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How It Works

LithiBatt designs and builds systems that can process the largest EV battery packs to the smallest watch batteries. LithiBatt systems can be ordered individually or as full EV to PCAM turnkey wet or dry systems although wet LI-ION recycling offers many advantages.

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LithiBatt DESIGNS and BUILDS systems for Li-Ion, Li-Fe, NiMH, and Lead Acid Batteries

LithiBatt designs and builds systems that can process the largest EV battery packs to the smallest watch batteries

Our systems can be ordered individually or as full EV to pCAM turnkey wet or dry systems although wet Li-ION recycling offers many advantages. LithiBatt’s systems include some unique, proprietary design features based on the company’s decades of experience recycling various types of products.

At each individual processing method, there is an opportunity for profit. Each processing method works as its own entity and a company may choose to perform any or all. The more sophisticated the process, the more demand there is for it.

Primary Reduction

Shreds the batteries in inert atmosphere and water, and is only needed for EV and larger size packs.

Secondary Reduction

Further reduces the material to smaller, more recyclable sizes with black mass separation.


Final reduction to 10 mesh with remnant black mass separation.


Lithium, Cobalt, and Nickel separation producing pCAM from black mass.

Innovative Design

For customers that want to process LI-ION EV batteries to final stage of regeneration LithiBatt partners with Green LI-ION and it’s proprietary technologies for systems that separate lithium, cobalt, manganese, and PCAM.

  • Patented TriPlus Technology
  • Closed-Loop Water Treatment Systems
  • Turbo-Mill Downstream Density Separation Systems
  • Filtration and Separation Systems to PCAM, Graphite, and Lithium Carbonate Supplied by Green LI-ION
  • Black Mass Hydro Injection Separation Systems
  • Variable Temp PLC Control Drying and Conveyance
  • Drying System with Ferrous Separation
  • Primary and Secondary Shredding Reduction


Discover common questions and answers below. Don't see something you're wondering about? No problem! Contact us with your inquiry today!

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A turnkey Li-ion battery recycling system is a combination of several separate but complementary processes. The primary system safely shreds the batteries, modules or packs (with latent charge) without thermal events in inert atmosphere and water. Air lock systems are employed to assure safety and VOC control.

Secondary systems further reduce the material to smaller, more separatable sizes using our Patented TRIPLUS knife technology which allows for wet materials to be shredded, chipped and sized without screening. The methods used in these phases agitate and separate “black mass” using an aqueous solution ( water treatment system) for collection and drying of clean “black mass” without appreciable contamination.

Additional processing using proprietary chemical injections and drying methods removes valuable battery cell “black mass” from the shredded material and aqueous solution for sale or further processing.

The downstream system uses turbo-milling to take the remnant foils, black mass, waste plastics down to 10 mesh for density separation and collection of each material and metal type.

The entire system is closed loop and electrolytes can be removed separately and treated. A sealed air system collects VOC gases but most of the VOC content is captured and treated in the water system. There is no water effluent to dispose of while PH and other build up issues are managed.

Several novel elements are employed using both our years of experience and years of experimentation. Our water treatment system, drying systems, patented TRIPLUS shred systems and chemical injection systems are all unique to Lithibatt. These innovations are proven and operating around the world for the largest battery recycling company in the world to the largest EV producer in the world. Properly sized systems designed for our customers facilities and for the tonnage per our requested by our customers is also unique. These designs are rarely able to be “cookie cutter” in nature.

Li-ION batteries are not one thing but more accurately a thousand things. The same is true for other emerging battery types. There is little standardization and each type has its own challenges. Prizmatic, cylindrical, primary, pouch style batteries all react differently to a reduction system for instance. Lithibatt can help show a customer how to effectively batch them for optimal results and value capture then create programs within the systems we design to optimize the result. LiFePO4 batteries can be run in the same system however NiCad and NiMH are and must be separate systems. We also retain a Chemical Engineer on staff for specific solutions needed that has the experience required to work with these combinations of materials, metals and chemical reactions.

Lithibatt is a division of BCA Industries noted for 25 years of revolutionizing both portable recycle systems and as patent holders for systems that have contributed to efficiencies gained in waste to energy, electronics, plastic reclamation, high carbon waste, metals separation, end of use tires and one of the only shredder companies that offers full design and engineering of systems not just shredders. The Lithibatt division is housed within the BCA facility and is now building a full and working test facility in Milwaukee where companies can bring there feedstock to us and get their unique process results from out full working system for proof of concept questions.

Profit Opportunities

With primary, secondary, and downstream equipment, Li-ion batteries of all sizes and chemistries can be quickly and profitably reduced into valuable, reusable, or saleable materials

Industry Leaders Collaborate

Integrating complementary recycling technologies to maximize the value of recoverable materials and reduce operational costs.

Recycled Materials

A growing market for LI-ion batteries and the increasing value for recycled materials, spur the development of regional facilities.

Increasing Value

Black mass after filtration to pCAM cam go right back into new battery production or into new products and applications.

Lowering Costs

Our technology lowers the cost of producing new batteries and reduces emissions related to battery raw material logistics.