The stages of qualification
Qualification usually starts with small samples tested against the buyer's specification. If those pass, the material moves to pilot cathode synthesis, then into test cells that are cycled under controlled conditions. Only when those cells perform in line with cells made from established supply will the buyer consider production volumes.
Each stage can reveal issues that send the supplier back to adjust its process. Timelines vary widely by product, customer and how critical the application is, so it is sensible to plan for a long qualification period rather than a quick commercial start.
| Stage | What is tested | Common failure points |
|---|---|---|
| Sample assay | Chemical specification | Trace impurities, moisture |
| Pilot synthesis | Behaviour in cathode production | Particle morphology, reactivity |
| Test cells | Capacity, cycling, safety | Capacity fade, gas generation |
| Site audit | Process control, quality system | Traceability gaps, inconsistent batches |
| Production trial | Performance at volume | Batch-to-batch variation |
What auditors look for
A site audit checks whether the refinery can repeat its results. Auditors look at feed assay procedures, process control, sampling, laboratory accreditation, change control and how non-conforming batches are handled. A quality management system certified to a recognised standard helps, but auditors will still test how it works in practice.
Increasingly, buyers also ask where the input material came from. Chain-of-custody records linking refined output to specific consignments of batteries or black mass support recycled content claims and responsible sourcing requirements, and they are expected to become more important as battery passport rules take effect in the EU.
- Documented feed assay and blending procedures
- Accredited or externally verified laboratory methods
- Formal change control for process adjustments
- Chain-of-custody records from input consignment to output batch
Keeping a qualification once earned
Qualification is not permanent. Significant changes to feed sources, process steps or equipment can require requalification, so suppliers need to notify customers and agree how changes will be validated. Surprising a customer with a process change is one of the fastest ways to lose a qualified position.
Ongoing performance is tracked through certificates of analysis, customer incoming inspection and periodic re-audits. Suppliers that share process data openly and resolve deviations quickly tend to move from trial volumes to long-term contracts more easily.
Field note