Leipzig. Electrification continues at BMW Group Plant Leipzig: Four months after launching production of the combustion-engined MINI Countryman, the all-electric version is now rolling off the lines at Leipzig as well. After phasing out production of the BMW i3, the birthplace of electric mobility at the BMW Group has welcomed another fully electric car to its range. It now manufactures four models with three drive types by two brands, all on a single production line: the BMW 1 Series, the BMW 2 Series Active Tourer (including the plug-in hybrid version), the BMW 2 Series Gran Coupe and the MINI Countryman in both its fully electric and combustion-powered versions.

The MINI Countryman Electric represents a major step in the MINI brand’s transition to full electrification by 2030 and combines an electrified go-kart feel with zero local emissions mobility. It comes in two fully electric variants: the Countryman E (150 kW, 204 hp | electricity consumption 17.4 – 15.7 kWh/100 km | CO2 emissions 0 g/km) and the more powerful all-wheel Countryman SE ALL4 (230 kW, 313 hp | electricity consumption 18.5 – 16.8 kWh/100 km | CO2 emissions 0 g/km).  

Consistent plant upgrades and flexible production system

To enable production of up to 350,000 units a year – 100,000 more than previously – Plant Leipzig has been continuously upgraded since 2018, with extensive additions and upgrades to the bodyshop, paintshop, assembly and logistics. “Our cars and components are very much in demand. In recent years the BMW Group has invested around 1.6 billion euros in the Leipzig site to produce additional vehicles and electric components, and now we’re increasing vehicle volumes too – which is great news for our plant,” said Petra Peterhänsel, Plant Director.

The main driver behind the volume increase is the MINI Countryman. During the course of 2024, output will rise to almost 500 units a day – on top of the 800 or so BMW vehicles the plant is producing. What’s more, thanks to its flexible production system, Plant Leipzig is in a position to respond quickly to customer demand, for example by increasing the share of fully electric vehicles.

Flexible assembly structures also meant the MINI Countryman Electric could be integrated seamlessly into production. The situation is similar with the different drive units, which are all produced on one and the same line in aggregate assembly and prepared for what’s known as “marriage” with the body. The e-drives, transmissions and control electronics (collectively known as the highly integrated electric drive topology, or HEAT) for the two all-electric models are connected directly in the plant. A new production line was required only for the control electronics.

More staff and nightshifts for increased production volume

Higher production volume means secure employment and up to 900 additional employees in vehicle production alone. By the end of 2024, Plant Leipzig will employ around 7,000 BMW staff. Working hours will need to be adjusted in all technologies, with nightshifts in assembly starting for the first time in September of this year and cars being produced round the clock in three shifts.

“Plant Leipzig first went on stream in 2005 with about 2,600 employees in production. 19 years later there are over 7,000. Over the years, the plant has grown steadily and considerably. The start of nightshifts in assembly represents another important milestone in the success story of our plant and is a clear show of confidence by our company in our site here in Leipzig,” emphasised Works Council Chairman Jens Köhler.

Made at Plant Leipzig: high-voltage batteries for the MINI Countryman Electric

With the production launch of the MINI Countryman Electric, all three stages of the Gen 5 high-voltage battery production process are now represented at BMW Group Plant Leipzig: cell coating, module production and battery assembly. Operations in all three are currently ramping up, with five cell-coating, three module-production and two high-voltage battery-production lines now in place.

“We are in the middle of the transformation to e-mobility,” said Markus Fallböhmer, Head of Battery Production at the BMW Group. “Starting this year, Plant Leipzig will carry out every stage of our in-house high-voltage battery production process. It’s our next great step forwards.”

Plant Leipzig’s e-component production capacity has been increasing since 2021. It will now manufacture not just the high-voltage batteries for the MINI Countryman Electric but also e-components for the BMW iX1, BMW iX2, BMW i4, BMW i5 and BMW iX made at other sites. The e-component production unit at Leipzig currently employs some 1,000 people.

To enable production of high-voltage batteries, spaces previously used for the BMW i3 and BMW i8 have been converted and new buildings added. One of them is a new hall with a footprint of about 61,000 m². This houses two lines capable of producing up to 300,000 high-voltage batteries a year. The BMW Group has invested over 900 million euros in e-component production at Plant Leipzig to date.

