Interview: Chemetall Drives Sustainable Innovation with Chromium-Free Gardolene® D Technology

ChemAnalyst Talks with Mr. Frank Naber, Senior Vice President, Global Surface Treatment at BASF Coatings

Chemetall, the global surface treatment business unit of BASF Coatings, is at the forefront of advancing sustainable innovation in metal treatment technologies. As a leading provider of next-generation surface treatment solutions, Chemetall combines technical excellence with environmental responsibility to serve industries such as automotive, battery, and electronics. BASF Coatings, a global expert in developing and marketing sustainable OEM and refinish coatings, supports this mission through a commitment to circularity and regulatory compliance across diverse substrates. ChemAnalyst spoke with Mr. Frank Naber, Senior Vice President, Global Surface Treatment at BASF Coatings, about Chemetall’s breakthrough innovation Gardolene® D, the world’s first chromium- and fluoride-free passivation technology for copper foils. Naber emphasized how this development reflects the company’s vision for sustainability-driven transformation in the battery materials industry, enabling customers to meet stringent EU Battery Regulation standards while improving battery efficiency and lifecycle performance, thus reinforcing Chemetall’s leadership in responsible surface treatment solutions.

Complete Interview with Mr. Frank Naber

Q: Please share an overview of your professional journey and leadership experience in the coatings and surface treatment industry. How have these experiences shaped your vision for advancing sustainable innovation at BASF’s Surface Treatment business unit?

Mr. Frank Naber: My professional journey with BASF began in 2004 in Lemförde, Germany, within the Polyurethanes division. Starting in regional marketing and later advancing to global strategic marketing in Brussels, I gained a strong foundation in customer-centric innovation and international collaboration. In 2012, I transitioned to BASF Coatings in Münster, where I led account management and subsequently took on regional leadership in Asia Pacific as Vice President for Automotive OEM Coatings Solutions. These roles, spanning both European and Asian markets, deepened my understanding of diverse customer needs and regulatory frameworks.

Since August 2023, I’ve had the privilege of becoming the Senior Vice President Global Surface Treatment at BASF Coatings, based in Frankfurt. Throughout my career, I’ve remained committed to aligning technical excellence with sustainability. At Chemetall, this vision is reflected in innovations like Gardolene® D, the industry’s first chromium- and fluoride-free passivation technology for copper foils. Developed in response to regulatory momentum, such as the EU Battery Regulation, it exemplifies our strategic focus on helping customers achieve long-term environmental and operational goals.

Q: What strategic factors and market dynamics motivated Chemetall to pioneer the industry’s first chromium- and fluoride-free passivation technology for copper foils?

Mr. Frank Naber: At Chemetall, we are driven by innovation, sustainability, and customer-focused solutions. The development of Gardolene® D was a strategic response to evolving market demands and regulatory pressures. The surge in global demand for high-performance batteries, especially for EVs, ESS, and consumer electronics, has raised expectations for copper foil treatment. Manufacturers now face pressure to enhance battery performance, lifespan, and energy efficiency. Gardolene® D meets these needs by delivering superior corrosion protection and improved electrode conductivity, resulting in up to 6% longer battery life compared to conventional chromium-based treatments. Regulatory changes, particularly the EU Battery Regulation (EU 2023/1542), have further accelerated the need for sustainable innovation. From 2027, only batteries meeting strict standards on carbon footprint, digital passports, and hazardous substance elimination will be allowed on the European market. Gardolene® D is fully compliant, ensuring our customers are prepared for future requirements.

Beyond compliance and performance, our commitment to sustainability guided our decision. As the first provider of a chromium- and fluoride-free copper foil treatment, we’re setting a new industry benchmark. Our global R&T teams collaborated closely with customers to develop a solution that integrates seamlessly into existing operations—without requiring additional investment.

Q: Gardolene® D represents a major shift from conventional chromium(VI)-based treatments. Could you elaborate on the technological principles and R&D milestones that enabled this breakthrough?

