After around 1,500 charging and discharging cycles, which is some 160,000 kilometres over 8 to 10 years, it is highly likely that the batteries of electric cars will no longer be cost-effective anymore. The reason for this is that the reduced charging capacity of the batteries greatly reduces the range compared to that of a new system. However, a residual capacity of about 80% grants the batteries a second life as part of a battery farm. As the disassembly process is increasingly automated, recycling the batteries is becoming more flexible and dynamic; this, in turn, makes recycled material available more quickly. Festo is a key driving force behind this development since it fits in with its vision of a sustainable circular economy.

However, after the batteries have been removed from the vehicle and before they can be recycled, they can be used in so-called "battery farms" or stationary storage systems. The final stage in the life of a battery is proper recycling. First, the packs have to be mechanically disassembled. The next step is to separate the materials such as metal, plastics and other materials.

Special factory systems are already in the planning for these tasks. So far, Festo has developed and presented a first version of a mechanical modular disassembly system for battery modules and packs. This uses both handling and gripping systems as well as proven components from Festo's pneumatic and electric automation portfolio.

Festo also has an eye on the future of electromobility. and is involved in research into production concepts for new types of solid-state batteries. Experts predict that these even more powerful storage devices will replace the lithium-ion batteries currently in use in the coming years.