BREYER IONDry
Dry Electrode Manufacturing Technology
Advanced dry coating and calender technology for solvent-free battery electrodes
Discover BREYER IONDry – advanced dry electrode manufacturing technology for solvent-free battery electrode production. From laboratory development to pilot-scale dry coating and calendering.
BREYER IONDry is an innovative calender technology for dry electrode manufacturing and the production of Dry Battery Electrodes (DBE). The system is designed to process dry, ideally solvent-free battery materials into homogeneous electrode films with precisely controlled thickness, density and compression.
With the growing demand for more sustainable and energy-efficient battery production, dry coating technology offers an attractive alternative to conventional wet electrode coating. By eliminating the need for solvents and energy-intensive drying processes, dry electrode production has the potential to reduce both environmental impact and manufacturing costs.
BREYER IONDry - More than 15 years of experience in dry electrode processing
BREYER has been developing technologies for dry electrode manufacturing and dry electrode processing since 2009. In parallel with our proven IONPress technology for the calendering of conventionally wet-coated electrodes, we have continuously expanded our expertise in dry electrode processing and precision calendering.
Our development focuses on transforming dry electrode compounds into a stable, homogeneous electrode film and applying it precisely to the current collector foil.
The IONDry process combines several critical process steps in one system while allowing each calendering zone to be individually optimized through dedicated roll arrangements and precisely controlled pressing forces.
One integrated process for Dry Battery Electrode (DBE) production
BREYER IONDry is designed for continuous, solvent-free manufacturing of high-quality dry electrodes for lithium-ion batteries.
The process begins with the dry mixing of the electrode materials. The premixed material is then continuously and precisely fed into the calender. Within several precisely controlled roll gaps, the dry material is compacted and formed into homogeneous free-standing electrode films.
The thickness of the films is precisely adjusted during the process. In the final stage, the electrode films are laminated onto both sides of the current collector foil – aluminium for cathodes or copper for anodes – to create the finished electrode structure.
The key advantage: forming, thickness adjustment and lamination are integrated into one continuous roll-to-roll process for dry electrode manufacturing.
Precise material feeding and controlled calendering
The BREYER IONDry 600 pilot is a drycoating pilot line designed for the continuous production of battery electrodes. A specially developed dosing and conveying system, synchronized with the calender, ensures controlled distribution and precise feeding of the dry electrode material into the roll gap.
The material is processed through several precisely controlled calender gaps. This allows the electrode films for the top and bottom sides of the current collector to be produced simultaneously and subsequently laminated into a stable composite structure.
BREYER's extensive experience in precision calendering, calender roll technology and closed-loop gap control provides the foundation for highly controlled and reproducible dry electrode processing.
From laboratory development to pilot-scale production
BREYER offers scalable solutions for the development and industrialization of dry coating technology.
BREYER IONDry 400 core
The compact laboratory and development system is designed for material development, process optimization and early-stage research into dry battery electrode technology.
BREYER IONDry 600 pilot
The pilot line is designed for process development, scale-up and initial production runs of Dry Battery Electrodes (DBE). It provides an important bridge between laboratory research and future industrial dry electrode manufacturing.
Technical data – BREYER IONDry Dry Electrode Calenders
IONDry machine series provides scalable roll-to-roll technology for dry battery electrode (DBE) film formation and lamination – from material development to pilot production.
| Technical data | IONDry 400 core | IONDry 400 lab* | IONDry 600 pilot |
| Application | Dry electrode formation | Dry electrode formation and one-side lamination | Film formation and double-sided lamination |
| Final product | Free-standing electrode film | Free-standing electrode film, one-side laminated | Double-sided coated electrode |
| Roll configuration | 2 rolls / 1 nip | 4 rolls / 3 nip | 6 rolls / 5 nip |
| Roll working width | 400 mm | 400mm | 600 mm |
| Line speed | up to 10m/min | up to 20 m/min | up to 40m/min |
| Roll temperature | up to 150°C | up to 150°C | up to 150°C |
*design in progress
BREYER IONDry – from laboratory development to pilot-scale production
Learn more about BREYER's technology for dry electrode manufacturing, precision calendering and process scale-up.
Discover more about BREYER IONDry →
Advantages
Solvent-free electrode production
No chemical solvents are required for the dry electrode process. This supports more resource-efficient and environmentally responsible battery manufacturing.
No energy-intensive drying process
By eliminating conventional solvent drying, dry coating technology can significantly reduce energy demand and operating costs.
Integrated and continuous production process
Material feeding, film formation, thickness adjustment and lamination are combined in one continuous production process.
Precise calender gap control
Advanced electro-hydraulic control technology enables precise adjustment of the roll gaps according to both distance and force requirements.
Automated material handling
The dosing and conveying system is synchronized with the calender to ensure continuous and controlled material feeding.
Inline process monitoring
Integrated sensors enable continuous monitoring of key process parameters and support stable, reproducible dry electrode production.
Designed for scale-up
From laboratory development to pilot-scale production, BREYER IONDry supports the scale-up and industrialization of next-generation Dry Battery Electrode (DBE) manufacturing processes.
Dry coating technology for the future of battery manufacturing
Dry electrode manufacturing is one of the most promising technologies for the next generation of lithium-ion battery production. The potential to eliminate solvents and energy-intensive drying steps can contribute to more sustainable, efficient and cost-effective electrode manufacturing.
With BREYER IONDry, we combine decades of expertise in precision calendering with more than 15 years of development in dry electrode processing.
Whether for research, material development, process optimization or pilot-scale production – BREYER IONDry provides advanced technology for companies and research institutions shaping the future of dry battery electrode manufacturing.
Talk to our experts about BREYER IONDry and your requirements for dry electrode manufacturing, dry coating and scale-up.
Examples of application
