Integrated Thermal Processing Systems for
Advanced Battery
Materials and Components
KEPKA designs and delivers complete thermal processing systems for the energy and battery industry, supporting the production of functional materials and components used in modern battery packs, modules and cells. Our solutions are engineered for continuous tunnel-based processes, combining precision coating, controlled heating, thermal stabilization, cooling and in-line cutting into a single, fully synchronized production line.
These systems are dedicated to materials where thermal behavior directly determines performance, safety and reliability, including thermally conductive mats, stress-compensation layers, fire-resistant protection materials and functional composites used in EV and energy-storage applications.
Tunnel Systems for Thermally
Conductive and Safety-Critical Mats
A core application of KEPKA tunnel systems is the production of thermally conductive interface mats, stress-compensation layers and fire-resistant battery protection materials. These materials are typically manufactured from two-component compound systems (Compound A + B), where precise mixing, coating thickness and thermal activation are critical.
KEPKA tunnel lines integrate a precision coating head at the line inlet, enabling extremely accurate control of layer thickness across the full material width. The coated substrate then passes through a sequence of multi-zone tunnel furnace sections, where controlled convection heating activates, cures or stabilizes the compound without damaging internal structure or functional additives.
Controlled Heating, Cooling and
In-Line Cutting
After thermal activation, the material enters chiller-supported cooling sections, where temperature is reduced in a controlled and repeatable manner to lock in material properties and dimensional stability.
Immediately after cooling, in-line cutting systems perform synchronized cutting of the material “in flight”, producing sheets with defined dimensions and clean edges — without stopping the production flow.
This approach allows the production of:
- battery thermal interface sheets,
- insulation and fire-protection layers,
- elastic stress-relief mats,
- functional composite sheets,
- coated polymer and silicone-based materials.
All stages operate as a single, continuous process, ensuring consistent quality from coating through to final cut.
Thermoforming Systems for Battery Cooling Components
In addition to flat-material processing, KEPKA supplies thermoforming furnaces for polymer tubes and conduits used in battery cooling systems. These systems are applied to the production of:
- liquid cooling lines for battery modules and packs,
- multi-channel polymer tubes,
- connectors and shaped conduits for thermal management circuits.
Dynamic convection heating ensures uniform softening of technical polymers, allowing precise forming without internal stress, deformation or loss of mechanical integrity. The result is repeatable geometry and long-term stability in demanding EV operating conditions.
Thermal Processes in
Battery Cell and Pack Manufacturing
KEPKA thermal systems also support additional heat-treatment stages involved in battery manufacturing, including:
- thermal conditioning and stabilization of electrode-related materials,
- curing and activation of coatings and binders,
- controlled heating of separator materials,
- pre-heating and drying processes within module assembly lines,
- heat treatment of structural and insulating components within battery packs.
In each case, precise temperature control, uniform heat distribution and process repeatability are essential to meet safety and performance requirements.
Modular, Scalable and
Industry-Ready Solutions
All KEPKA Energy & Battery systems are built on a modular architecture, allowing flexible line configuration, fast installation and efficient commissioning at customer sites. Tunnel length, heating zones, coating heads, cooling capacity and cutting modules can be adapted to specific material formulations, production speeds and final product formats.
Advanced automation and recipe-based control minimize operator involvement while ensuring stable, data-driven production. This makes KEPKA systems well suited for both pilot-scale development and high-volume industrial manufacturing.
