The global demand for lithium-ion batteries continues to accelerate, driven primarily by the rapid adoption of electric vehicles (EVs) and the expansion of large-scale energy storage systems. While EVs remain the dominant driver of battery demand, growing investment in renewable energy infrastructure is also contributing to unprecedented growth across the battery supply chain. Recent International Energy Agency (IEA) data shows global battery demand surpassed 1 terawatt-hour (TWh) for the first time in 2024, with demand expected to exceed 3 TWh by 2030. Electric vehicles account for more than 85% of battery demand, and global manufacturing capacity continues to expand rapidly to keep pace.
As battery production continues to scale, so too does the processing of critical raw materials used in cathodes and anodes, including lithium, nickel, cobalt, graphite and manganese. At the same time, battery recycling is becoming an increasingly important part of the industry's future, helping recover valuable materials and support a more circular supply chain.
Hand in hand with this growth is the need for equipment that delivers exceptional levels of safety, product containment and operational reliability. Whether processing virgin battery materials or recycled components, manufacturers are handling valuable and often hazardous powders that demand robust process controls.
One of the major concerns from a health and safety perspective is that many minerals used in battery manufacturing, such as lithium compounds and cobalt-based materials, can be harmful when airborne. Many battery materials are also high-value products, meaning contamination, product loss or leakage can have a direct impact on production efficiency and profitability.
Keeping these powders contained within the process while preventing contamination of both the manufacturing environment and the product itself is therefore critical. Investing in quality equipment throughout the production chain is essential. However, even the most advanced machinery relies on the performance of the flexible connectors that link individual process steps together.
The reality is that maintaining a hygienic and dust-free facility can be extremely challenging when using traditional clamped flexible connectors.
Traditional sleeve-and-clamp systems are installed around the outside of a pipe and secured with external clamps. Fine powders can migrate through small folds and creases in the sleeve material, particularly when systems are operating under pressure. Leakage is often amplified around vibratory equipment such as sifters and screening machines.
Unlike traditional clamp-and-sleeve connections, the BFM® fitting system seals from inside the pipe, creating a secure, dust-tight connection that becomes even tighter under pressure. This helps prevent valuable product loss while contributing to a cleaner and safer manufacturing environment.
Dust leaks from conventional flexible connectors are not only a workplace health concern. Certain battery materials, including lithium dusts and carbon-based powders, can also present combustible dust hazards. In these environments, minimising dust escape is an important part of an overall plant safety strategy.
The BFM® fitting system helps reduce the potential for dust release and, in the event of an explosion, the Seeflex range has been independently tested to contain internal explosions exceeding 60 kPa. Seeflex connectors have also been tested for ATEX compliance, providing additional confidence for operators working in potentially explosive environments.
Several battery manufacturing processes operate at elevated temperatures, creating additional challenges for flexible connectors.
Teflex NP Black can operate continuously at temperatures up to 300°C and withstand short-term excursions to 316°C. The material is also highly static dissipative, with a surface resistivity of 10⁶ ohms, helping reduce the risk of electrostatic charge build-up. These characteristics make it particularly well suited to demanding battery manufacturing and recycling applications where both temperature resistance and static control are critical.
Downtime is expensive in any manufacturing operation, but the costs can be especially significant in battery production facilities where high-value materials are being processed continuously.
Traditional clamped flexible connectors often require adjustment during installation and reassembly, with variable installation lengths and tolerances adding time to routine maintenance activities.
An additional advantage of the transparent Seeflex connector range is the ability to visually monitor product flow without removing the connector. This enables operators to quickly identify flow issues while supporting quality control and process visibility.
As battery demand continues to grow and new production facilities and recycling plants come online around the world, manufacturers are increasingly focused on improving safety, reducing product loss and maximising operational efficiency.
Reliable dust containment may seem like a small component of the overall process, but it plays a critical role in protecting people, products and profitability throughout the battery value chain.
Contact us to find out more on how BFM® flexible connectors help battery manufacturers and recyclers improve containment, safety and operational performance.