Scaling up battery production isn’t just a necessity—it’s a race against time. As gigafactories become the backbone of electrification, efficiency, speed, and innovation are the defining factors of success. The 2nd Gigafactory Summit, held on March 4-5, 2025, in Berlin, brought together the minds shaping the future of large-scale battery manufacturing. Industry leaders, engineers, and innovators tackled the critical challenges of rapid construction, cost management, and next-gen facility design. This article covers key sessions, sponsor contributions, and the most valuable insights from this pivotal industry event.
Key Sessions at the 2nd Gigafactory Summit
The 2nd Gigafactory Summit had in-depth sessions on all gigafactory design, construction, and operation aspects. Experts from the industry presented insightful views, best practices, and creative solutions to overcome the challenge of constructing and operating leading-edge gigafactories. Below is an in-depth examination of each session and the lessons learned from the presenters at the battery manufacturing conference:
Next-Generation Gigafactory Layouts: Maximizing Efficiency and Scalability
Speaker: Stefan PERMIEN, CEO, UniverCell Holding GmbH
This keynote session was about how to maximize gigafactory floor plans to boost production flow. The presentation investigated design approaches that optimize material handling, reduce bottlenecks, and optimize operations. Furthermore, the presentation highlighted the value of scalability as a design factor. It pointed out how to construct modular and expandable facilities to accommodate future demand. Incorporating cutting-edge automation technologies and energy-efficient practices in factory design was also discussed. This gave away how they lower operational expenses and environmental footprints.
Defining Customer Superiority & Cost Competitiveness in Battery Programs
Speaker: Michael KÖNIG, Head of Program Management Cost Optimized, PowerCo
The session touched on realizing competitive costs in battery projects. This is by way of best practices and effective cross-functional collaboration. The presenter imparted knowledge regarding factory ramp-up studies, benchmarking, and customer-centric solutions in battery projects. Moreover, project management approaches adapted to battery ventures were debated. This had its focus on industrialization issues specific to European battery manufacturing. The presentation also provided keen insights into weighing cost optimization versus customer satisfaction in the competitive battery sector.
Advanced HVAC Solutions for Gigafactories
Speakers: Federico TIEZZI, Director of Applications & Battery Centre of Excellence, Munters Europe, and André MEYER, Manager of Key Applications Sales, Munters Germany
This extensive session highlighted the most recent developments in energy-efficient HVAC systems specifically designed for gigafactory conditions. The presenters shared solutions for smart control and IoT integration. It helps in optimized performance in massive facilities. With real-world examples of successful HVAC installations, the speakers illustrated the quantifiable advantages of enhanced HVAC systems. This is on operational expenditure and sustainability. The presentation also outlined how effective climate control is in sustaining optimal production conditions while conserving energy.
Project Management for Chinese Gigafactory in Slovakia – Challenges and Opportunities
Speaker: Tobias FRIESER, Head of Project Management Office, L&B International
The session offered key lessons on how to handle Chinese investors’ expectations of project timelines in European settings. The speaker covered important issues of public infrastructure development, change management practices, and sound decision-making frameworks. Cross-cultural and business practice bridging communication strategies were identified as key to successful project delivery. The presentation also provided takeaways for global collaboration in gigafactory development. This came along with a focus on cultural sensitivity as key to global project management.
Challenges & Opportunities in Setting Up Large-Scale Battery Cell Production
Speaker: Saskia WESSEL, Division Director Product and Production Technology, Fraunhofer Research Institution for Battery Cell Production FFB
This presentation at the 2nd Gigafactory Summit presented lessons from building a gigafactory in Germany. So, there were real-world insights into implementation challenges. The presenter provided a comprehensive insight into energy consumption patterns in battery cell manufacturing. It was pointing to key areas for optimization. Additionally, an energy idea for factories on an industrial level was showcased, dealing with efficiency and sustainability issues. The session also highlighted the importance of combining renewable energies with factory ideas. This gave away how the integration serves environmental objectives and operating efficiency as well.