Resource-saving painting processes

At launch, the fully electric MINI Countryman comes in three additional body colours: British Racing Green, Chili Red and Blazing Blue – and with MINI’s trademark contrast roof, if desired. This is painted using a new overspray-free method that saves resources and is currently being readied for series operation. The term “overspray” refers to the mist of excess paint particles that forms when bodies are painted the conventional way. With the new technique, this mist no longer occurs. This makes it easier to paint in multiple colours as the laborious process of masking is no longer required. Overspray-free painting also helps save CO₂ emissions, as exhaust from the cabin requires less cleansing. In addition, it requires considerably less conditioned air, i.e. air that is brought to the exact temperature and humidity required for painting. As a result, less energy is needed to temper air and treat exhaust.

The burner technology used to dry the paint on contrast roofs was also converted for the start of MINI Countryman production and now consists of a bivalent system. The fuel-flexible burners can run on hydrogen (H2) as well as gas (methane, CH4) and even switch between the two while in operation. Five such bivalent hydrogen-capable burners are used to produce the contrast roofs for the MINI Countryman.

Further burners in the paintshop will also gradually switch to bivalent operations, with the next six hydrogen-capable burners just installed. This makes Leipzig a pioneer in the automotive industry and takes it ever closer to lower CO₂ emissions. “Our vision at Plant Leipzig is to decarbonise production as far as possible by replacing fossil fuels with green hydrogen,” said Petra Peterhänsel, explaining the long-term focus of the facility. This will require sufficient green hydrogen from a grid. A regional hydrogen grid is currently in planning, with Plant Leipzig set to benefit.

MINI Countryman E

Electricity consumption combined: 17,4 – 15,7 kWh/100 km according to WLTP
CO₂ emissions combined according to WLTP: 0 g/km
CO₂ Class: A
Electric range according to WLTP: 462 – 423 km

MINI Countryman SE ALL4 

Electricity consumption combined: 18,5 – 16,8 kWh/100 km according to WLTP
CO2 emissions combined according to WLTP: 0 g/km
CO2 Class: A
Electric range according to WLTP: 432 – 399 km

Spartanburg (USA)/Munich. The BMW Group continues the roll-out of its electromobility plan with a new investment in the U.S. to expand Plant Spartanburg and the company’s manufacturing footprint in the U.S. BMW Group Chairman of the Board of Management, Oliver Zipse, announced today a
$1.7 billion investment in its U.S. operations, including $1 billion to prepare for the production of electric vehicles at the company’s existing U.S. manufacturing facility in South Carolina, and $700 million to build a new high-voltage battery assembly facility in nearby Woodruff, SC. By 2030 BMW Group will build at least six fully electric models in the U.S.

Zipse was joined today at Plant Spartanburg by South Carolina Governor Henry McMaster, Secretary of Commerce Harry Lightsey III, Chairman of Spartanburg County Council Economic Development Committee, David Britt, and Woodruff, SC Mayor, Kenneth Gist as he also announced an agreement to source next generation lithium-ion battery cells from Envision AESC, which will build a new plant in the state.

“For decades, Plant Spartanburg has been a cornerstone of the global success of the BMW Group. The home of the BMW X models that are so popular all over the world. Going forward, it will also be a major driver for our electrification strategy, and we will produce at least six fully electric BMW X models here by 2030. That means: The ‘Home of the X’ is also becoming the ‘Home of the Battery Electric Vehicle’,” said Zipse on Wednesday. “In addition, we can showcase BMW Group’s ‘local for local’ principle: Our newly developed sixth generation battery cells, which were specifically designed for the next generation electric vehicles, will be sourced here in South Carolina – where X goes electric.”

 

Envision AESC Battery Cell Plant in South Carolina to Supply Plant Spartanburg

In line with the principle of "local for local,” the BMW Group aims to purchase battery cells for its electric vehicles where production takes place. The company has found a partner in Envision AESC, which will build a new battery cell factory in South Carolina, to supply Plant Spartanburg. Envision will produce newly developed round lithium-ion battery cells, which were specifically designed for the sixth generation of BMW eDrive technology, and will be used in the next generation NEUE KLASSE electric vehicles. The annual capacity of the battery cell factory will be up to 30 GWh.

