Impact Clean Power Technology Creates GigafactoryX

In a state-of-the-art factory based on Polish know-how, a battery system weighing up to 500 kg for e-mobility and power generation will be created every 11 minutes.

Polish company Impact Clean Power Technology of the Grenevia Group, a leader in the European electromobility market, has unveiled a visualization of GigafactoryX. This is a large-scale battery factory for electric vehicles and energy storage, which will be launched in the city of Pruszków, near Warsaw.

The modern plant, designed in accordance with ESG aspects, will be one of the largest of its kind in Europe. Its construction will increase Impact’s production capacity to 1.2 GWh in 2024 and more than 4 GWh per year in 2027. The fully automated, state-ofthe-art production line will make it possible to produce a new battery for heavy duty e-mobility every 11 minutes.

GigafactoryX’s production area will eventually be 16,300 sqm. Among other things, the factory will include a battery testing facility and an advanced research and development center.

Upon completion of the investment in Poland, batteries will be made for various types of electric vehicles, including those serving public transportation, such as e-buses, e-trucks and the rail sector. The plant will also produce energy storage systems designed for the commercial power industry, including for large-scale electricity storage. The battery systems will be based on lithium-ion cells in technologies: LTO (lithium titanate), LFP (iron-phosphorus) batteries and NMC (nickel-manganese) batteries.

The GigafactoryX project is another big step in the development of Impact Clean Power Technology. The first phase of the investment will allow us to increase production capacity to 1.2 GWh per year as early as next year, thanks to which we will guarantee the security of supply of battery systems for leading global brands, which are our partners.

Ultimately, in 2027, production will reach 4 GWh per year. The creation of GigafactoryX means that Poland will be Europe’s leading supplier of batteries for the e-mobility industry, all based on Polish solutions, comments Bartek Kras, CEO of Impact.

Additionally, it is extremely important to us that the new plant has been designed in accordance with the principles of sustainable development, he adds.

The design of the GigafactoryX building was prepared by Medusa Group. The architects’ goal was to create a new dimension of industrial architecture that would be more environmentally friendly.

In the design, this intention is reflected, among other things, through the wooden structure holding the exterior balconies and equipping the building with pots of greenery.

The pro-environmental trend is also reflected in the interiors designed by the COBU DESIGN studio, which furnished the office space with numerous green and plant elements.

Impact Clean Power Technologies’ business in the areas of battery systems, energy storage and electromobility is one of Grenevia Group’s four main business segments. The strong emphasis on ESG issues placed on the GigafactoryX project is a result of the Sustainability Strategy, which defines Grenevia’s commitments in this area.

In the case of GigafactoryX, this includes partially powering the plant with energy from photovoltaic panels. An en- ergy storage facility for about 1 MWh is also planned, which will work in conjunction with the photovoltaic plant and the electric grid.

The company teamtechnik Production Technology Poland is responsible for the supply and installation of the production line that produces batteries for public transportation at GigafactoryX. It is a TDJ-owned company specializing in building automated assembly lines for the e-mobility, industrial goods and life science industries.

The technologically advanced, safe production line will be dedicated to the production of battery systems for electric buses in three references, with the possibility of expanding by more.

The first phase line has dimensions of 60 by 16 meters and is thus the largest project implementation in the history of teamtechnik Poland for battery systems. Fourteen engineers worked continuously for four months on its mechanical, electrical and automation design.

The flexibility of the line is influenced by the use of a production loop, which allows production to be optimized depending on the type of product being produced.

As a result, it guarantees savings in both space and costs for the investor. The safety of employees operating the line is taken care of by thermal imaging cameras; when an elevated module temperature is detected, the product evacuation procedure is activated.

The teamtechnik solution is also a key element for increasing Impact’s production efficiency. In 2024, the line will enable the production of 16,000 units of battery systems, compared to the current capacity of about 2,500 units. It also guarantees reproducible product quality, as it includes full automation of processes such as robotic assembly of individual components, batching, screwing, vision inspection and a range of tests.

It will use Bosch Rexroth’s TS7 conveyor system for the first time in the world. Assembly work is scheduled to begin in July 2023.

Thanks to the high automation of processes, we are raising not only the efficiency of production, but also the quality of the batteries produced.

The effect of the technologies used will be a fast assembly cycle of a single battery, which will be only 11 minutes. This is of great importance in view of the growing popularity of e-mobility and forecasts of increasing demand for battery systems in Europe, comments Bartek Kras.

Our cooperation with teamtechnik is a model example of cooperation and achieving synergies by companies that are part of TDJ. The combination of our competencies and development potential within one group enables us to gain significant market advantages. The support of both TDJ and Grenevia is an important support for business development and scaling, he adds.

The batteries for heavy duty e-mobility that will be made at the new plant owned by Impact will be a large-size productwith maximum dimensions of 1400 mm x 1000 mm x 400 mm and weighing up to 500 kg.

The design of the line will be based on technologies from the Industry 4.0 area, and includes the use of full traceability, NOK and re-Work policies.

Their production will be based on full product traceability, product management policies in case of non-conformities and their correction or repair.

The use of such solutions makes it possible to repair a non-conforming product already on the production line and run it through functionality tests again to get a result that confirms the expected quality.

The factory will be certified to IATF 16949:2016, ISO 45001:2018 and ISO 14001.:2015, ISO 9001:2015, as well as have the 6S system, which addresses workplace maintenance standards.

The commissioning of the first automated production line is scheduled for January 2024.

For more information, visit: https://icpt.pl/