In high-precision electrode manufacturing, High-Pressure Controlled Cold Rolling (Calendering) is the standard method for densifying electrodes that do not require thermal assistance or where heat might negatively affect the binder/active material interface. While hot rolling is popular for dry electrodes and PVDF softening, Cold Rolling is often preferred for maintaining the mechanical crystal structure of certain active materials and for processes where high-throughput consistency is the priority.

Cold rolling relies purely on linear pressure to reduce the thickness and porosity of the electrode. (1) Porosity Control: The primary goal is to reach a "target porosity" (typically 25%–35%). This balance is critical: too high, and the energy density is low; too low, and the electrolyte cannot penetrate the pores, leading to poor performance on your Neware testers. (2) Elastic Recovery: Because the process is cold, the material may experience more "spring-back" (elastic recovery) once it leaves the nip. To compensate, the gap must be set slightly tighter than the final desired thickness.

Part Number	ESMECHPCRP (ESM-EC-HPCCRP)
Power	AC220V±10%, single-phase, 50/60Hz, 1000 W
Cold Rollers	Φ230x220mm mm (effective width for cold rolling: 200 mm) 9Cr3Mo, surface coated with chromium layer with a thickness of  ≥0.1mm HRC65~70, hardness layer thickness ≥18mm 0.75 KW AC frequency conversion motor
Hydraulic Pressure	Max. 80T, adjustable in HMI touch screen
Calendering Speed	0.3-5.0 m/min, digital display, adjustable
Calendering Gap	0-1.5 mm, manually adjustable
Calendering Effect	± 2 μm
Roll-to-Roll Integration (Optional)	A roll-to-roll unit can be integrated with the hot rolling press for electrode roll calendering
Note	Each time the reduced thickness is 20%-25%. Multiple-rounds calendering is needed for higher coating thickness reduction. For example, the initial electrode thickness is 200 um, then 180 um, 160 um, 140 um and so on under a certain pressure.
Dimension	L1000 * W600 * H980 mm
Weight	~845 kg

References:

J. Zhang, et al., Investigation on mechanical and microstructural evolution of lithium-ion battery electrode during the calendering process, Powder Technology, 2022, 409, 117828

M. Abdollahifar, et al., Insights into Influencing Electrode Calendering on the Battery Performance, Adv Energy Mater., 2023, 13, 2300973.