How to Plan and Realize a State-of-the-Art eVB Cell Factory
Speakers: Alexandru POPOVICI, Managing Director Central Eastern Europe, EFESO Management Consultants, and Uwe STEINKÖTTER, Vice President & Partner, EFESO Management Consultants
The session detailed a value-based, sustainable manufacturing model that facilitates high-performance cell production. The speakers delivered bespoke digital and AI solutions. These were specifically designed to address the distinct needs of today’s battery plants. Furthermore, the optimal site and factory design strategies were explored to achieve maximum efficiency and enable long-term objectives. A modular, flexible factory approach was also presented – a scalable, economical 5 GWh design capable of responding to market conditions and technological innovation. The session ended with strategies to reduce risk by minimizing risk through quality assurance measures.
Cleanroom Modular System Approach in EV Gigafactories – Real Applications
Speaker: Gianluca URBANO, Head of Industrial Division, Mangini Srl – Mangini Group
The practical session identified the most important factors to consider in the design of EV cleanrooms and dry rooms in gigafactory conditions. The speaker contrasted conventional methods with Mangini’s unique IMP approach. It showed the benefits of modular systems. Moreover, a major emphasis was given to intricate design challenges, especially the engineering and construction of seismic walls up to 13 meters tall. By presenting real-world applications, the presentation illustrated how cleanroom solutions in modular form can improve construction efficiency. This is while preserving key environmental requirements for battery manufacturing.
Cooling GigaFactories with Sustainability Goals
Speaker: Bill WILLIAMS, Global Director Business Development-EV Battery, BAC
The presentation presented a new method for gigafactory cooling system design with sustainability as the focus. The presenter elaborated on how cooling solutions can be tailored to fit any climate around the globe. This is to enable maximum performance anywhere. In addition, methods of maximizing water and energy consumption in cooling systems were discussed. It includes the environmental and economic advantages. The presentation also illustrated how new cooling solutions ensure tight budget and timeline compliance. This is while ensuring environmental stewardship during gigafactory operations.
Building the Future: Leveraging Prefabrication and Modular Construction for Gigafactory Excellence
Panel Moderator: Bill WILLIAMS, Global Director Business Development-EV Battery,
Panelists: Stefan PERMIEN, CEO, UniverCell Holding GmbH; Andreas MAIER, Chief Operating Officer, Morrow Batteries ASA; Ben FARAKISH, Director of Engineering, AESC; Gianluca URBANO, Head of Industrial Division, Mangini Srl – Mangini Group
This panel discussion delved into the revolutionary potential of prefabrication and modular construction methods in gigafactory construction. Industry experts discussed how these techniques speed up construction schedules, enhance quality assurance, and increase scalability. The discussion also touched on actual implementations, challenges faced, and lessons derived from different international projects. Moreover, special focus was placed on how modular construction enables agile responsiveness. This is toward technological advancements and market needs while maximizing resource efficiency and minimizing environmental footprint.
Battery Atlas/ Shaping the European Lithium-Ion Industry
Speaker: Jessica SCHMIED, Group Leader of Battery Production Management, Production Engineering of E-Mobility Components, RWTH Aachen University
The presentation charted Europe’s plans to boost its battery sector’s competitiveness and sustainability in the international market. The speaker concentrated on research and innovation investments in developing battery technology and manufacturing techniques throughout the continent. Furthermore, the discussion went toward the regulatory system that is molding the European battery sector. It came along with challenges as well as opportunities for industry development being noted. The presentation also gave insights into how collective European action is making the region a power player in sustainable and innovative battery manufacturing.
Going Green, Morrow’s Simple Path to Sustainable Batteries
Speaker: Andreas MAIER, Chief Operating Officer, Morrow Batteries ASA
This session at the 2nd Gigafactory Summit outlined the end-to-end way forward for sustainable battery manufacturing in Europe. This went deep into the steps for practical implementation. The presenter provided insights on sustainable gigafactory design principles. These minimize environmental footprint while ensuring production efficiency. Moreover, the session went toward production ramp-up learnings, providing key takeaways for new plants. The session then went to carbon emission-saving opportunities for different cell chemistries and informed technology selection. Also, the presentation concluded with a roadmap for developing an integrated sustainable supply chain for battery manufacturing.
