Siemens Charts Path to Scalable and Sustainable Battery Ecosystem

HONG KONG, July 29, 2025 – At The Battery Show 2025 in Hong Kong, Siemens made a compelling case for digital transformation as a key enabler in the global battery value chain. Speaking with AsiaBizToday.com, Puneet Sinha, Senior Director, Battery Industry at Siemens Digital Industries Software, shared insights on how the company is helping the battery ecosystem navigate the twin challenges of scaling operations and meeting sustainability goals.

“Siemens’ vision is to empower battery companies — across engineering, manufacturing, and operations — through digital transformation,” said Sinha. “We are focused on bridging the digital and real worlds so companies can explore and optimise battery designs virtually and execute them effectively in manufacturing.”

Sustainability as a Design Principle

For Siemens, sustainability is not an afterthought. “At Siemens, sustainability is built into the very foundation of how we design, build, and operate,” Sinha explained. The company advocates for simulation and digital twin technologies to reduce physical testing, lower material waste, and enable design-for-recycling from the outset.

One practical application is in robotic systems used on production floors. By reducing the weight of robotic heads through additive manufacturing, companies can decrease electricity usage and improve overall efficiency. Siemens also supports battery manufacturers in optimising factory energy consumption through automation and data analytics, reinforcing its commitment to circularity and resource efficiency.

Battery recycling, a looming concern for the industry, is another area Siemens is targeting. “Disassembling battery packs is still largely a manual process,” Sinha noted. “We are applying AI and automation to improve the efficiency and safety of battery discharge and disassembly.”

The Recycling Challenge

With a wave of end-of-life EV batteries expected by the end of the decade, Sinha identified three major hurdles to efficient recycling: collection and logistics, cost and efficiency of recycling processes, and lack of holistic thinking around reuse.

“Lead-acid batteries have over 90% recycling rates, but lithium-ion batteries are still around 5-7%,” Sinha pointed out. “As volumes rise, the need for regulatory frameworks and technological innovation becomes critical.”

He also called for a shift in mindset. “Many EV batteries still have 70% usable energy when retired. These should be considered for reuse in residential or stationary energy storage before being recycled.”

Enabling Smart, Scalable Manufacturing

Siemens does not manufacture batteries, but it plays a critical role in enabling battery makers to scale with precision and sustainability. “We help battery manufacturers simulate factory layouts and production lines before they are physically built,” said Sinha. This approach helps manufacturers avoid costly late-stage modifications and improves operational efficiency.

A core focus is ‘data-driven manufacturing’, especially vital for newer companies lacking the years of operational experience of legacy battery giants. “Even for experienced players, transferring processes across geographies or adapting to new chemistries is complex,” Sinha explained. “By harnessing data, digital twins, and AI, we can improve quality, reduce scrap, and accelerate time to scale.”

Siemens’ approach has already delivered tangible benefits. “We’ve seen clients reduce scrap by 10% by combining real-time data insights with traditional know-how.”

Energy Storage: The Boeing of the Battery World

Sinha highlighted the complexity of stationary energy storage systems, which are increasingly vital for grid stability. “One gigawatt-hour of energy storage has up to 9 million parts — equivalent to a Boeing 787,” he said. Managing the inventory, servicing, and lifetime performance of such systems requires industrial-scale precision.

Siemens is working with the entire energy storage value chain, from cell production to container assembly and utility-scale operations. The goal is to enable 20-year operational lifespans, particularly for lithium iron phosphate (LFP) chemistries, through smarter design, manufacturing, and servicing strategies.

Southeast Asia: A Digital-First Frontier

Sinha sees Southeast Asia as a critical growth engine for the battery sector, especially in light electric vehicles like two-wheelers and public transport electrification. Countries such as India, Malaysia, and others are pursuing aggressive renewable energy targets that require robust battery storage capabilities.

“These companies are digitally native and eager to leapfrog legacy systems,” said Sinha. “They are building ecosystems locally while learning from global best practices.”

Siemens is also working with governments in the region. “Our leadership engages with policymakers to promote adoption of digital twin and automation technologies. We see it as our responsibility to help countries accelerate sustainable industrial development.”

Looking Ahead: The Next Battery Revolution

Reflecting on industry progress, Sinha recounted how, in 2008, battery costs were around $1,000 per kilowatt-hour. “Back then, a 60 kWh battery would have cost more than the car itself,” he recalled. “Today, we are at $100 per kWh, with energy densities three times higher.”

Looking ahead, he anticipates continued breakthroughs in battery technology. “By the end of this decade, we may see widespread adoption of solid-state and sodium-ion batteries. Energy density improvements could unlock short-haul electric aviation. The pace of innovation is staggering.”

Practising What They Preach

Importantly, Siemens applies the same technologies in its own factories, several of which are recognised as global ‘lighthouse’ facilities for digital transformation. “We don’t just advise others — we implement, learn, and refine within our operations,” Sinha noted.

As global demand for batteries surges, Siemens is positioning itself not only as a technology provider but as a partner in sustainable transformation. “We’re helping the industry shift from experience-driven operations to data-driven manufacturing,” Sinha said. “The future of battery production lies in this convergence of digital tools, automation, and sustainability.”