Chris Marinucci
Client & Market Officer: Energy & Advanced Manufacturing
E: chris.marinucci@ramboll.com
D: +1 315 481 3567
Turnkey Battery Manufacturing Solutions
Ramboll delivers turnkey battery manufacturing plants, integrating advanced engineering, permitting, automation, and commissioning for clients scaling new technologies from bench to commercial scale. Our team combines deep sector expertise with digital acceleration through our proprietary 10X platform, enabling faster site selection, master planning, and early-stage engineering using parametric geometry, machine learning, and AI. We are recognized for our ability to take projects from concept to commissioning, compressing time to FID and reducing risk for first-of-a-kind and next-generation chemistries.
Why Ramboll?
We are uniquely positioned to deliver every phase of a battery manufacturing plant – from initial permitting through commissioning. Our integrated teams bring process safety and environmental controls into the design from day one, mitigating risks related to hazardous chemistries and combustible dust through early engineering. We approach factory design “process outward,” collaborating with owners to capture technical requirements and configure building systems to effectively support unique process needs. Our proven experience with gigafactory-scale projects means fewer handoffs, a shorter critical path, and a single line of sight from design through commissioning.
Our approach is built on four pillars:
- Environmental permitting and approvals: We navigate complex regulatory landscapes, securing permits and approvals that align with facility planning and sustainability goals. We have a variety of specialty services to assist our clients through the regulatory and safe handling who are working with first-of-a-kind chemicals and compounds.
- Engineering design and scale-up: Our teams excel at scaling new technologies, moving from bench and pilot operations to full commercial production. We orchestrate program management and integrate OEM equipment for seamless process flow. We leverage the FEL process to incrementally advance the engineering design and cost estimating to achieve FID.
- EPC delivery and project management: Ramboll’s disciplined FEL (Front-End Loading) methodology aligns the project for EPC delivery and ensures projects stay on schedule and budget. We manage every detail from concept through construction and commissioning.
- Automation, controls, and fabrication: With a 100,000 sq. ft. Technology Center and UL 508A certified panel shop, Ramboll provides in-house fabrication, automation, and controls engineering. We deliver factory-tested systems, integrated commissioning, and robust process control solutions.
Our services
10X accelerated site selection and early engineering
Ramboll’s 10X platform transforms how battery manufacturing sites are selected and planned. By leveraging parametric master planning, AI-assisted risk screening, and linked discipline models, 10X enables rapid evaluation of multiple sites and robust risk screening. Early-stage engineering outputs are seamlessly handed off to FEL and EPC phases, reducing project risk and compressing timelines. This workflow clarifies off-site utility needs and quantifies earthworks, logistics, and environmental sensitivities before you commit.
- Site selection at scale: 10X screens hundreds of locations for technical, environmental, and commercial fit
- Parametric master planning: Automated workflows generate site layouts and engineering concepts in days, not weeks
- AI-driven decision support: Machine-learning models optimize siting, utilities, and logistics for long-term success
Delivery lifecycle – concept to commissioning
Ramboll’s delivery lifecycle ensures quality and certainty at every stage. We start with scope, program, and business case, then progress through FEL 1–3 with disciplined decisions and transparent cost maturation. During execution, we integrate owner’s equipment packages, controls, and safety-instrumented systems, and we factory-test critical skids at our technology center to shorten site work. Commissioning, training, and early operations support complete the handover so the plant reaches rate and quality targets sooner.
Automation, controls, and fabrication
With a 100,000 sq. ft. Technology Center and UL 508A certified panel shop, Ramboll provides in-house fabrication, automation, and controls engineering. We deliver factory-tested systems, integrated commissioning, and robust process control solutions. Our technical staff includes chemical, mechanical, electrical, and automation engineers, certified welders, and instrument technicians, all focused on delivering safe, high-performance solutions. This integrated approach offers single-point accountability from process design through controls, FAT, and site commissioning.
Water and wastewater
Battery facilities succeed on reliable, low-carbon utilities. We design water recovery and reuse around local constraints, specify wastewater treatment that fits your waste profile, and validate options in our in-house treatability labs before committing capital. The utility concept is developed together with air permitting and process ventilation, so the overall design reflects best available control and community expectations. Our expertise in industrial water stewardship and treatability testing is a practical differentiator for battery manufacturing clients.
Project highlights
iM3NY Lithium-Ion Gigafactory, NY
Ramboll supported Imperium 3 in scaling up high-energy density lithium-ion battery manufacturing. Our team provided environmental, safety, program management, engineering, construction, installation, startup, and commissioning support. The project included:
- ~125,000 sq. ft. total interior, with 52,000 sq. ft. of dry room space
- Upgrades to electrical distribution and bulk gas systems
- Abbreviated FEL-3, detailed design, PM/CM/CX services
- Project delivered on budget and schedule, with larger multi-GW factory design underway
GE Battery Facility, Schenectady, NY
Ramboll led the fast-track conversion of a former gas turbine manufacturing facility into a state-of-the-art battery R&D and manufacturing headquarters. Highlights include:
- Relocation and consolidation of bench, lab, and pilot-scale operations
- Integration of dozens of OEM equipment providers into a unified process
- Scale-up of production from 30,000 to over 1,000,000 cells per year
- Factory floor integration and program management
By the numbers
100,000
sq. ft. advanced manufacturing center
18,000
global employees, 2,200 in the Americas
+$1M