Mr. Frank Naber: Gardolene® D is based on a newly developed passivation chemistry that eliminates chromium(VI) and fluoride while maintaining essential performance characteristics such as adhesion and surface/interface resistivity. The product was developed through a multi-year R&D process involving formulation design, validation in laboratory and pilot-scale environments, and close collaboration with customers during implementation. Gardolene® D is the result of strategic foresight, regulatory responsiveness, and a deep understanding of our customers’ challenges.

Q: How does the introduction of Gardolene® D align with BASF Coatings’ broader sustainability strategy and its commitment to the European Union’s Battery Regulation (EU 2023/1542)?

Mr. Frank Naber: Gardolene® D supports BASF Coatings’ sustainability strategy by removing hazardous substances from the passivation process. It aligns with the European Union’s Battery Regulation (EU 2023/1542), which promotes safer and more transparent battery materials. This reflects our commitment to proactive compliance and long-term environmental stewardship.

Q: Copper foil quality directly affects battery efficiency and longevity. What specific mechanisms in Gardolene® D improve adhesion, conductivity, and cycle stability in lithium-ion batteries?

Mr. Frank Naber: Gardolene® D improves copper foil performance by protecting the pure metal surface against re growth of an oxide layer and simultaneously enhances surface functionality. These two main factors strengthen adhesion between the foil and the active material, maintain low surface resistivity, and reduce degradation over time. These characteristics contribute to improved cycle stability and battery efficiency.

Q: You’ve mentioned that Gardolene® D extends battery lifetime by up to 6% after 1,000 cycles at 25 degrees Celsius. Could you elaborate on how this improvement translates into real-world performance gains for EV and ESS manufacturers?

Mr. Frank Naber: The performance data for Gardolene® D reflects results from intensive analyses and tests. For EV and energy storage system manufacturers, this improvement can contribute to longer operational life of battery cells, which in turn supports extended product lifespans and reduced maintenance cycles. While actual performance depends on specific cell designs and operating conditions, the data indicates that the passivation chemistry has a measurable impact on cycle stability and overall efficiency.

Q: From a manufacturing perspective, how does the new passivation chemistry integrate into existing production lines without requiring additional capital investment?

Mr. Frank Naber: Gardolene® D is compatible with existing copper foil treatment processes and does not require changes to equipment or infrastructure. This allows manufacturers to adopt the new chemistry without additional capital investment, supporting a smoother transition and faster implementation. In addition, our technical experts are always close to our customers ensuring a seamless integration into existing processes in their operations thanks to their deep knowledge and expertise.

Q: Chemetall is the first in the world to offer a fluoride-free and chromium-free solution for copper foils. How significant is this achievement from a regulatory compliance, environmental, and competitive standpoint?

Mr. Frank Naber: Introducing a fluoride- and chromium-free passivation solution for copper foils marks a significant step in surface treatment innovation and for the industry itself. It supports regulatory compliance, reduces environmental impact, and provides manufacturers with a safer and better performing alternative. This development reflects Chemetall’s commitment to advancing sustainable technologies.

Q: What role did global collaboration between Chemetall’s R&D and technology centers play in accelerating the development and validation of Gardolene® D?

Mr. Frank Naber: The development of Gardolene® D involved close collaboration across Chemetall’s global R&D and technology centers. Teams in Europe, Asia, and the Americas contributed to formulation, testing, and customer validation. Our deep understanding, expertise and this international cooperation laid the foundation for a real innovation and ensured the solution meets diverse market requirements.

Q: How do you foresee the new passivation technology influencing supply chain sustainability and the broader battery manufacturing ecosystem over the next five years?

Mr. Frank Naber: Over the next five years, the new passivation technology is poised to enhance supply chain sustainability and reshape the battery manufacturing ecosystem. By reducing reliance on hazardous substances, it simplifies regulatory compliance across global supply chains. Its adaptability to emerging trends – such as dry coating, silicon-rich anodes, and high-strength foils – empowers manufacturers to meet ambitious sustainability targets without compromising performance. Furthermore, its global availability and compatibility with diverse customer needs may influence upstream material sourcing and downstream recycling strategies, driving a more circular and responsible battery value chain.

Q: As energy storage and EV battery markets expand, how is BASF Coatings positioning its surface treatment innovations to serve next-generation battery chemistries and materials beyond copper foil?

