Battery Cell Manufacturing and Gigafactories

Battery Facility Integration Services, Procurement and Construction Oversite

Integrated Solutions for Battery Infrastructure Development

The global shift toward electrification and energy storage is driving unprecedented demand for battery production and recycling infrastructure. Hatch offers integrated services that span the entire battery value chain—from raw material extraction to chemical processing, battery material production, cell manufacturing, and end-of-life recycling.

Our approach is grounded in technical excellence, project delivery experience, and a deep understanding of the evolving battery ecosystem.

Comprehensive Value Chain Coverage

Battery facility development is complex and multidisciplinary. Hatch supports clients across all stages of the battery lifecycle:

Upstream: Mining and processing of lithium, nickel, aluminum, cobalt, and graphite
Midstream: Battery material (cathode and anode) production
Downstream: Cell and module manufacturing, gigafactory design
End-of-life: Battery recycling and reuse infrastructure

This integrated perspective enables us to design and deliver facilities that are technically robust, scalable, and aligned with sustainability goals. It also provides Hatch with a unique capability to assist clients in vertical integration, to bolster their investment margins.

Core Services

Research, Studies and Preliminary Planning

R&D support, scale up strategies
Scoping studies, trade off studies
Pre-feasibility studies
Process comparison studies
Site selection
Market assessments
Environmental and social impact studies
Financial modeling and risk analysis

Engineering Design, Execution Planning

Process engineering and plant layout
Utility and infrastructure integration
FEED Engineering
Permit Support
Execution strategies and schedules
Early works construction coordination
Modular and scalable design strategies

Project Delivery

Detailed engineering
Code compliance
Integration engineering
Procurement and contract management
Construction oversight
Schedule and cost control
Quality management strategy and infrastructure

Operational Support

Commissioning support
Ramp up support
Operator training programs
Business and operations systems
Reliability and maintenance planning
Quality management plans
Energy efficiency and decarbonization
Digital tools for performance optimization
Lifecycle and circularity assessments

Addressing Industry Challenges

Battery materials, cell manufacturing and recycling developers face several technical and strategic challenges. Hatch provides solutions that respond to:

Technology evolution: Navigating emerging chemistries and manufacturing platforms
Supply chain constraints: Designing facilities with flexible sourcing and local content strategies
Sustainability requirements: Integrating low-carbon design, water management, and circular economy principles
Regulatory complexity: Supporting compliance across jurisdictions and permitting processes
Workforce development: Incorporating automation and training programs to address skills gaps

Project Execution Excellence

As complete facility designers and integrators, we deliver complex projects with precision and speed:

Front-End Loading Framework: Rigorous gate reviews from concept to execution
Integrated Design & Construction: 3D modeling, automation, and commissioning-driven engineering
EPCM Delivery Approach: Unified engineering, procurement, and construction management
Participation in other delivery approaches such as Design-Build and Integrated-Project-Delivery (IPD)
Health, Safety & Risk Management: Industry best safety performance and risk mitigation strategies

Let’s Build Better Batteries Together

Our teams are ready to support your battery facility development with tailored, technically sound solutions. Whether you're planning a new facility or optimizing an existing one, Hatch brings the experience and insight needed to deliver results.

Download our Battery Facility Integrators brochure to explore our capabilities, project experience, and insights into building resilient, future-ready battery infrastructure.

Project Experience

Cathode and Anode Material Expertise

Hatch delivers comprehensive solutions for battery material production, supporting clients from concept through detailed engineering for both cathode active materials (pCAM/CAM) and battery anode materials (BAM).

Notable Clients: UltiumCAM (POSCO/GM), Vianode, Panasonic, Nano One, Duracell, Lyten, Mitra Chem, BASF, Urbix, Graphite One, Syrah Resources, Ingevity and Novonix.
Hatch Scope:
- Research and Scale Up: testwork, piloting, demonstration, commercial plant scale-up
- FEL0–FEL3 studies: scoping, concept, pre-feasibility, feasibility studies
- FEED engineering for project execution readiness
- Project execution (FEL 4) including full EPCM delivery, and participation in design-supply models
- Market studies
- Financial analysis
- Permitting support
- Due Diligence for acquisitions and investments
- Operational support for process optimization
Target Products:
- Cathode Materials: Ni-rich pCAM/CAM, LFP pCAM/CAM
- Anode Materials: BG anode graphite, spherical coated graphite, Li foil anode, silicon-infused graphite, silicon
- Integration with battery recycling processes

Select examples:

Cathode active material - Confidential client
We were appointed to perform two roles at the project site in Quebec. In the initial mandate, Hatch performed the detailed design of the “outside-battery-limits” scope (OSBL), which included the site infrastructure, utilities, and buildings as a sub-contractor. Detailed engineering was completed in 2025.
Shortly after this mandate kicked off, the client requested support from Hatch on the “inside-battery-limit” scope (ISBL, or the core manufacturing process), where we were responsible for the integration of the ISBL scope with the OSBL component. We worked closely with equipment suppliers in Asia to review their designs and provide input on compliance with local codes and regulations.
Once nameplate production is reached, the first-of-its-kind in North America plant is expected to produce 30,000 tonnes per year of high-nickel NCM CAM.

