Orbia completes major U.S. electrolyte capacity expansion, tripling output to meet surging battery demand and strengthen resilient domestic supply chains.
Orbia Advance Corporation S.A.B. de C.V.’s Fluor & Energy Materials business has announced the successful completion of a major capacity expansion at its Custom Electrolyte manufacturing facility in Madison, Wisconsin, significantly strengthening its position in the fast-growing global battery materials market. The expansion, which boosts production capacity by approximately 300%, marks an important milestone in Orbia’s strategy to support the accelerating demand for advanced battery technologies through reliable, U.S.-based manufacturing.
The second and final phase of the expansion was completed in early December 2025. As part of this phase, the facility was equipped with an additional 75-liter mixer alongside a newly installed 200-liter mixer. With these new assets now fully commissioned, the Madison site is operating at full capacity and is well positioned to serve a broad and diverse customer base requiring high-quality, customized electrolyte solutions.
The Custom Electrolyte facility was originally inaugurated in August 2024 and represented a major step forward for domestic sourcing of small- and medium-batch battery electrolytes in the United States. From the outset, the site was designed to produce electrolytes precisely tailored to customer specifications, supporting not only conventional lithium-ion batteries but also emerging and next-generation chemistries. These include lithium-sulfur, sodium-ion, and other advanced battery systems that are increasingly critical for future applications in energy storage and mobility.
Since becoming operational, the Madison facility has supplied battery electrolytes to hundreds of customers across the globe. Its products are used in a wide range of applications, spanning industrial manufacturing, medical devices, stationary energy storage systems, electric vehicles, Department of Defense programs, laboratory-scale research, and even aerospace projects. This broad customer reach underscores the versatility of the facility and the growing importance of customized electrolyte solutions in enabling innovation across multiple sectors.
One of the site’s key competitive advantages is its ability to deliver short lead times. Orbia’s Custom Electrolyte plant can typically fulfill orders for common formulations within four weeks or less, offering this service to customers worldwide. Strategically located in an urban area of Madison, Wisconsin, the facility also benefits from close proximity to Chicago, a major logistics hub. This location enhances distribution efficiency and allows Orbia to respond quickly to both domestic and international customer needs.
By producing electrolytes within the United States, Orbia reduces dependence on overseas suppliers and avoids the challenges associated with long international shipping routes. This localized production model helps minimize freight-related delays, extends product shelf life, lowers the risk of excess or obsolete inventory, and strengthens overall supply chain resilience—factors that have become increasingly critical for battery manufacturers.
According to Avicenne Energy, the global battery electrolyte market was valued at approximately US$9.5 billion in 2024 and is projected to grow to around US$22 billion by 2030. Against this backdrop of rapid market expansion, the newly completed capacity increase enables Orbia to meet future demand while accelerating innovation and collaboration with customers.
Commenting on the expansion, Carl Thoemmes, Business Development Director at Orbia Fluor & Energy Materials, emphasized its strategic importance. He noted that tripling production capacity not only supports surging demand for battery electrolytes but also contributes to building a stronger, more resilient supply chain and opening new avenues for technological advancement. Thoemmes further highlighted that faster lead times and advanced production capabilities will help customers move more quickly from concept to commercialization, while also reducing the carbon footprint associated with importing electrolytes and supporting the next generation of sustainable energy technologies.
