of these production facilities are located in the southern states of the United States and thus within a very favorable logistical radius for ElringKlinger South Carolina, LLC.
Growth in Neuffen
Not far from the ElringKlinger headquarters, the Group has consolidated all the battery technology activities of its E-Mobility business unit into a center of excellence at the Neuffen site. This is where high-volume orders such as the major series contract for cell contacting systems for the BMW Group or the order placed by a global battery manufacturer will be realized. Establishing the corresponding infrastructure for battery technology is an important prerequisite for accelerating the success of product transformation. ElringKlinger has therefore added a logistics center measuring around 4,500 m² to the existing 13,500 m² roduction area. In the meantime, more than 350 #transformationpioneers are employed in Neuffen in this business unit and in production. The investments made in the strategic growth area of battery technology will equip the company and the Neuffen facility for handling the ongoing large-scale production of battery components, modules, and systems.
» Thanks to our strength as an innovator, we can already provide answers to the questions of the future and overcome the challenges of progressive transformation as a driver of innovation. «
Jürgen Weingärtner, Senior Vice President Electric Drive and Battery Technology
3 questions for
Senior Vice President Electric Drive and Battery Technology,
and his team at the Neuffen site are working on solutions for an electrifying future.
1. What do you hope to gain from the battery hub in America?
For the EV market in the United States, experts predict an annual growth in revenue of around 10% in the next few years. With the new battery hub, we aim to be close to our customers, specifically, to their development centers in the United States. Rapidly decreasing development timelines are resulting in more complex projects that are challenging to manage from Europe. The production facility adjoining the battery center will ensure close interaction between the development and industrialization functions, guaranteeing the successful future ramp-up of production based on the Neuffen model.
2. What’s the schedule for further ramp-up in Neuffen?
In 2025, we will start production for the large-volume order from the BMW Group for cell contacting systems for its New Class series. Existing production operations will also be stepped up. An additional highly automated production line for another cell contacting system is set to start early in 2026. Work on an order for a battery system based on a battery module with cylindrical cells developed by ElringKlinger is also being intensified.
3. Which new projects or products are in the pipeline?
ElringKlinger is working continually on fine-tuning its modules and battery systems. In Neuffen, we are focusing on our performance module with direct cell cooling and of course also on the next generation of cell contacting systems. In this context, we will be concentrating on design, cost optimization, and technological improvements. We aim to offer our customers improved solutions for cell arrangements, i.e., relating to cell spacing, but also for the functionality of “cell balancing” during charging processes, to allow a further reduction of charging times for battery users.
