Scalable Automation Solutions for Battery Recycling

Battery recycling is becoming a critical component of the electric mobility value chain as end-of-life volumes increase and material recovery requirements intensify. In this context, Bosch Rexroth will present a scalable automation concept for battery recycling at IFAT 2026 (May 4–7), aimed at improving process efficiency and operational safety.

Growing battery volumes challenge existing recycling capacity
The increasing adoption of electric vehicles is expected to significantly raise the number of batteries reaching end-of-life, with volumes projected to increase tenfold within five years. This trend places pressure on recycling infrastructure, which is currently dominated by small-scale facilities with limited automation.

At the same time, the diversity of battery types complicates standardized processing, requiring flexible systems capable of handling variations in design, condition, and chemistry. These constraints highlight the need for scalable and automated solutions that can support higher throughput while maintaining consistent recovery rates.

Applying industrial automation to recycling workflows
Bosch Rexroth’s approach adapts established manufacturing technologies, including drive and control systems, linear motion, assembly, and tightening technologies, to the requirements of battery disassembly and material recovery.

The concept focuses on increasing automation across key process stages to reduce manual intervention, particularly in safety-critical operations such as discharging and dismantling. This aligns with broader efforts to integrate recycling processes into a more efficient digital supply chain, where material recovery feeds back into production cycles.

Pre-treatment solutions are also included to improve the quality of recovered materials and increase recycling rates, supporting more efficient reintegration into the value chain.

Diagnostics and discharge as critical first steps
A central element of the process is the initial diagnosis of battery type and condition, which determines the appropriate handling and discharge strategy. This step is particularly relevant for older batteries that lack standardized digital identification.

Bosch Rexroth’s system includes diagnostic tools that assess whether a battery pack can be safely discharged and defines the required procedure. Both mobile and stationary discharge systems are available, allowing flexibility depending on facility layout and throughput requirements.

Modular automation from manual to fully automated systems
The solution portfolio combines components such as linear motion systems, tightening tools, assembly technologies, and collaborative robots to support transport, handling, and disassembly processes.

This modular approach allows operators to implement manual, semi-automated, or fully automated configurations depending on their current capacity and investment strategy. Existing systems can be reused or expanded, enabling incremental upgrades rather than complete infrastructure replacement.

Scaling recycling capacity for future demand
The concept will be presented at IFAT 2026 in Munich, Germany, where Bosch Rexroth will outline how scalable automation can address both capacity constraints and safety requirements in battery recycling facilities.

By combining diagnostics, controlled discharge, and automated disassembly within a modular framework, the approach supports higher throughput and improved process consistency. This is intended to help recycling operators adapt to increasing battery volumes while maintaining cost efficiency and operational safety.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

www.boschrexroth.com