Orbia Fluor & Energy Materials has announced the completion of a major expansion at its Custom Electrolyte facility in Madison, Wisconsin, boosting production capacity by roughly 300%.
The second and final phase of the expansion wrapped in early December 2025, adding a second 75-liter mixer and a new 200-liter mixer, making the site fully operational.
Since opening in August 2024, the Madison plant has become a key U.S. source for small- and medium-batch battery electrolytes, tailored to lithium-ion as well as emerging chemistries such as lithium-sulfur and sodium-ion. The facility has supplied hundreds of businesses worldwide, supporting industrial, medical, energy storage, EV, Department of Defense, lab-scale, and aerospace applications.
Orbia’s Custom Electrolyte plant offers most common formulations with a lead time of four weeks or less, serving domestic and international customers from its urban Madison location, near Chicago, for efficient logistics. U.S.-based production reduces dependence on overseas suppliers, cuts shipping delays, extends product shelf life, and strengthens supply chain resilience.
The global battery electrolyte market, valued at $9.5 billion in 2024, is projected to reach $22 billion by 2030, according to Avicenne Energy. Orbia’s expansion positions the company to meet growing demand and accelerate innovation.
Carl Thoemmes, Business Development Director, Orbia Fluor & Energy Materials, said: “This expansion represents a significant step forward in our commitment to advancing the global energy transition. By tripling our production capacity, we’re not only meeting the surging demand for battery electrolytes, we are developing a more robust supply chain and creating more opportunities for innovation and collaboration."
He added: "With advanced capabilities and faster lead times, our plant empowers the battery industry to accelerate the journey from concept to commercialization, all while cutting the carbon footprint associated with importing electrolytes and driving the next generation of sustainable technologies.”
