The Greenerity GmbH contribution to the EMSigBZ consortium focused on the development of a modular, scalable production system for fuel‑cell stacks, with a particular emphasis on the catalyst‑coated membrane (CCM) as a roll. The project, funded under the National Innovation Programme for Hydrogen and Fuel‑Cell Technology Phase II by the German Federal Ministry of Transport and Digital Infrastructure, ran from 1 March 2019 to 31 August 2022. Greenerity’s role was to design and integrate a Post‑Handling Machine (PHM) into the CCM‑roll handling process. The PHM performs rewinding, longitudinal cutting, edge trimming, and the application of a protective film. Crucially, it incorporates an inline quality inspection system that detects defects on the catalyst electrode, the membrane, and lamination faults, and transfers these marks onto the CCM roll with a precision of ±2.0 mm. This capability enables automated processing of CCM rolls and supports the production of high‑quality, defect‑free membranes for stack assembly.

Technical results from the project demonstrate significant improvements in material utilisation and defect management. Four CCM designs (A–D) were evaluated for full‑sheet cutting from rolls; two designs were selected for final implementation based on cutting efficiency and defect rates. The PHM’s integrated inspection and marking system reduced the incidence of unrecognised defects and enabled real‑time correction, thereby lowering scrap rates. Process stability was quantified through a process‑capability analysis, and the resulting data fed into Advanced Product Quality Planning (APQP) documentation. By the end of the project, the technology reached Technology Readiness Level 4–5, indicating that the core concepts had been validated in a relevant environment and that the system was ready for pilot‑scale deployment.

Collaboration within EMSigBZ involved a network of national suppliers, research institutes, and universities. Greenerity worked closely with Elring Klinger (EKPO), which supplies the fuel‑cell components and manufacturing infrastructure, ensuring that the CCM roll production could be integrated into the broader stack assembly line. The consortium also leveraged findings from the earlier MAS‑TECH project, which had established continuous quality‑control concepts for catalyst layers and MEA production. By combining these insights, the EMSigBZ team was able to refine the CCM manufacturing process and align it with industry requirements for flexibility, cost reduction, and high precision.

The project’s milestones were tightly scheduled: a specification for CCM rolls was defined by March 2020, procurement and integration of the PHM were completed by October 2020, and process‑stability studies and APQP documentation were finalized before the project’s conclusion. Throughout, the consortium maintained close coordination on component selection, equipment procurement, and validation studies, ensuring that the final CCM roll product met the stringent volume, quality, and economic targets demanded by the fuel‑cell market. The successful development of the PHM and the associated inline inspection and marking system represent a key step toward industrialising scalable, high‑quality CCM production for automotive, mobility, and stationary energy applications.