The new battery format will increase energy density by more than 20 percent, improve charging speed by up to 30 percent and enhance range by up to
30 percent. At the same time, CO₂ emissions from cell production will be reduced by up to 60 percent through the partial use of secondary lithium, cobalt and nickel material, as well as renewable energy for production. 

The cooperation with Envision AESC is an important step in the BMW Group's plan to strengthen its regional supply chains. The expansion of electric vehicle production in combination with a local battery cell factory will lead to the creation of new supply chains, new networks for sub-suppliers, and new jobs throughout the entire region.

BMW Group has already announced that four additional battery cell factories will be built in Europe and China to meet its demand for next generation battery cells. The cell factories are being built by partners and will each have an annual capacity of up to 20 GWh.

 

Increased Investment and Expanded Manufacturing Capacity in SC

Of the new $1.7 billion investment announced today, $700 million will be used to build a new high-voltage BMW battery assembly center in Woodruff, SC, near Plant Spartanburg. The new facility will encompass over 1 million sq. ft., and produce next generation batteries for fully electric vehicles. Around 300 new jobs will be created on site.  

Plant Spartanburg currently produces lithium-ion battery modules for the two plug-in hybrid electric vehicles built at the plant, the BMW X3 xDrive30e (fuel consumption combined: 2.6-2.0 l/100 km WLTP; power consumption combined: 20.5-18.9 kWh/100 km WLTP, CO₂ emissions combined: 59-45 g/km WLTP) and BMW X5 xDrive45e (fuel consumption in l/100 km combined: 1.7-1.2 WLTP; power consumption in kWh/100 km combined: 27.7-24.3 WLTP; CO₂ emissions in g/km combined: 39-27 WLTP.). In 2021, nearly 70,000 electrified BMWs were built on site. The site in Woodruff will also leverage the experience and expertise developed in Plant Spartanburg’s existing operations at the new facility.

“BMW’s sustained and impactful presence in South Carolina demonstrates the power of partnership and shared commitment to our state’s automotive industry success,” said Governor McMaster. “With today’s announcement of a $1 billion expansion to Plant Spartanburg for manufacturing electric vehicles as well as $700 million for a new plant in Woodruff to assemble battery units, the road to the future is here. And I applaud BMW on helping lead the way.”

 

BMW Group Plant Spartanburg

Plant Spartanburg was established 30 years ago and began producing vehicles two years later. Since then, the plant has become the global center of competence for BMW Sports Activity Vehicles and a critical component of the company’s global production network. The plant currently represents an investment of nearly $12 billion, employs more than 11,000, and has an annual capacity of up to 450,000 vehicles. To date more than six million BMW vehicles have been built in the U.S. – for the U.S. and global markets. Based on this strength, BMW has been the largest automotive exporter from the U.S. by value for the past eight years.

Plant Spartanburg currently produces 11 models including the BMW X3, X4, X5, X6 and X7 Sports Activity Vehicles, four BMW M models and two plug-in hybrid electric models. Production of the all-new hybrid-electric BMW XM (fuel consumption in l/100 km combined: 1.6-1.5 WLTP; power consumption in kWh/100 km combined: 30.1-28.9 WLTP; CO2 emissions in g/km combined: 36-33 WLTP. Preliminary figures that have not yet been officially confirmed.) will begin later this year.

The plant is supported by more than 300 suppliers in the U.S., including over 40 direct tier 1 suppliers in South Carolina alone.

“This is a very important step for Plant Spartanburg as we continue our legacy of producing high-quality vehicles, and build on the success of the last 30 years,” said Robert Engelhorn, President and CEO, BMW Manufacturing Co. “With this latest investment, we futureproof our operations and prepare the plant for electrification and new technologies, ensuring both the long-term success of our company and our position as an attractive and viable employer in the state of South Carolina.”

 

Ongoing Commitment in the U.S.

In addition to sales and marketing operations, the BMW Group footprint in the U.S. consists of nearly 30 locations in 12 different states, including an advanced design studio, a technology research and development center, and a venture capital fund in California, BMW Group Financial Services, and BMW Manufacturing Corporation, which operates Plant Spartanburg in South Carolina. The BMW Group dealer network consists of nearly 650 independently owned BMW, MINI, Rolls-Royce and BMW Motorrad dealers nationwide. Taken together, the BMW Group’s operatons in the U.S. directly and indirectly provide and support more than 120,000 jobs in the U.S., and has contributed $43.3 billion to the U.S. economy.

