PEMELYonROLL: Scalable roll-to-roll production for PEM electrolysis MEAs

Development, optimisation and validation of a process for R2R production of high-performance CCM for PEM water electrolysis

PEMELYonROLL is developing a scalable roll-to-roll process for the production of high-performance catalyst-coated membranes (CCM) and membrane electrode assemblies (MEA) for PEM water electrolysis. The aim of the project is to transfer production processes from the laboratory to pilot and industrial scale and to systematically improve the use of materials, product quality and process robustness.

Scaling PEM electrolysis production as a key challenge

The ramp-up of the hydrogen economy requires PEM electrolysers that are not only efficient but can also be produced economically in large quantities. This is precisely where PEMELYonROLL comes in. The project addresses the scaling of production, a scalable MEA design and robust and sustainable production with integrated inline quality control. In the kick-off presentation, this challenge is explicitly linked to the necessary expansion of electrolysis capacities and the resulting need for significantly larger active areas.

The focus is on the development of a roll-to-roll producible PEM electrolysis CCM or MEA with significantly reduced precious metal loading of iridium and platinum, high current density and high long-term stability. At the same time, the suitability for use, service life and durability of the developed MEA are to be demonstrated. PEMELYonROLL thus combines material efficiency, performance and manufacturability in a joint development approach.

From KID formulation to scalable R2R production

A key focus of the project is the development of a fully scalable production process from laboratory development to pilot plant and industrial implementation. This includes the development of catalyst ionomer dispersions (KID), direct coating, drying and the assembly of membrane electrode assemblies (MEA). The project is therefore not just looking at individual materials, but at the entire production process chain.

Project partners and kick-off in Krefeld

The consortium brings together complementary expertise for this purpose. Among other things, ZBT takes on tasks in ink development, layer application, transferability to roll-to-roll (R2R), MEA development, assembly and testing. The Institute for Energy and Material Processes (EMPI) at the University of Duisburg-Essen is working on the development of the KID, analytical issues and structure-property relationships. Xaptec is developing the inline quality assurance and the machine learning-based evaluation. Laufenberg is contributing its expertise to the transfer optimisation of the R2R process, the development of the production line and the transfer of the project results into marketable roll goods. These key areas of work were presented and jointly agreed at the kick-off meeting on 16. December 2025 at Laufenberg in Krefeld.

Quality assurance, error detection and robust series production

In addition to process development, quality assurance is a key project objective. PEMELYonROLL is developing an inline QA system with a multi-camera system, optimised lighting and machine learning evaluation to detect defects at an early stage and reduce rejects. In addition, material quality, batch inspections and defect and damage analyses are systematically considered in order to reliably verify product quality.

In addition, critical material and process parameters are to be identified, a damage catalogue drawn up and a robust QA concept for series production derived from this. The milestones mentioned in the project planning range from specifications for material and quality assurance, stable KID formulations and inline-capable QA on a laboratory scale to the integration of inline analytics into the R2R system and a guideline for the production of high-performance MEAs via direct coating. PEMELYonROLL thus creates the basis for scalable, quality-assured and industry-oriented production of components for PEM water electrolysis.

Project information

Project acronym: PEMELYonROLL
Project title: Development, optimisation and validation of a process for R2R production of high-performance CCM for PEM water electrolysis
Implementation period: 1.10.2025 – 30.9.2028
Funding program: ERDF/JTF program NRW, Energie.IN.NRW 2021-2027
Funding reference number: EFRE-2080 1468
Project budget (total): approx. € 2.5 million
Funding amount (ZBT share): 624.147,90 €
Project partners:
- Laufenberg
- Xaptec
- Institute for Energy and Material Processes, University of Duisburg-Essen
- ZBT – The Hydrogen and Fuel Cell Center GmbH

This project is funded by the European Union.

Questions about the project?

gladly to

Wladimir Philippi

Electrochemical Components

+49 203 7598-3129

w.philippi@zbt.de

Other current projects

7. April, 2026

PEMELYonROLL: Scalable roll-to-roll production for PEM electrolysis MEAs

The PEMELYonROLL project is developing scalable manufacturing processes for high-performance CCM and MEA for PEM water electrolysis. The aim is to develop material-efficient, quality-assured and industry-oriented manufacturing processes.

30. March, 2026

NEREUS – Next-Generation Scalable AEM Electrolysers as Sustainable Hydrogen Production System

NEREUS develops next-generation anion exchange membrane electrolysers (AEM electrolysers) for high-performance, long-lasting and cost-efficient hydrogen production.

30. March, 2026

FeNCy-PEM – Production and use of precious metal-free Fe-N-C catalysts

FeNCy-PEM develops scalable, precious metal-free Fe-N-C catalysts and integrates them into the production and application of PEM fuel cells.

17. March, 2026

HyQualityLab4NRW – Laboratory for AI-supported quality control and assurance in H2 research

With the “HyQualityLab4NRW”, a high-performance AI-supported material analysis laboratory is being set up at the ZBT to enable research institutions and industry to carry out comprehensive quality control of their products.

12. March, 2026

PARZELL: Qualitative and quantitative PFAS analysis in realistic PEM electrolysis and fuel cell operation

The PARZELL research project systematically investigates the release of PFAS from PEM electrolysers and PEM fuel cells and develops methods to realistically measure, evaluate and reduce emissions in the long term.

12. March, 2026

HiHyPe: New AEM technology for electrochemical hydrogen compressors

The HiHyPe project is developing a low- to non-precious metal AEM technology for electrochemical hydrogen compressors, thereby strengthening the future of the hydrogen economy.

4. March, 2026

HY-Infra – Cross-border Initiative to Advance Hydrogen Infrastructure in the Meuse-Rhine Region

Hy-Infra strengthens the cross-border hydrogen infrastructure in the Rhine-Meuse region. The interregional project creates transparency about future hydrogen requirements and derives the necessary infrastructure by 2030/2035.

4. March, 2026

NH3Avi – Inline production of metal-supported SOFC MEAs for aviation

Climate-neutral flying requires new energy sources – and new production technologies. NH3Avi is developing metal-supported SOFC membrane electrode assemblies (MEA) for use with ammonia in aviation.