British clean-tech company Altilium unveiled a multilayer pouch cell made from recycled cathode materials at Cenex Expo 2025.
The NMC811 cells, developed in partnership with luxury vehicle OEM Jaguar Land Rover (JLR), are designed for the electric vehicle (EV) market.
The cells were produced using cathode active material (CAM) recovered from end-of-life batteries using its Altilium’s proprietary EcoCathode process at its facilities in Devon, UK.
Initial testing by Imperial College London suggests the recycled cells can perform as well as those made from virgin materials. JLR is now conducting full validation at its state-of-the-art battery testing laboratory.
The concentration of recycled metals in the pouch cells meet the EU’s 2036 targets for battery content: 26% cobalt, 12% lithium, and 15% nickel. This means the cells have the potential to become a vital link in the UK’s role within the global EV supply chain.
Dr Christian Marston, Altilium’s Co-founder and Chief Operating Officer, said:
“This is more than just a demonstration — it’s proof that the UK can lead in sustainable battery technology.”
He added: “The future of mobility isn’t just electric — it’s circular. And the UK now has a chance to lead in both.”
The batteries were manufactured at the UK Battery Industrialisation Centre (UKBIC). The project is supported by the Advanced Propulsion Centre UK (APC) under its ARMD 3 programme, which aims to accelerate the commercialisation of clean mobility technologies.
The Cenex showcase in early September included a single-layer pouch cell also made from recycled cathode and anode materials.
From scrap to supercell
Altilium’s EcoCathode process recovers more than 95% of cathode metals and 99% of graphite from battery waste. The materials are then refined and upcycled into high-nickel CAM and purified graphite for reuse.
A Life Cycle Assessment by sustainability consultancy Minviro found that using fully recycled CAM could reduce greenhouse gas emissions by 32% compared to materials mined and refined in Asia.
Altilium is building a ‘mini-commercial’ plant in Plymouth, UK. It is also planning an EV battery recycling facility in Teesside, UK that will be able to process scrap from more than 150,000 EVs per year — producing 30,000 metric tonnes (MT) of CAM, enough to meet around 20% of the UK’s projected needs by 2030.
The company’s aim is to supply 50% of the lithium and nickel needed for EV batteries in the UK by 2040 through recycling existing waste streams within the country.
Image: Altilium battery pouch cells produced at UKBIC. Credit: Altilium
