LORDSTOWN, Ohio – One hundred million and counting.
That’s how many battery cells Ultium Cells LLC’s manufacturing plant here has produced since it was commissioned in August 2022.
Then, officials had also projected conservative job figures for the new plant, noting that the $2.3 billion factory would likely employ at least 1,100 workers. It employs approximately 2,200 today.
“We’re so proud of the workforce,” said Tom Gallagher, vice president of operations at Ultium Cells. “Reaching 100 million cells is significant and makes us one of the largest battery manufacturers in North America.”
On Thursday – exactly five years to the day that General Motors and South Korea-based LG Energy Solution announced a joint venture to create Ultium Cells LLC and build its first plant here – more than 200 workers, supervisors, labor officials and executives gathered at the plant to celebrate the milestone.
Ultium has since emerged as the largest employer in the Mahoning Valley. Battery cells produced at the plant are used to power General Motors’ new electric vehicle portfolio.
“Your incredible work has made this possible,” David Kim, CEO of LG Energy, told employees as he hinted toward future collaboration and technological development with GM. “This facility represents a major step forward in our commitment to a zero emissions future and job creation here in Ohio.”
Ultium currently operates two battery plants in the United States – the Lordstown site and a new factory commissioned earlier this year in Spring Hill, Tenn. The cells manufactured at Ultium are large format, pouch-type cells that use NCMA – an acronym for nickel, cobalt, manganese, aluminum – chemistry designed to deliver better battery range at a lower cost.
More recently, GM and LG Energy announced that they would collaborate on new prismatic battery cell technology that would power GM’s future EVs. JP Clausen, GM’s executive vice president for global manufacturing and sustainability, said the agreement would usher in “a new phase of innovation with our partners to ensure we continue to evaluate not only chemistry but also form factors. We are learning as we build.”
Gallagher said Ultium plans to look ahead toward the latest technology, and the Lordstown plant is flexible to accommodate new business. “We believe this type of work – working on future technology – will position Ultium so it can move forward and potentially manufacture that new technology.”
In the short-term, Gallagher said Ultium needs to continue its momentum to support the marketplace, as more GM electric vehicle products hit the road.
“Ultium will be there to support GM and its growth,” Gallagher said. “We’re going to plan around the chemistry and the form factor to ensure its ongoing flexibility and sustainability. It’s important to continue to evolve the business and be innovative.”
Although the rate of EV adoption across the country is less than what was first anticipated several years ago, the market is still growing. “The rate of growth has slowed, but we’re seeing more customers year over year,” Gallagher said.
At present, GM boasts the second highest sales of EVs in the country, behind Tesla, Gallagher said. “That’s a significant milestone. You’re seeing incredible growth, specifically with the Cadillac Lyriq,” he said, gesturing to a model parked inside the plant for the event.
Ultium’s Lordstown facility became the first of its kind to become organized under the United Auto Workers union and helped pioneer the landmark national agreement between GM and the UAW that led to the inclusion of Ultium workers in that pact.
“That was a commonsense agreement,” said Mike Booth, international vice president of the UAW and director of General Motors and gaming departments. “The UAW has always had very well-trained members that work in the auto industry,” he said. “This was another opportunity to bring in well-trained people to produce a component for an electric vehicle.”
For Ultium to celebrate 100 million cells produced is a testament to the workforce here, he said. “It speaks volumes on what these workers here have done.”
Josh Ayers, the UAW’s Ohio chairperson at Ultium, expressed gratitude to the union, GM and LG Energy. “The agreement reached between GM and the UAW signified a positive step toward ensuring fair wages, improved working conditions and job security for all those involved,” he said.
Ultium manufactures cells through a highly automated process that begins with chemical mixtures that combine raw materials to produce electrode sheets. Then, the electrode cells are assembled and sent through the formation process.
Zachary Cherol, production shift manager of formation at Ultium, said formation is the final process before the cells are shipped to customers. “Once it leaves formation, it goes to the customer,” he said.
He said the formation process is what “gives the battery life,” as the cells are charged. “Once it goes through this process, it’s a live battery cell.” In between, the cells are formed, heated in a chamber at 140 degrees for 24 hours, moved through a de-gassing line, trimmed, stored in racks for a period for voltage checks, and then moved through a charge/discharge process before they are shipped to customers.
Each cell resembles a rectangular pouch that measures approximately 2 feet in length and 4 inches in width. Multiple cells comprise a single module pack. The number depends on the vehicle.
A single battery pack for The Silverado EV, for example, would require approximately 400 Ultium cells.
“We want to extend our congratulations to the entire Ultium team on this incredible milestone, especially the 2,200 Valley men and women working at the Warren facility,” said Guy Coviello, president and CEO of the Youngstown/Warren Regional Chamber. “Ultium recognizes the winning combination we have here – a strong and experienced labor force, national research institution, tradition of innovation and the political willpower to work together to shape our region’s future. Its leadership’s commitment to the Valley has resulted in our ability to truly have ‘Voltage Valley’ be a hub for the EV industry.”
For executives such as Ultium’s Gallagher – he has been a part of the program since its launch – the Mahoning Valley and Ohio play a significant role in the future of the EV market. “Ohio is Ultium Cell’s headquarters,” he reminded reporters Thursday. “There’s certainly a vision in Ohio to be a part of the next generation of technology. We’re excited to be here.”