Innovations in Dry Room Solutions & Process Isolators for Giga Factories
Speaker: Dan KRISTENSSON, CEO, AirSon Engineering
This session discussed leading-edge technologies in dry room architecture and process isolation systems essential for battery manufacturing. The presenter outlined new methods of ensuring ultra-low humidity conditions and reducing energy consumption. New process isolator technologies that improve production quality and the safety of workers were showcased. The presentation also identified how these specialized products meet the distinctive environmental control demands of contemporary battery production processes. It ensures overall production efficiency and product quality.
Gigafactories, Giga-Challenges – What it Takes to Master the Large-Scale Industrialization of Battery Cells
Speaker: Robert HEILER, Senior Manager Global Operations Practice, Porsche Consulting GmbH
The presentation gave an overview of the current performance gaps between aspiring newcomers and seasoned market players in battery manufacturing. The presenter drew a picture of the usual challenges most newcomers encounter when growing operations to gigafactory size. Essential topics that can enable businesses to leapfrog the competition were discussed. This came with a focus on differentiation strategies. An industrialization master plan was also presented. It gave a structured strategy for battery cell manufacturing mastery. It was one that is cognizant of usual pitfalls and builds on successful factors proven in practice.
Introduction to Gigafactory Infrastructure “Common Building Block” Model
Speaker: Ben FARAKISH, Director of Engineering, AESC
This look-ahead session spoke to the ramping-up demand for high-efficiency, scalable, and cost-effective gigafactory facilities. The speaker discussed the potential of repeatable, high-performance design solutions. This is to streamline engineering, decrease construction periods, and keep down expensive design changes. The enabling role of modular construction for speedy deployment was mentioned. Additionally, the talk illustrated how these approaches bring down CAPEX and running expenses. This is while increasing dependability, flexibility, and scalability. This helps gigafactories stay responsive to advancing technology and market needs.
CircularFactory: The Sustainable Gigafactory Revolution through the 3Rs
Speakers: Ernesto GARCÍA, Head of Partnerships, GDV and Germán AGULLÓ GARCÍA, CEO, GDV
This session at the 2nd Gigafactory Summit presented the 3Rs approach—Reduce, Reuse, Recycle—as a basis for the sustainable operation of gigafactories. The speakers described the circular factory concept that reduces waste and makes the best use of resources. Furthermore, three interlinked factory ideas were investigated: Re·Factory for battery fleet recycling and waste minimization, Re·Using Factory for G·ONE Megabatteries, and Re·Cycling Factory for black mass purification. The talk also emphasized how the use of recycled raw materials provides new synergies throughout the battery value chain. This advances environmental objectives while generating economic benefits.
Contamination Control and Management: Maintaining Clean and Controlled Environments in Manufacturing Settings
Speaker: Bill WILLIAMS, Global Director Business Development-EV Battery, BAC
This session highlighted the vital significance of contamination control in battery manufacturing environments. The presenter outlined major contamination control practices and technologies. These guarantee product quality and uniformity. Moreover, procedures for monitoring and sustaining clean environments during production processes were discussed. The presentation also demonstrated the immediate effect of good contamination control on product quality and reliability. This is with emphasis on how good environmental management has a direct influence on battery performance and safety profiles.
