Mercedes-Benz has officially inaugurated its cutting-edge battery plant in Bibb County, Alabama, marking a significant step in the luxury automaker’s ambitious journey towards an all-electric future. This new facility, opening its doors just ahead of the production launch of all-electric Mercedes-EQ vehicles in the United States, underscores the pivotal role of the “Mercedes-Benz plant Alabama” within the company’s global electrification strategy. As the automotive world pivots towards sustainable mobility, this Alabama plant is poised to become a cornerstone of Mercedes-Benz’s electric vehicle production network.
The strategic importance of the United States, and Alabama specifically, in Mercedes-Benz’s global production landscape cannot be overstated. For a brand recognized as the world’s most valuable luxury automotive entity, ramping up electric vehicle production across three continents is a monumental undertaking. The “Mercedes-Benz plant Alabama” not only solidifies the United States’ position in this global network but also elevates Alabama’s status as a crucial export hub for luxury SUVs, now extending into the electric era. This plant will be instrumental in producing batteries for the forthcoming EQS SUV and EQE SUV models, both of which are slated for production at the Tuscaloosa facility, forming part of a wider initiative to manufacture all-electric vehicles at seven locations spanning three continents.
Ola Källenius, Chairman of the Board of Management of Mercedes-Benz Group AG, emphasized the significance of this moment, stating, “The opening of our new battery plant in Alabama is a major milestone on our way to going all-electric. With our comprehensive approach including a local cell sourcing and recycling strategy, we underline the importance of the U.S., where Mercedes-Benz has been successful for decades. We’re proud to create new, future-proof jobs to build all-electric SUVs ‘Made in the USA’ at a plant that is such an established part of our production family since 25 years.”
The Tuscaloosa plant, synonymous with Mercedes-Benz SUV production since 1997, is now embarking on an electric transformation, starting with the EQS SUV. Before its official world premiere on April 19th, Mercedes-Benz offered a sneak peek into the spacious and technologically advanced interior of the EQS SUV, highlighting the vehicle’s digitalized and progressive design.
Mercedes-Benz Made in America: A Legacy of Investment and Growth in Alabama
Mercedes-Benz’s commitment to Alabama stretches back to the 1990s, with total investments exceeding seven billion dollars in the state. A significant portion of this, one billion dollars, has been channeled into the new battery plant, logistics enhancements, and upgrades to the production line to accommodate electric vehicle manufacturing. The “Mercedes-Benz plant Alabama” has become a major employer, with Mercedes-Benz U.S. International (MBUSI) providing approximately 4,500 jobs directly and supporting an estimated 11,000 additional positions within the regional supplier and service network. Since 1997, around four million vehicles have rolled off the Tuscaloosa production line, including 260,000 SUVs in 2021 alone. Notably, approximately two-thirds of the annual production is exported, positioning MBUSI as one of the leading automotive exporters in the United States.
The hallmark of the “Mercedes-Benz plant Alabama” is its highly flexible production system. This system allows for the assembly of diverse models and powertrains on a single production line, enabling the plant to nimbly respond to evolving customer demands. Alongside the GLE, GLE Coupe, GLS, and Mercedes-Maybach GLS, the plant will now integrate two electric models, equipped with batteries produced at the adjacent Bibb County facility.
Jörg Burzer, Member of the Board of Management of Mercedes-Benz Group AG, responsible for Production and Supply Chain Management, emphasized the global perspective, stating, “The global Mercedes-Benz production network is digital, sustainable, efficient and flexible. Now the new battery plant, with its highly qualified and motivated U.S. workforce, will be a crucial driver of our electric vehicle roll-out plan. Team USA will play a major role in the continued success of Mercedes-Benz and we are proud that our new electric SUVs will also be built here in Alabama for global markets.”
The opening ceremony of the battery plant was attended by notable figures, including Kay Ivey, the Governor of Alabama, and other prominent regional and international guests. Governor Ivey remarked on the long-standing partnership, “With the production launch of the ground-breaking M-Class 25 years ago, Mercedes-Benz helped put our state on the cutting- edge of automotive manufacturing. Today, with the opening of this new battery plant, Alabama is helping Mercedes accelerate its production of industry leading electric vehicles. We’re proud to call Mercedes a partner, and we’re excited about the future that we are building together in Alabama.”
Bibb County: Joining the Global Battery Production Network
The “Mercedes-Benz plant Alabama” in Bibb County is not just about scale; it’s about sustainable and efficient production. The high-performance lithium-ion batteries produced here for the EQS SUV and EQE SUV are manufactured with a CO2-neutral footprint. The battery assembly line, spanning approximately 984 feet and featuring over 70 workstations, utilizes a fully digitalized production process. This intricate process involves combining various components, including up to twelve cell modules and the EE compartment, ensuring intelligent integration of power electronics. This operation is expected to generate up to 600 new jobs in Bibb County, further boosting the local economy.
The battery systems produced are characterized by a modular design, similar to those used in the EQS and EQE sedans, and employ advanced cell chemistry with a nickel, cobalt, and manganese ratio of 8:1:1. The reduction of cobalt content to around ten percent, coupled with the CO2-neutral production, significantly enhances the sustainability profile of these batteries.