Mr. Frank Naber: Chemetall is actively exploring how surface treatment technologies can support emerging battery materials and chemistries. While copper foil remains a key substrate, there is growing interest in aluminum and other technologies and materials used in solid-state and next-generation batteries. R&D efforts are focused on adapting solutions to meet these evolving requirements. With Gardobond® C, we offer pretreatment solutions for bare aluminum surfaces such as electric motor housings, power electronics housings and powertrain components. Another solution for electro vehicles is Gardobond® X, our non-chrome passivation systems for aluminum coil, and for parts such as battery enclosures.

Q: Could you discuss how partnerships with battery producers and foil manufacturers are shaping the future roadmap for Chemetall’s surface treatment portfolio?

Mr. Frank Naber: Strategic partnerships with battery producers and foil manufacturers are instrumental in shaping the future of Chemetall’s surface treatment portfolio. Collaborations with foil manufacturers have been key to validating Gardolene® D under real production conditions, while close engagement with battery producers ensures our technologies align with evolving cell designs. These partnerships not only guide product development but also keep us closely connected to emerging trends and customer needs across the value chain. By working directly with both tiers and end users, we gain critical market feedback that drives innovation. Ultimately, these relationships are essential for enabling market transitions and supporting our partners in achieving approvals and sustainability goals.

Q: What have been the key challenges in replacing legacy chromium-based processes – both technically and in terms of customer acceptance – and how has Chemetall addressed them?

Mr. Frank Naber: Replacing chromium(VI) has always been a major hurdle. Chromium(VI), despite its disadvantages, sets a high standard in corrosion protection. This situation is familiar to us from other markets, where Chemetall has historically been a pioneer in replacing CrVI. It is a significant task to reach this level of performance and even more so to exceed it. Achieving comparable adhesion and conductivity without chromium required extensive formulation work. Customer acceptance depended on demonstrating compatibility with existing production lines and consistent performance. These requirements were addressed through rigorous testing and technical support during implementation.

Q: Looking ahead, do you envision scaling the chromium- and fluoride-free passivation technology into other substrate applications or metals beyond copper? If so, what potential markets or industries are being explored?

Mr. Frank Naber: There is potential to extend this passivation technology to other substrates, particularly where similar performance and environmental requirements exist. While copper was the initial focus, the underlying chemistry may be adapted to meet broader industry needs.

Q: Is Chemetall leveraging digital tools, market intelligence, or advanced analytics to enhance process optimization, monitor emerging trends in battery manufacturing, and maximize the performance and market impact of innovations like Gardolene® D across global operations?

Mr. Frank Naber: Chemetall is leveraging digital tools and market intelligence to enhance process optimization and support innovation across its global operations. Solutions like Gardo® Control play a key role in this approach. As a modular, automated process monitoring system, Gardo® Control enables real-time tracking of key parameters such as temperature, pH, conductivity, and chemical consumption. It also automates chemical replenishment, helping ensure consistent product performance while improving efficiency and reducing resource use.

In parallel, market intelligence is used to identify emerging trends and evolving customer needs in battery manufacturing. These insights inform product development and strategic planning, helping maximize the performance and market impact of innovations like Gardolene® D.

ChemAnalyst Insights on Copper Wire

In Europe, the Copper Wire Price Index recorded a modest quarter-over-quarter rise of around 1.5%, driven by steady downstream consumption and persistent cost pressures. Spot prices strengthened amid elevated energy tariffs, carbon compliance costs, and inland logistics challenges that collectively increased production costs and supply risks. The Copper Wire Price Forecast indicates a mild upward trajectory into the fourth quarter of 2025, though potential headwinds may arise from macroeconomic softness and improving freight and logistics conditions. Production costs continued to rise, influenced by high energy prices, copper input premiums, and transport bottlenecks across major European manufacturing hubs. On the demand front, the outlook remains positive as growth in renewable energy projects, grid modernization, and electrification continues to support consumption, even as traditional construction activity stays muted. In September, the Price Index was particularly shaped by inland transport delays, high energy and carbon costs, and stable procurement from cable and transformer manufacturers, while limited capacity in smelting and wire-drawing operations kept prices firm.