Sponsors At The 2nd Gigafactory Summit
The 2nd Global Gigafactory Summit was sponsored by several industry players who shared their expert knowledge and creative solutions with the event. The sponsors helped increase the summit’s content quality and practical applicability through their technical sessions and exhibition booths. A brief overview of each sponsor and their contributions to the battery manufacturing conference is provided below:
Mangini – Gold Sponsor
Mangini S.r.l. is a leading supplier of cleanrooms and dry rooms for more than 60 years. The company excels in designing, building, and maintaining ISO-compliant EV batteries, semiconductors, aerospace, electronics solutions, and more. With five R&D units and three factories, Mangini has successfully implemented over 4,000 projects worldwide. Moreover, at the 2nd Gigafactory Summit, their presentation on “Cleanroom modular system approach in EV Gigafactories” provided worthwhile insights into actual applications. It highlighted how their prefabricated modular systems and seismic-certified interiors meet intricate manufacturing needs for EV manufacturing.
BAC – Bronze Sponsor
BAC has been a leader in cooling solutions since 1938. It provides sustainable comfort cooling, process cooling, and refrigeration for mission-critical industries. With more than 85 years of history, BAC is the industry leader in evaporative condensers and adiabatic coolers. Moreover, their customer-driven philosophy delivers efficiency, energy conservation, and top-quality products. BAC’s presentation at the summit on “Cooling GigaFactories with Sustainability Goals” gave delegates hands-on insights on applying sustainable cooling solutions. This is to support gigafactories’ achievement of operational performance and sustainability objectives. It creates enormous value for facilities planning procedures.
Munters – Bronze Sponsor
Munters is a world leader in climate control solutions. It excels at ensuring the best humidity, temperature, and air quality for mission-critical uses. Their technologies serve battery manufacturing, pharmaceuticals, data centers, and food production and minimize energy and water use. Furthermore, Munters added value to the 2nd Gigafactory Summit with their presentation on “Advanced HVAC Solutions for Gigafactories”. They provided insights into designing ideal production environments. So, this presentation gave delegates an understanding of how effective climate control directly benefits the quality of production, efficiency, and uptime in battery manufacturing operations.
EFESO – Bronze Sponsor
EFESO is a leading consulting company specializing in industrial operations and performance improvement. Operating from 35 offices globally and delivering over 1,000 projects per year, they drive organizational transformation and sustainable development. Their presentation on “How to plan and realize a state-of-the-art eVB Cell Factory” gave summit participants detailed advice on factory planning and optimization. EFESO‘s presentation also showed how their end-to-end value chain methodology drives quicker, visible, and lasting improvements in gigafactory operations. So, this gave actionable strategies for manufacturers.
AirSon – Bronze Sponsor
AirSon offers bespoke MEP engineering services for high-demand, installation-intensive facilities with strict tolerances. It includes industries such as med-tech, pharma, and batteries. Their engineers offer turnkey construction, HVAC and cleanroom solutions, and energy optimization services. Additionally, AirSon added great value at the summit with their presentation on “Innovations in Dry Room Solutions & Process Isolators for GigaFactories”. It highlighted innovative methods to preserve the stringent environments required in battery production. It also helped delegates in grasping solutions to pivotal production issues.
Pophen Technology Hungary – Exhibiting Partner
Pophen Technology Hungary is a cleanroom construction specialist in air duct and panel manufacturing. Supported by its parent company in China with close to 70 patents and large production capacities, Pophen offers energy-saving and environmentally friendly solutions. This is for microelectronics, pharmaceuticals, and biotechnology. Being an exhibiting sponsor at the 2nd Gigafactory Summit, Pophen presented its flexible cleanroom technologies designed for unique industry demands. Their attendance also offered visitors a glimpse into how their green-friendly solutions enable gigafactories and high-tech manufacturing plants to meet strict standards while maximizing performance.
To Sum Up
The 2nd Global Gigafactory Summit effectively connected industry innovators, leaders, and experts in a comprehensive endeavor to resolve challenges and prospects in gigafactory construction, design, and operations. The summit featured actionable intelligence, practical insights, and networking events that will reshape the gigafactory development process. While demand for lithium batteries keeps increasing with the electric vehicle revolution in full swing, such events are important in pushing industry expertise and promoting collaboration. So, don’t miss the chance to attend upcoming summits like these to stay ahead in your sector!
