Accelerating Sustainability: BMW Group’s New High-Voltage Battery Assembly Plant in Irlbach-Straßkirchen

Rapid Progress

In the quaint municipalities of Irlbach and Straßkirchen, situated in the Straubing-Bogen district, the BMW Group is making remarkable strides in constructing a state-of-the-art high-voltage battery assembly plant. This ambitious project aims to support the burgeoning demand for electric vehicles by producing the latest generation of high-voltage batteries. According to Project Manager Sabrina Kugler, the recent completion of key infrastructure, including the Energy Centre and fire station, marks a significant step towards commencing serial production in Lower Bavaria.

Prioritizing Safety

Safety is a top priority at the Irlbach-Straßkirchen site. As part of the preparations for the factory’s operations, the BMW fire brigade has initiated a 24/7 duty shift to protect employees and the facility. Equipped with five service vehicles and a team of 26 trained and experienced individuals, the fire brigade is not only focusing on safety protocols but is also currently undergoing an accreditation process to operate as a formal plant fire brigade. The team includes both seasoned personnel from various BMW locations in Bavaria and fresh recruits from the local community, thus fostering strong ties with Irlbach and Straßkirchen volunteer firefighters.

The Heart of Operations: The Energy Centre

According to Silvia Meyer, the Head of Real Estate Management at the Irlbach-Straßkirchen plant, the Energy Centre serves as the “heart” of the new facility. It is responsible for supplying crucial utilities such as electricity, cooling, and compressed air to the production areas and ancillary buildings. The Operations Centre within the Energy Centre monitors these utilities, employing automated systems for heating, ventilation, and lighting that prioritize resource efficiency. This tech-driven approach ensures real-time visualization of all essential production facilities, enhancing operational efficiency.

Innovative Heating Solutions

The plant is taking an environmentally conscious approach by repurposing waste heat generated during production processes. This heat is utilized for heating spaces like the canteen and storage facilities. The Energy Centre employs heat pumps that convert water heated to approximately 23°C into heating energy, thereby promoting sustainability and reducing energy costs. The plant’s extensive piping network, spanning over 3.8 kilometers, is initially filled with 500,000 liters of water, underscoring the scale of the operation while ensuring efficient use of water resources.

Compressed Air for High Automation

Efficiency in the assembly process is further enhanced through the continuous provision of compressed air, essential for the plant’s highly automated material-handling technology. The Energy Centre provides air at a pressure of 6 bar using a combination of redundant and variable compressors to meet both base and peak load demands. Interestingly, the waste heat generated by these compressors is reintroduced to the cooling-water circuit, showcasing a closed-loop system that maximizes energy utilization.

A Commitment to Renewable Energy

Breaking away from traditional energy sources, the BMW Group’s Irlbach-Straßkirchen plant is committed to sustainability by relying entirely on renewable energy for its operations. Despite the presence of a natural gas pipeline across the site, the plant will not connect to it. Instead, a substantial photovoltaic installation spanning around 62,000 square meters will help meet energy demands, equating to the area of nine football pitches. This solar system, set to be operational by spring 2026, is expected to generate over 6 MW peak and more than 6,000 MWh annually, thus contributing significantly to the facility’s energy needs.

A Robust Electrical Infrastructure

The plant’s electrical supply system is meticulously designed to ensure stability and efficiency. It will utilize underground 110 kV cables connected to a substation operated by Bayernwerk Netz GmbH, currently under construction. To maintain an uninterrupted power supply during this phase, a provisional 34 MW connection to existing high-voltage lines is in place. Additionally, two transformers with a capacity of 68 MW have been installed to manage the distribution of electricity across different voltage levels effectively.

Comprehensive Mobile Coverage

Understanding the importance of communication in a modern workplace, the Energy Centre is also spearheading efforts to secure mobile phone coverage across the site. A radio mast installed atop the Energy Centre will provide coverage for outdoor areas, while around 220 antennas within the plant ensure seamless connectivity. This sophisticated setup involves the installation of over 9.5 kilometers of radio frequency (RF) cable and 3.5 kilometers of fiber optic cable, creating a robust communication network.

Harnessing Digital Innovation Through BIM

One of the standout features of this construction project is the use of Building Information Modelling (BIM), a cutting-edge digital planning tool that aids in project management and efficiency. The Energy Centre and fire station were completed in under 14 months, thanks in part to BIM’s ability to streamline workflows and promote collaboration among project participants. This innovative approach helps in identifying potential issues early on, allowing for timely interventions that keep construction on track.

For those intrigued by the advancements and efforts involved in establishing the BMW Group’s new plant in Irlbach-Straßkirchen, further information can be accessed on the official project website: BMW Group Plant Irlbach-Straßkirchen.

In this age of electric vehicles and renewable energy, the developments in Irlbach-Straßkirchen are not just about expanding manufacturing capabilities; they represent a commitment to a sustainable future and responsible corporate practices.