Battery Manufacturing &
Gigafactory Engineering Services

Dry rooms are the defining engineering challenge of any Gigafactory — dew point control to as low as −60°C dew point.

• Dew point analysis — determining target dew point class for each manufacturing zone
• Dehumidification system selection — rotor dehumidifiers, dual-stage dehumidification
• Supply air condition calculation — moisture load analysis, air flow rate determination
• Make-up air handling unit (MAHU) design — pre-conditioning before dehumidification
• Recirculation air handling unit (RAHU) design — internal loop control
• Chilled water system design for dehumidification rotors and cooling coils
• HVAC load calculation — sensible heat, latent heat, process loads
• Energy consumption modelling — annual dry room HVAC energy estimate
• Controls philosophy — dew point control, temperature control, pressurisation

Gigafactories require an extensive range of process utilities for cell manufacturing — all designed, sized, and coordinated by KVRM.

• Compressed dry air (CDA) — ultra-dry air to ISO 8573 Class 1.2.1
• Deionised / ultrapure water (DI water / UPW) — generation and distribution loop
• Vacuum system design — process vacuum for slurry mixing, coating, calendering
• Cooling water system — chilled water and process cooling water (PCW) loops
• Nitrogen gas system — blanketing for electrode and electrolyte handling
• NMP solvent recovery system — HVAC for solvent recovery
• HT/LT electrical distribution — power for formation, ageing, and process equipment
• Earthing and static control system — anti-static flooring, ESD protection

Lithium-ion battery fires present unique hazards — thermal runaway, gas venting, re-ignition risk — all addressed in our NFPA 855 compliant designs.

• NFPA 855 compliance — Standard for Stationary Energy Storage Systems
• Fire protection strategy — suppression, ventilation, separation, detection philosophy
• Smoke detection system design for manufacturing and storage areas
• Sprinkler system design for cell manufacturing and module assembly
• Gas venting and exhaust system for thermal runaway events
• Battery storage area protection — rack sprinkler systems, flood systems
• Fire barrier and compartmentation strategy for high-energy storage areas
• Emergency response plan support — HAZMAT considerations

Some battery manufacturing processes require controlled cleanliness — KVRM designs the complete classified environment alongside dry room and HVAC systems.

• Electrode manufacturing — particle contamination control strategy
• Cell assembly — cleanroom classification for winding and stacking processes
• ISO 14644 classification and airflow design for applicable zones
• HVAC system design — temperature and humidity control alongside dew point control
• HEPA filtration where particulate contamination control is required

Gigafactories are major energy consumers — energy management is both a cost and ESG issue.

• Total plant energy model — production-normalised energy consumption targets
• Dry room energy optimisation — heat recovery, free cooling
• Formation and ageing energy management — charge/discharge efficiency optimisation
• Renewable energy integration — rooftop solar PV sizing and yield modelling
• ISO 50001 energy management system implementation support
• Carbon footprint reporting — Scope 2 (purchased electricity) reduction strategy

End-to-end PMC for Gigafactory construction projects.

• Pre-FEED and FEED stage PMC — basis of design, contractor selection, value engineering
• EPC stage oversight — schedule management, QA/QC, cost control, site supervision
• Dry room qualification and HVAC commissioning oversight — dew point performance testing
• Utility system commissioning — UPW, CDA, chilled water, vacuum systems
• Mechanical completion and handover documentation management