Flexiwall separates diesel engine production from EV battery assembly at Ford

Creating a clean, controlled environment

Ford’s Cologne facility has been at the heart of European automotive manufacturing since 1930. In 2023, it underwent a $2 billion investment, converting the site into the Cologne Electric Vehicle Center.

Transitioning a legacy manufacturing facility from combustion engine production to EV assembly required a complete rethink of how space is used. Battery assembly and storage introduce requirements that are incompatible with the particulates, oil mist, and metal dust generated by diesel engine production. Contamination of battery components can compromise performance, longevity, and safety.

Ford required a partition solution that would create a clean, controlled environment for the incoming EV battery assembly line and storage area, while diesel engine production continued on the other side of the same building. The solution also had to satisfy the requirements of Ford’s own works fire brigade. a non-negotiable compliance requirement given the nature of the materials on both sides of the divide.

Flexiwall enables production to continue

Westgate Global worked closely with the Ford team to understand the precise requirements of the space, including the production hall’s distinctive barrel roof architecture. The team specified Flexiwall, a tensioned, floor-to-ceiling fabric partition system engineered for exactly this type of complex industrial environment.

The material selected was a polyurethane-coated glass cloth, tested to DIN EN 13501-1 A2 s1 d0. This classification ensures that the material makes no contribution to fire development and produces no flaming droplets in the event of ignition. This specification directly addressed Ford’s fire brigade requirements and ensured full compliance across both sides of the installation.

The finished installation comprised five runs of Flexiwall totalling more than 492ft at 37ft high, incorporating framework for three pedestrian access doors, four integral curtains for forklift access, and a 13ft wide roller shutter door. The system was installed around existing machinery, gantries, and live production equipment, with the lightweight panels hung at roof level, tensioned, and fixed securely to the floor, occupying only millimetres of floor space throughout.

Critically, the modular nature of Flexiwall means the installation is not a fixed commitment. As Ford’s EV transition progresses, the partition can be reconfigured, extended, or relocated to meet changing operational requirements, without structural alteration to the building.

Turnkey solution with expert delivery

The completed installation provided Ford with a clearly defined, compliant, and contaminant-controlled environment for their EV battery assembly line and storage. The system protects the integrity of battery components from oil, metal, and dust particulates generated by adjacent diesel engine production. Operational continuity was maintained throughout, with the Westgate Global team delivering the full solution around live manufacturing with minimal disruption.

For a facility in the middle of one of the most ambitious manufacturing transformations in the automotive industry, having a segregation partner capable of working quickly and to a high standard made all the difference.

Learn more about Flexiwall