MAHLE Starts Series Production of Battery Cooling Plates at the Montblanc Plant, Tarragona

• The expansion of the plant and production coincides with a double milestone: 50 years of plant history, 25 of which as part of the MAHLE Group
• MAHLE Battery Cooling ensures fast charging, long cruising range and long service life for sensitive lithium-ion batteries in electric vehicles
• Gradual ramp-up of series production with possible peaks of 15,000 units per week
• Workforce benefits from new skills and technologies
• Institutional support has been key to the project’s rapid development

Coinciding with the 50th anniversary of its launch and its 25 years as part of the global automotive supplier, the MAHLE plant in Montblanc, Tarragona has commenced series production of a new project, a battery cooling plate for electric vehicles. The cooling plates ensure temperatures below 40°C and uniform heat distribution across battery cells for electric vehicles, supporting the performance, fast charging capability, and longevity of lithium-ion batteries in electric vehicles. The site has received a double-digit million-euro investment to upgrade and transform its operations and can produce up to 15,000 units per week. With a total workforce of 750 employees, the project created skilled jobs and new development opportunities in the region. The development of the project within a particularly demanding timeline has been made possible thanks to the support of public institutions and authorities.  

Selecting its Montblanc, Tarragona (Spain) plant to manufacture the battery cooling plate MAHLE strengthens the company’s industrial footprint in Spain. The decision was driven by the plant’s strategic proximity to the local market—whose potential production capacity is close to three million vehicles per year—and to key logistics corridors. This is further supported by the plant’s extensive track record and the expertise of its teams in launching highly automated, long-term projects, a key factor in the development and industrialization of this technology. “The launch of this project has required a transformation of the plant, which we have successfully executed in record time. Within one year we were ready for production,” said Roger Gombau, plant manager of MAHLE Montblanc. “The production of the battery cooling plate impressively demonstrates our industrial capabilities, and we are ready to further expand the site should demand require it.” After adapting approximately 10,000 m² within the facilities, production is set to ramp-up gradually from 1,000 units per week to 8,000 by the end of 2026, with a possible peak production of 15,000, depending on demand.

Highly automated production with new technologies

Despite appearing to be a straightforward component, the battery cooling plate demands a highly automated process with minimal manual handling due to stringent requirements regarding corrosion resistance, surface quality, and cleanliness. To achieve this, new technologies were integrated into the production line: The cathodic dip coating process (e-coating) is an automated immersion coating method that provides strong corrosion protection, excellent adhesion, and uniform coverage. Together with PVC surface treatments, it significantly expands the site''s technical capabilities. Accordingly, MAHLE relies on specialized professionals in the fields of industrial electronics, robotics, and precision mechanics.

Commitment to sustainable production

As part of the company’s ongoing commitment to a more sustainable production model, the Montblanc plant has installed a state-of-the-art water treatment system that enables 95% water savings in the cathodic dip coating (e-coating) process. In addition, the plate is manufactured using aluminum, a 100% recyclable material, helping to minimize its environmental impact at the end of its lifecycle. At the same time, the Montblanc plant covers approximately 10% of its electricity consumption through on-site photovoltaic generation, with an annual output of 2.9 GWh.

Institutional support and regional collaboration

The Government of Catalonia, through ACCIÓ, has classified the initiative as a strategic industrial project—a designation that has helped prioritize and streamline the administrative processes required for its launch. Meanwhile, the project has received support from PERTE VEC 2—a Spanish government initiative aimed at accelerating the automotive industry’s transition to electromobility and reinforcing the electric vehicle value chain.

Throughout the process, key stakeholders have been involved, including the Montblanc City Council, the Catalan Water Agency (ACA), Aigües de Montblanc, Endesa and Endesa X, and ADIF, along with various departments of the Government of Catalonia.

In parallel, the company is working with the Conca de Barberà Regional Council to connect the plant with students and educators, fostering interest in technical careers and exploring vocational training and dual education programs aligned with industrial needs.