Ready2Stack™ was born out of our joint recognition that electrolyser manufacturers need a fully integrated, cost-efficient and scalable BPP solution that fits seamlessly into their systems. By combining HOERBIGER’s expertise in precision engineering with James Cropper’s advanced material science, we are not only enabling highly reliable quality standards and drastically reduced complexity for our customers but also improving bipolar plate performance by a great margin, thus ultimately lowering the cost of hydrogen production.
The two biggest bottlenecks in hydrogen production today are operational (OPEX) and capital expenditures (CAPEX) of PEM Electrolyser stacks, both of which are strongly influenced by bipolar plates. Due to the harsh environment in stacks, conventional plates degrade quite rapidly, which leads to declining system efficiency with every operational hour. Not only does this directly waste increasing amounts of electricity over time but also increases CAPEX indirectly by reducing stack lifetime. Furthermore, due to a lack of fully integrated solutions on the market, stack producers must source most production processes separately, which leads to a myriad of complications and difficulties, such as repeatedly non-conforming parts or the sheer impossibility to optimise all interconnected process steps located at different suppliers. This results in high indirect costs resulting from unnecessary engineering and logistics effort. Even worse, it reduces stack reliability, undermining the trust of the buyers and investors in PEM Technology.
Ready2Stack™ eliminates these hurdles by offering a plug-and-play solution with an optimised BPP design that is built on automotive industry reliability, improves stack performance, and extends system lifetime.
Scalability is key because it allows manufacturers to reduce costs very effectively. It is essential to cut the CAPEX of PEM-Electrolysers by at least half to get competitive to grey hydrogen on a free market, even in the presence of very cheap electricity. The good news is that this is very possible, but a transition from current design and manufacturing processes to mass manufacturing approaches must be conducted. Ready2Stack™ does just that for bipolar plates by applying highly efficient automotive process strategies as well as design to manufacturing methods to get the best possible outcome in price and quality. Since Electrolyser plants are expanding at an unprecedented pace, our Ready2Stack™ approach is tailored to the individual customers ramp up strategy. Providing a low-risk entry for lower volumes and the ability to scale seamlessly to high volumes when the market demands it.
Bipolar plate performance is a key factor in hydrogen production efficiency. By optimising BPP performance and integrating high-performance, corrosion-resistant BPPs with Resillion™ coatings, Ready2Stack™ reduces energy loss, enhances system longevity, and ensures stable, high-efficiency electrolysis over time. Our test data shows a significantly lower degradation rate, reducing operational expenses and improving the Levelized Cost of Hydrogen (LCOH). According to our calculations, a reduction of only 1 µV/h in degradation rate is enough to save roughly half a million Euros for a 1 MW system over lifetime considering typical electricity prices for renewables.
The hydrogen economy depends on making clean hydrogen affordable and widely available. Ready2Stack™ supports this by reducing complexity and cost at critical points in the value chain as well as increasing BPP performance. Our collaboration with James Cropper ensures that electrolyser manufacturers benefit from materials that enhance durability and efficiency, ultimately accelerating the adoption of hydrogen technologies across industries.
Many manufacturers are hesitant to adopt new technologies due to integration risks, supply chain inconsistencies, and reliability concerns. By leveraging HOERBIGER’s precision engineering and James Cropper’s expertise in electrochemistry and material coatings, Ready2Stack™ offers a tailor made, high-performance solution that simplifies sourcing, assembly, and maintenance—ensuring seamless implementation and long-term reliability.
As hydrogen production scales up, the demand for efficient, high-capacity BPP technology will only grow. We anticipate a shift towards more integrated and performance-optimised solutions that can be deployed rapidly, reliably and cost-effectively. For the buyer of the BPPs this is a very meaningful transition from a mere sourcing of manufacturing processes towards sourcing a fully functional product with validated performance parameters. Ready2Stack™ is a step in that direction, setting the stage for a more resilient and scalable hydrogen infrastructure. Additionally, advancements in coatings like Resillion™ will continue to drive efficiency gains and lower operational costs.
Our focus extends beyond BPPs. We are actively researching next-generation technologies, aimed at simplifying stack assembly and enabling automation for our customers. The aim is to get reliability of the stack system up as well as cost down, ultimately enabling competitive green hydrogen prices on the market. The transition to a hydrogen-based economy requires continuous innovation, and we are committed to being at the forefront of that journey, alongside partners like James Cropper.
