Case Study - Production Scale Up

Proton Exchange Membrane (PEM) Water Electrolysers are crucial for hydrogen production, and the transition to sustainable energy. With surging demand, a major European manufacturer needed to significantly boost its production capacity by 100% to reach multi megawatt levels, all while maintaining exceptional product quality. This case study demonstrates how James Cropper successfully met this challenge.

The Challenge

The primary challenge involved scaling production capacity whilst maintaining high quality performance of components. Primary concerns were:

Maintaining interfacial contact resistance of components produced at scale.
Capacity of supply to meet increasing demand.
Quality process and control.

The Solution

Over a six-month period, our team of electrochemists conducted trials alongside our customer to build robust process control and quality infrastructure to assist in their rapid growth. We optimised our coating specifications for their stack, ensuring that the characteristically high performance of the Resillion™ coating technology was maintained at scale.
The coating, which applies a low PGM content to the substrate, provided excellent fluoride ion protection and significantly reduced electrical resistance, enhancing the efficiency's and longevity of the PEM water electrolysers.

To manage the production scale-up, James Cropper implemented a detailed ramp-up schedule:

Month 1 : Increased production capacity by 50%.
Month 2 : Further increased capacity to 75%.
Month 5 : Achieved full production capacity, reflecting a 100% increase.

Operational Collaboration

James Cropper made rapid operational adjustments, including acquiring additional equipment and recruiting personnel. Teams worked extended hours to meet production targets, leveraging resources and material science expertise to bolster operational capabilities.

James Cropper prides itself on its collaborative approach. The company’s team of material scientists and production engineers worked closely with the customer to overcome coating process difficulties.

Results

By the end of six-month schedule, the manufacturer successfully met its production target, achieving a 100% increase in capacity. Throughout this process, James Cropper maintained high product quality, demonstrating flexibility, resourcefulness, and dedication to customer satisfaction and operational excellence.

The ability to rapidly scale up production while maintaining high product quality demonstrates James Cropper’s operational excellence and commitment to customer-centric problem-solving.