Global demand for battery energy storage systems (BESS) is skyrocketing. BESS stabilize power grids, store renewable energy, and provide grid-friendly power. But while the market offers new opportunities, BESS manufacturers, project developers, and grid suppliers are under pressure: without industrial scaling, digital manufacturing processes, and flexible production systems, potential remains untapped. EDAG presents solutions for successful industrialization and scaling.
Market development: Battery energy storage systems
According to forecasts, the global BESS market will grow massively, from around US$25 billion (2024) to over US$114 billion by 2032.[1] This growth is supported by key trends: the expansion of volatile energy sources such as photovoltaics and wind, the decentralization of energy systems, the transition to electromobility, and the increasing demand for supply security and grid resilience.
The utility-scale segment is developing particularly dynamically. These large, grid-connected plants feed electricity into the public power grid. According to the "European Market Outlook for Battery Storage 2025-2029," this segment will account for around 55 percent of annual additions in Europe in 2025. By 2029, this share will rise to over two-thirds.
Technology openness and standardization
As the market grows, so do the demands on production processes. In addition to high-performance storage technologies, the BESS market requires industrializable and scalable production solutions. Flexibility and modularity are essential here: Cell chemistries based on lithium iron phosphate (LFP), nickel manganese cobalt (NMC), and sodium ion (SIB) batteries, as well as various cell formats (prismatic, cylindrical, pouch) must be integrated without compromising quality, safety, or scalability.
EDAG has developed a technology-neutral concept study for 2023 that features a cost-efficient system architecture and high charging and discharging rates combined with high cycle stability.
Production blueprint: From idea to scalable manufacturing
A modular production blueprint was developed based on the concept study. It covers production capacities from 500 to 3,000 MWh per year and can be scaled to specific project requirements. The blueprint includes the plant layout and material flow design, the degree of automation and vertical range of manufacture, quality requirements, and end-of-line test systems.
Simulation as an enabler
Simulation-supported development is central to BESS manufacturing. It ensures mechanical, thermal, electrical, and fluid dynamic processes and precisely coordinates all steps through material flow planning. Coupling these models in a digital environment enables digital factory planning. Even before the production line is set up, production parameters, throughputs, cycle times, and variant flexibility can be digitally mapped and optimized.
This shortens development times and avoids planning errors before the actual plant construction begins.
Automation and flexibility
Volatile demand and ambitious growth targets also require an automation strategy that can respond flexibly to cell types and modules. Future-proof automation therefore encompasses not only robotics and plant control, but also digital twins for flexible adjustments and virtual commissioning, AI-based process control, and the integration of MES and ERP systems. The result is shorter time-to-market, lower scrap rates, and consistent quality despite growing product diversity.
Industrialization and scaling of battery energy storage systems can be planned – with the right partner
The industrialization and scaling of BESS production is not a standard process. Above all, it requires battery and production know-how, system expertise, simulation methodology, and regulatory understanding. EDAG has this expertise and supports battery manufacturers and project developers in the development of robust, scalable, and future-proof production solutions that are technology-neutral and application-oriented.
Discover the white paper "Battery energy storage systems on an industrial scale: market, technologies, and production strategies"
The complete white paper from EDAG provides an overview of the market situation, presents the EDAG concept study and blueprint, and discusses key success factors for industrialization and scaling, such as the simulation-based development of BESS. If you have any further questions about battery energy storage systems, please feel free to contact our expert Robert Wilschrey, Expert Energy Storage Systems. Or download our white paper “Battery Energy Storage Systems on an Industrial Scale: Market, Technologies, and Production Strategies” right here!
