Powering Battery Production with Engineered Precision
As global demand for electric vehicles, renewable energy storage, and advanced electronics continues to climb, battery manufacturers must balance rapid growth with strict environmental, health, and safety compliance. IAC is a trusted EPC contractor and OEM with more than 35 years of experience supporting both established lead-acid producers and next-generation lithium-ion innovators.
We deliver fully integrated solutions that combine engineering, equipment manufacturing, and self-perform construction under one roof. Our systems for dust collection, pneumatic and mechanical conveying, bulk storage, and thermal processing are engineered to handle the unique challenges of battery production, from toxic and combustible dusts to energy efficiency and emissions control.
With proven project experience meeting NESHAP, OSHA, and EPA standards, IAC enables manufacturers to stay ahead of regulatory requirements while scaling production to meet surging market demand. Whether modernizing an existing facility or building a greenfield plant, our expertise ensures reliable performance, safety, and long-term ROI.
Industry Challenges
Battery manufacturing facilities face a unique set of technical, regulatory, and operational challenges that require specialized solutions:
System Integration Across Complex Processes
Battery plants require seamless coordination between bulk material handling, dust collection, drying, storage, and automation. A single point of accountability reduces risk and ensures compliance-ready performance.
Strict Environmental & Safety Compliance
Lead, lithium, and other hazardous particulates are subject to stringent OSHA, NIOSH, and EPA standards. Manufacturers must control emissions and maintain safe workplaces without sacrificing productivity.
Scalability to Meet Market Growth
With EV adoption and grid-scale storage driving unprecedented demand, facilities must be designed for fast-track construction and flexible expansion, while minimizing downtime during upgrades.
Hazardous Dust Control
Toxic and combustible dusts created during material preparation and handling pose risks for worker safety, equipment reliability, and regulatory compliance.
Energy Efficiency & Cost Pressures
Drying, handling, and pollution control systems must deliver reliable performance while reducing energy use and operating costs to remain competitive.
Core Capabilities for Battery Manufacturing & Storage
IAC delivers fully integrated systems designed to address the complex needs of battery production facilities, from lead-acid to lithium-ion and large-scale energy storage. Our engineered solutions cover every stage of the process, ensuring compliance, safety, and scalability.
Air Pollution Control Systems
- M-Pulse and modular pulse-jet baghouses designed for high-volume lead oxide and lithium dust capture.
- Cartridge dust collectors and filter receivers for fine particulate applications.
- Stainless steel and high-temperature baghouses for corrosive or specialized environments.
- Proven success in emissions abatement projects meeting NIOSH, NESHAP, and OSHA requirements.
Thermal Processing Equipment
- Rotary dryers engineered for battery material preparation and moisture control.
- Indirect-fired calcining and drying systems for specialty material processing.
- Flighting design optimized for heat transfer efficiency and reduced energy use.
Bulk Material Handling
- Dense- and dilute-phase pneumatic conveying systems for powders and oxides.
- Mechanical conveyors (screw, belt, bucket elevators) for rugged transfer needs.
- Bolted or welded silos, domes, and bin vents with NFPA-compliant explosion protection.
- Automated truck and rail loadout systems for efficient product distribution
Automated Controls
- MCCs and PLC-based systems for integrated plant automation
- Remote monitoring and diagnostics to maximize uptime and throughput
- NFPA-compliant designs with explosion mitigation for combustible dust environments
IAC Smart Plant™
- Real-time monitoring of baghouses, conveying systems, MCCs, and process equipment to quickly detect issues that impact product quality and environmental compliance.
- Predictive analytics and automated alerts that help maintenance teams address developing problems before they cause downtime or production loss.
- Secure, cloud-based dashboards that integrate with facility DCS systems, giving engineers and plant managers data-driven insights for optimizing throughput and energy use.
- Remote support from IAC specialists for troubleshooting, parameter adjustments, and performance benchmarking across multi-line or multi-site operations.
IAC unifies engineered equipment, fast-track EPC execution, and lifecycle support into a single, dependable partnership that helps battery and energy-storage manufacturers scale safely and efficiently. Whether supporting a greenfield build, upgrading critical process systems, or tightening environmental compliance, our integrated approach ensures your facility operates with the reliability, throughput, and precision today’s high-growth energy sector demands. With proven performance across battery, chemical, and advanced materials applications, IAC delivers solutions built for operational certainty and long-term growth
Solutions for Battery Segments
IAC supports battery manufacturers across diverse technologies and production scales, delivering systems engineered for safety, compliance, and long-term performance.
Lead-Acid Battery Plants
- Proven expertise in lead oxide dust containment, meeting NIOSH, NESHAP, and OSHA standards.