Anode active material - Vianode
By 2030, Vianode aims to deliver a world-leading carbon footprint of only 1 kg CO2 emission/kg high-performance, high-quality anode graphite for 3 million EVs annually. The current market average is 20 kg CO2/kg conventional anode graphite. Vianode is in the process of commercializing proprietary graphitization furnace technology and is expected to set a new industry standard for low-carbon production of graphite anode material.
Hatch was appointed by Vianode to prepare a feasibility study and the basic engineering design for Vianode’s first commercial-scale battery-grade graphite anode production facility in North America. Our work includes integration of the core manufacturing process packages, and design of the “balance-of-plant” including the site plan, buildings, on-site infrastructure, and utilities. Vianode and Hatch have completed the basic engineering phase, as the project progresses toward execution.

Cell Manufacturing

We deliver end-to-end solutions for battery cell plants, from consulting and permitting to design and oversight of gigafactory construction.

Notable Clients: QuantumScape, Ford, Freyr, Forge Nano/Battery, Samsung SDI, Lyten, Bathium (Blue Solutions), and multiple confidential partners.
Hatch Scope:
- Research and Scale Up: cell design, piloting, commercial plant scale-up, quality certification support
- FEL0–FEL3 studies: scoping, concept, pre-feasibility, feasibility studies
- FEED engineering for project execution readiness
- Project execution: EPCM, PMC services, detailed engineering, plant integrator, interface design and management, equipment installation, code compliance
- Market studies
- Financial analysis
- Permitting support
- Due Diligence for acquisitions and investments
- Operational support for process optimization
Target Products: Li-ion cells (NMC, LFP), solid-state cells, Li-S cells, LMP cells. Forms include prismatic, cylindrical, pouch cells.

Example - Forge Battery Gigafactory

Forge Battery plans to establish a 3-GWh gigafactory in Morrisville, North Carolina, to produce high energy density cylindrical cells and has secured $100 million in funding from the U.S. Department of Energy. Hatch contributed by providing the design FEED for the 3-GWh facility, which includes process design and equipment selections, plant layout and integration (including the dry room), as well as CAPEX/OPEX estimates and control and manufacturing systems architecture.

Battery Recycling

We help clients close the loop with innovative recycling solutions, from black mass processing to CAM production.

Notable Clients: Sibanye-Stillwater, VW Group, Cylib, Glencore, Li-Cycle, Altilium, Battery Metals Inc, CirCoLi, Aleon, GreenLIB, Electra Battery Metals, Aurubis, Recyclico, and multiple confidential partners.
Hatch Scope:
- Research and Scale Up: bench-scale testing, piloting, commercial plant scale-up
- FEL0–FEL3 studies: scoping, concept, pre-feasibility, feasibility studies
- FEED engineering for project execution readiness
- Project execution: EPCM, PMC services, detailed engineering, plant integrator, interface design and management
- Market studies
- Financial analysis
- Permitting support
- Technology development and supply
- Due Diligence for acquisitions and investments
- Operational support for process optimization
Target Products: Black mass, battery-grade sulfates, lithium products, Ni-rich pCAM/CAM, LFP.

Example - Altilium

Altilium is a UK-based clean technology group supporting the transformation of the global energy sector from fossil-based to zero carbon. Their vision is for a domestic EV battery supply chain, where the critical minerals powering the energy transition are recovered from recycling existing waste streams, reducing mining and preserving our natural resources.
Hatch has engaged with Altilium for five years to help them develop their critical UK battery recycling projects. We have assisted from initial early conceptual design and laboratory testwork, to completing engineering studies on their major projects. This included scaling up testwork data, process optimization, plant layout development, equipment package development, execution planning, and cost estimation. We have assisted them with their two key commercial-scale projects:

ACT 3: Black mass to MHP and lithium sulphate, completing the pre-feasibility study
ACT 4: Feasibility study for a black mass and MHP feed to battery and technical-grade salts project.

We have also assisted with smaller studies working towards Altilium's ultimate vision of an integrated EcoCathode™ battery metals plant, including battery recycling to black mass production, and producing pCAM & CAM products.

Battery Facility Integration Services, Procurement and Construction Oversite

Integrated Solutions for Battery Infrastructure Development

Comprehensive Value Chain Coverage

Core Services

Addressing Industry Challenges

Project Execution Excellence

Let’s Build Better Batteries Together

Project Experience

Select examples:

Example - Forge Battery Gigafactory

Example - Altilium

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Build better batteries

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Addressing Industry Challenges

Project Execution Excellence

Let’s Build Better Batteries Together

Project Experience

Select examples:

Example - Forge Battery Gigafactory

Example - Altilium

Build better batteries