With this new facility, Bibb County becomes an integral part of Mercedes-Benz’s expansive global battery production network, which includes factories in Germany, China, Thailand, Poland, and other locations. These factories are strategically positioned to supply local vehicle production and are equipped for export as needed. Mercedes-Benz is making a substantial investment of over one billion Euros in the development of this global battery production network.
Recognizing the specialized nature of battery production, “Mercedes-Benz plant Alabama” has implemented new safety and training protocols. Comprehensive high-voltage safety training is mandatory for every team member accessing the battery plant, underscoring Mercedes-Benz’s commitment to operational and occupational safety.
Envision AESC Partnership: Securing Battery Supply for the Future
To ensure a robust and localized supply chain, Mercedes-Benz has forged a strong partnership with Envision AESC, a leading battery technology company. Envision AESC will supply the “Mercedes-Benz plant Alabama” with high-performance battery modules from a new U.S. plant, with supplies commencing in the mid-2020s. This collaboration is crucial for Mercedes-Benz’s strategy to go fully electric by the end of the decade, wherever market conditions permit. The company, along with partners, plans to establish eight cell factories worldwide, aiming for a total production capacity of 200 Gigawatt hours by the end of the decade.
Markus Schaefer, Member of the Board of Management of Mercedes-Benz Group AG, Chief Technology Officer, responsible for Development and Procurement, highlighted the strategic importance of this partnership: “To be the leading luxury brand also in an all-electric future, Mercedes-Benz is accelerating the roll-out of its EQ models. Establishing a strong battery cell partner network in accordance with our global production strategy is a very important milestone on our way to CO 2- neutrality. Envision AESC will be a major supplier securing capacity for the next generations of our Mercedes-EQ products built in the U.S. in the years to come. With Envision AESC’s net-zero carbon solutions and battery technology, this new cooperation underlines our holistic approach regarding our sustainable value chain and allows us to secure supplies, to take advantage of economies of scale, and to provide our customers with superior battery technology.”
MO360: Digitalization and Flexibility in Production
The “Mercedes-Benz plant Alabama” leverages the MO360 digital production ecosystem, enhancing flexibility and efficiency in manufacturing processes. This digitalization is evident in areas like the “fullflex marriage,” where modular stations enable the connection of different drivetrain variants and vehicle bodies on the same assembly line. MO360 provides real-time information and work instructions to employees, optimizing processes and quality control across Mercedes-Benz passenger car plants. This digital infrastructure is crucial for managing the complexities of producing both electric and conventional vehicles within the same facility and ensures that the workforce is well-equipped to handle high-voltage technology.
Michael Goebel, Head of Production North America and President and CEO of Mercedes-Benz U.S. International, emphasized the team’s role, “Our team here in Tuscaloosa plays a major role in the global success of Mercedes-Benz. We are proud that not only the new all-electric EQS SUV and EQE SUV are being built here in Alabama for markets worldwide, but also their high-performance batteries.”
The New EQS SUV: Luxury Redefined, Made in Alabama
The EQS SUV, celebrated its world premiere on April 19th, represents the pinnacle of all-electric luxury SUVs and is the third model built on Mercedes-Benz’s dedicated electric vehicle architecture. It merges the luxury and comfort of the EQS sedan with the spaciousness and versatility of a large SUV. The interior showcases digital luxury with the optional MBUX Hyperscreen, a 56-inch curved screen spanning the dashboard, integrating the instrument cluster, infotainment, and passenger display seamlessly. With optional third-row seating and electrically adjustable second row, the EQS SUV offers exceptional flexibility and caters to diverse customer needs.
Sustainability: A Cornerstone of Alabama Operations
Sustainability is deeply embedded in the design and operation of the “Mercedes-Benz plant Alabama”. The building itself is designed for high energy efficiency, utilizing solar thermal energy for water heating and rainwater harvesting to conserve resources. LED lighting, intelligent ventilation, and air conditioning systems with environmentally friendly refrigerants further minimize the plant’s environmental impact. Hydrogen-powered forklifts replace diesel versions, and plans are in place to meet the site’s entire electricity needs through renewable energy sources from 2024 onwards, pending approval of solar energy projects.
Mercedes-Benz is committed to a comprehensive sustainability strategy that includes circular design, value retention, and battery recycling. The company is developing its own hydrometallurgy-based battery recycling plant in Germany and plans to establish similar partnerships in China and the United States to close the recyclable material loop. Furthermore, a five-year partnership with The Nature Conservancy supports the Working Woodlands site in northeast Alabama, focusing on sustainable forestry and wildlife protection, aligning with Mercedes-Benz’s “Ambition 2039” goal of a CO2-neutral vehicle fleet by 2039.
The “Mercedes-Benz plant Alabama” stands as a testament to innovation, sustainability, and the enduring partnership between Mercedes-Benz and the state of Alabama, driving forward the electric future of luxury automotive manufacturing.
