The Expert's Corner

The Power of Collaboration in U.S. Battery Manufacturing

The global shift towards cleaner and more sustainable energy sources has accelerated due to increased public demand, legislative measures, policy initiatives, and funding from both public and private sectors. This transition necessitates advancements in technology to reduce emissions and improve energy storage systems, particularly those that integrate renewable energy sources into the existing grid.

Energy storage is essential for integrating renewable resources like solar and wind into the power grid. According to the U.S. Energy Information Administration (EIA), large-scale battery storage systems added 10,000 megawatts of capacity between 2021 and 2023—ten times the capacity available in 2019. What will be needed for 2025 and beyond? It is crucial that the U.S. continues to invest in domestic battery manufacturing, advanced mixing technologies, and scalable energy storage solutions to meet the growing demand. Strengthening the supply chain, improving battery efficiency, and expanding grid-scale storage capacity will be essential to ensuring a resilient and sustainable energy infrastructure for the future.

As the U.S. strives to reclaim its position as a global leader in battery manufacturing, ROSS Mixers is playing a crucial role in rebuilding and strengthening domestic capabilities and innovations. A founding member of the U.S. Battery Machine Builders (US BMB) coalition, ROSS Mixers is committed to supporting facilities and companies within the battery sector that focus on research, development, energy storage technology, and battery supply chains.

One example of this commitment is ROSS’s partnership with the Battery Innovation Center (BIC), located in Newberry, Indiana, which specializes in energy storage technology. BIC manages all aspects of the battery and energy storage lifecycle while creating a secure environment for the interchange of information and expertise in rechargeable battery chemistries, including emerging chemistries and technologies. BIC’s research in vehicle-to-grid (V2G) technology aims for electric vehicles (EVs) to return power to the grid, which will improve grid stability and reduce costly infrastructure.

The collaboration between ROSS Mixers and the BIC has optimized battery slurry preparation, ensuring consistency and efficiency in electrode production. By working directly with U.S. battery manufacturers and research institutions, ROSS Mixers enhances domestic production competitiveness while reducing reliance on overseas suppliers.

ROSS MIXERS at the BIC

Precision in action: BIC’s ROSS 2-gal and ½-gal PowerMix Planetary Dispersers produce high-viscosity battery slurries with reliable consistency and optimal particle dispersion, a critical step in the production of lithium-ion batteries.

Before integrating ROSS Mixers into their pilot facility, BIC relied on benchtop stirrers and small centrifugal planetary mixers, which posed challenges such as material loss, evaporation, and inconsistent batch quality. Recognizing the need for a scalable, high-precision mixing solution, BIC invested in ROSS PowerMix Planetary Disperser Mixers (PDMs).

The Benefits of ROSS PowerMix Planetary Disperser Mixers

The ROSS PowerMix Planetary Disperser is a hybrid planetary disperser designed to impart a combination of high- and low-speed agitation for mixtures that start out very fluid and eventually thicken up throughout the course of the batching process, making it well suited for batching electrode slurries. It can also blend dry materials such as powders and granulations.

The PowerMix consists of a planetary stirrer blade and a high-speed disperser blade, both of which revolve around a central axis while rotating on their own axes. The planetary blade sweeps material away from the vessel’s sidewalls and bottom, carrying it to the high shear zone of the orbiting high speed disperser. This speeds up solids wet-out and dispersion while maintaining material and temperature consistency throughout the batch at all times.

Some key benefits for battery slurry mixing:

• Closed System Design: Prevents evaporation and oxidation, maintaining precise slurry consistency—crucial for lithium-ion battery performance.
• Improved Particle Dispersion: The combination of planetary motion and high speed dispersion ensures even distribution of high-energy active materials, leading to higher-quality electrode coatings.
• Scalability: Handles larger batch sizes compared to benchtop stirrers and centrifugal planetary mixers, reducing the need for multiple smaller batches and improving production efficiency. The PowerMix design is available in 500-gallon models and larger.
• Vacuum Mixing Capability: Eliminates air entrapment, preventing defects like surface bubbles that could impact battery integrity.

Strengthening the U.S. Battery Supply Chain with US BMB

Through the US BMB coalition, ROSS Mixers continues to advocate for policies that prioritize American-made equipment and infrastructure. The coalition collaborates with the U.S. Department of Energy (DOE) and Department of Defense (DOD) to promote domestic production, including:

• Battery manufacturing grants
• Tax incentives for U.S. battery makers
• Workforce development programs to train engineers and technicians in advanced battery manufacturing

Around the country, ROSS Mixers are used in national laboratories, universities and private R&D centers, where novel battery chemistries and manufacturing techniques are being developed. In addition, ROSS bridges the gap between laboratory breakthroughs and large-scale production, empowering companies to regain American leadership in energy storage technologies.

Why Domestic Control Systems Matter in Battery Production

ROSS Systems & Controls (SYSCON), based in Savannah, Georgia, plays a vital role in ensuring the reliability and precision of industrial mixing operations. As battery manufacturing scales up in the U.S., the demand for highly specialized control systems has never been greater. SYSCON designs and builds custom control panels that integrate seamlessly with ROSS Mixers, providing operators with real-time data monitoring and automation capabilities essential for maintaining batch consistency.

A domestic supplier for critical control systems is essential for reducing lead times, ensuring compliance with U.S. safety and manufacturing standards, and safeguarding national security, as over-reliance on overseas suppliers poses significant risks.

Driving the Future of U.S. Battery Manufacturing

Beyond its impact to the battery industry, ROSS Mixers remains committed to strengthening American manufacturing. With five U.S. plants in New York, Georgia and Florida, along with three global facilities, ROSS continues to invest in domestic production, employee ownership, union partnerships and workforce development.

Since its founding in 1842, ROSS has evolved alongside technological advancements across multiple industries, consistently addressing real-world processing challenges. Built on a legacy of innovative engineering, robust heavy-duty construction, and exceptional American craftsmanship, the company’s reputation is upheld by its knowledgeable, dedicated, and hardworking employee-owners—proud contributors to the resurgence of U.S. manufacturing.

Want to learn more about how ROSS Mixers supports the battery industry? Click here for an informative video.