 

“Technology Openness” and Customer Focused Flexibility

BMW Group is clearly focused on a sustainable future and shares common ambition in the U.S. with regard to climate goals and the reduction of greenhouse gas emissions. At the same time, the company is following a path of “technology openness” to offer a choice of fully electric, plug-in hybrid electric, and highly-efficient internal combustion options to its customers in meeting their diverse needs in vastly different geographies across the nation. BMW Group is committed to fulfilling its goal of making a minimum of 50% of its global sales battery electric vehicles by 2030.

 

360-Degree Approach

BMW Group has also set an initial target to reduce CO₂ emissions by 40% per vehicle by 2030. As BMW Group works towards the goal of climate neutrality, the company is focused on the reduction of CO₂ emissions throughout a vehicle’s entire life cycle. 

• Design and Engineering: Beyond simply electrifying its product portfolio, BMW Group begins the design and engineering phase of vehicle development with a ‘secondary first’ approach, so that currently on average nearly 30 percent of materials used in BMW Group vehicles are recycled or reused. In the longer term, the “secondary first” approach aims to increase this figure to 50 percent.
• Supply Chain and Procurement: BMW Group has been actively involved for many years in initiatives to develop standards for responsible raw material extraction and promote compliance with environmental and social standards for raw material extraction through certification of mines. The cobalt and lithium used as raw materials for the new generation of BMW battery cells will be sourced from certified mines which allows the company retains full transparency over extraction methods and ensures responsible mining.
• Vehicle Production: BMW Group’s global production network also relies on renewable energy such as solar, wind, and hydroelectric power in the manufacturing phase of its vehicles. All of the company’s production sites have been net CO₂ neutral by offsets since 2021.
• Vehicle Use Phase: BMW Group is also working to ensure that the electricity generated to charge battery electric vehicles is done so sustainably. For example, partnerships with dairy farms in California reduce greenhouse gas emissions by capturing methane gas and transforming it into renewable energy, which is exported to the power grid. The company also operates a pilot program called ChargeForward in the San Francisco Bay Area which makes it possible for owners to charge their vehicles with as much solar energy as possible.
• Vehicle Recycling & Post-Life:From the start BMW Group vehicles are designed with recycling in mind, thereby improving the possibility for components to be recycled or reused. The company has already demonstrated the ability to recover more than 90% of the material from high-voltage batteries and has approximately 3,000 collection points worldwide for the recycling of end-of-life vehicles.

As the BMW Group continues towards an electric future, the company is looking beyond the vehicles themselves to ensure that it delivers sustainable solutions across the value chain and throughout the entire lifecycle of the vehicle. In the U.S. BMW currently offers two fully electric vehicles including the BMW iX Sports Activity Vehicle and the BMW i4 Gran Coupe. The fully electric
BMW i7 Sedan (power consumption in kWh/100 km combined: 19.6-18.4 WLTP) will come to market later this year. With the NEUE KLASSE, BMW will make a significant step forward. For more information about the BMW Group’s focus on sustainability and unique approach to electrification, please visit: https://www.bmwgroup.com/en/sustainability.html

 

_{If you have any questions, please contact:}

_{BMW Group Corporate Communications}

_{Eckhard Wannieck, Head of Corporate, Finance and Sales Communications
E-Mail: Eckhard.Wannieck@bmwgroup.com, Tel.: +49 (0) 151 601 28042}

_{Sandra Schillmöller, Communications Purchasing, Supplier Network, Sustainability
Email: Sandra.Schillmoeller@bmwgroup.com, Telephone: +49-89-382-12225}

_{Bernhard Ederer, BMW Group Innovation Communications
Email: Bernhard.Ederer@bmwgroup.com , Tel.: +49 (0) 176 601 28556}

_{Martina Hatzel, Communications Production Network BMW Group
E-Mail: Martina.Hatzel@bmwgroup.com, Tel.: +49 (0) 151 601 11966}

 

_{For questions regarding Envision AESC please contact:}

_{Lauren Flanagan, Senior Director International Government Relations & Communications, Envision Group
E-Mail: lauren.flanagan@envision-energy.com, Tel. +44 7379 340 101}