- Baghouses and pneumatic conveying systems designed to manage toxic dust safely and efficiently.
- Track record of successful large-scale emissions abatement projects for lead processing facilities.
Lithium-Ion Battery Facilities
- Dust collection systems optimized for ultra-fine lithium and cobalt particulates.
- Explosion-protected silos and NFPA-compliant conveying systems.
- Automation and Smart Plant™ monitoring to ensure process reliability and worker safety.
Grid & Industrial Energy Storage
- Bulk storage silos, domes, and automated loadout systems for large-scale production.
- Turnkey EPC delivery for new plants and rapid expansion projects to support renewable integration.
- Custom drying and material handling systems engineered for throughput and energy efficiency.
Advanced Materials & Emerging Technologies
- Support for R&D and pilot-scale facilities producing cathodes, anodes, and electrolyte materials.
- Scalable, modular designs that grow with production requirements.
- Engineering collaboration for next-generation processes in EV, aerospace, and utility-scale storage.
Engineering, Procurement & Construction (EPC)
Battery manufacturing projects demand precision, speed, and accountability. As a vertically integrated EPC contractor, IAC manages every stage of the project lifecycle in-house—eliminating delays and ensuring seamless system integration.
In-House Engineering Expertise
- 57+ engineers across civil, structural, mechanical, and electrical disciplines.
- Advanced 3D modeling, CFD analysis, and laser scanning for accurate designs and expansions.
- Deep experience designing air pollution control, conveying, drying, and automation systems for hazardous battery environments.
Fabrication Capabilities
- 500,000 sq. ft. manufacturing facility for custom OEM equipment including baghouses, dryers, silos, and ductwork.
- Structural steel fabrication and specialty welding, including stainless and high-temperature alloys.
- Quality control programs ensure every component meets rigorous performance and compliance requirements.
Construction & Installation
- Self-perform construction through Adelphi Construction, IAC’s wholly owned subsidiary.
- Proven ability to deliver on accelerated schedules without compromising safety or quality.
- Mechanical, electrical, and civil construction capabilities, including foundations, MCC installation, and plant commissioning.
Turnkey Accountability
- One point of contact from design through commissioning, reducing complexity and risk.
- Fast-track project execution proven in both greenfield facilities and compliance-driven retrofits.
- Global experience with battery manufacturing and other high-compliance industries.
Field Services & Aftermarket Support
IAC ensures long-term reliability and compliance for battery manufacturing facilities through a complete suite of aftermarket services and support programs. Our commitment extends well beyond commissioning, helping plants maintain peak performance year after year.
Maintenance & Repair Services
- Scheduled bag change-outs, cage replacements, and leak testing for all baghouse brands
- Mechanical repairs including valve, damper, and fan replacement
- Equipment conversions to upgrade older reverse-air or shaker systems to modern pulse-jet technology
Training
- On-site or virtual seminars covering baghouse operation, troubleshooting, and maintenance scheduling
- Hands-on instruction from experienced IAC engineers to extend equipment life and avoid unplanned downtime
System Optimization
- Burner tuning and dryer flighting analysis to improve efficiency
- Airflow balancing and ductwork inspections to reduce emissions and wear
- Dust control retrofits for improved compliance and product recovery
Parts & Components
- 55,000+ stocked parts for baghouses, dryers, conveying systems, and controls
- Rapid shipment from strategically located warehouses to minimize downtime
- OEM and compatible parts available for multi-brand systems
Partnering with IAC
Battery manufacturers require more than just equipment vendors—they need partners who understand the complexity of hazardous materials, strict compliance standards, and the urgency of bringing capacity online. IAC delivers that partnership with a proven blend of engineering depth, turnkey execution, and lifecycle support.
- Single-Source Accountability
Full EPC delivery under one roof: engineering, fabrication, construction, commissioning, aftermarket parts, and service. - Proven Experience in Battery Manufacturing
Track record of large-scale lead oxide dust containment and compliance projects meeting NIOSH, NESHAP, and OSHA standards. - Compliance-Ready Design
Systems engineered from the ground up to meet EPA, OSHA, and NFPA requirements, reducing operational risk. - Scalable Solutions for Growth
Modular, future-proof designs that expand alongside facility needs—from pilot projects to multi-line production plants. - Lifecycle Support You Can Trust
With 55,000+ parts in stock, nationwide field service crews, and IoT-enabled Smart Plant™ monitoring, IAC ensures your facility continues to operate safely and efficiently long after commissioning.
When safety, compliance, and performance are mission-critical, IAC stands apart as the EPC and OEM partner trusted by the battery industry.
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