Sensing intelligence for hazardous industry

See abnormal EV-battery sensor patterns earlier at intake.

Turn physical sensing and process data into earlier anomaly detection and risk-scoring that supports your intake and safety-response decisions, smarter disassembly routing, and recovery-value estimates after the pilot.

Apply for the Guardian + Intake Pilot → See the pilot offer

Built for recyclers handling complex, damaged, mixed, or unknown EV battery packs. No sensor lock-in. No rip-and-replace. Start with one line, one workcell, or one site.

Anomaly detection Early abnormal-pattern signals that support your intake risk decisions.
Smarter routing Manual, automated, quarantine, or specialist inspection.
Yield after pilot Connect process data to expected material recovery value once intake intelligence is live.
Concept · intake assessment
Thermal deviation +8.4°C
Gas anomaly Moderate
Routing recommendation Manual
Alert tier Moderate
Guardian alert
Quarantine advised before disassembly
View modules
The first bottleneck

EV battery recycling starts with uncertainty.

Every incoming battery creates three immediate questions: Is it safe? Can it be processed automatically or manually? What is the recovered material likely worth?

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Unknown condition at intake
Damaged, mixed, undocumented, or partially diagnosed packs enter the process.
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Manual assessment does not scale
Operator expertise is valuable, but inconsistent across shifts and hard to automate.
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Fragmented data
Sensors, diagnostics, manual inspection, and recovery outcomes are rarely connected.
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Commercial value is uncertain
Material recovery value is often understood too late in the process.
The platform

One decision-support layer for intake assessment, routing, and recovery workflows.

DEXOLYTA Battery Intelligence Platform connects external sensors, internal battery data, and recycling process outcomes into one decision-support system.

Connect

Use existing data sources.

Thermal, gas, acoustic, video, 3D vision, battery diagnostics, BMS data, inspection logs, and recovery outcomes.

Fuse

Create a battery assessment profile.

Combine physical signals, battery history, operator observations, and process results into one decision case.

Decide

Support operational choices.

Anomaly flag, quarantine, manual disassembly, automated processing, specialist inspection, or value-focused routing.

Learn

Improve with every battery.

Connect intake signals to actual process and recovery outcomes to improve future estimates.

Three modules

Three modules. One intelligence platform.

Start with Guardian + Intake to address the first operational bottleneck. Add Yield once intake and process data are flowing.

Module 01 · DEXOLYTA Guardian

Battery anomaly detection and risk-scoring for EV battery recycling.

Supports: “Which packs show abnormal sensor patterns?”
  • Pilot-scoped sensing modalities (thermal, gas/HF, acoustic, vision) selected per site
  • Watch, Alert, and Critical risk-score tiers at intake and storage
  • Operator alerts and escalation recommendations
  • Anomaly and risk-score event log for audit and risk conversations

Designed to support the client's own safety-response process by surfacing abnormal sensor patterns earlier.

Include Guardian in Pilot
Module 02 · Triage & Smart Manual

Smarter routing and operator support.

Answers: “Manual, automated, quarantine, or specialist handling?”
  • Battery classification at intake
  • Manual vs automated processing recommendation
  • Operator guidance during manual disassembly
  • Consistent routing decisions across shifts and sites

The practical bridge from manual expertise to scalable, data-backed battery processing and future automation.

Apply for Guardian + Intake Pilot
Module 03 · Yield Module

Estimate material recovery value after the pilot.

Answers: “What is the recovered material probably worth?”
  • Expected black mass value estimates
  • Chemistry and yield intelligence
  • Contamination and batch-quality risk scoring
  • Commercial analytics for resale and offtake decisions

Use accumulated intake, process, and recovery data to connect operational decisions with material value.

Add after pilot
Guardian + Intake Pilot

Start with the Guardian + Intake Pilot.

A focused 8–12 week engagement to build your first data-driven intake intelligence layer — without replacing your sensors or rebuilding your plant.

Fixed scopeOne line, one workcell, or one site.
No lock-inHardware-agnostic and designed around existing data sources.
Real deliverablesDashboard concept, decision model, event log, and rollout business case.
Scale-readyPilot outputs become the basis for full deployment.
Apply for the Pilot → See pilot steps
Interactive pilot estimator

What if intake decisions became faster and more consistent?

Use this as a simple landing-page engagement tool. Replace assumptions with real customer data during discovery.

Estimated operator hours redirected per month 64h

This is not a guaranteed result. It is a discovery conversation starter for the pilot.

Pilot process

From first assessment to business case in 8–12 weeks.

Workflow mapping

Map intake, storage, disassembly, risk decisions, manual touchpoints, and available data sources.

Data connection

Connect selected sensors, diagnostics, inspection records, and process outcome data for the pilot scope.

Decision prototype

Build Guardian alerts, intake rules, operator guidance, and a dashboard concept for pilot users.

Scale decision

Deliver pilot results, success metrics, rollout roadmap, and Yield extension plan.

Before

  • Manual intake assessment
  • Fragmented sensor and diagnostic data
  • Late anomaly visibility
  • Inconsistent routing decisions
  • Automation readiness is unclear
  • Recovery value is understood too late

After

  • Structured battery assessment profile
  • Connected sensor, diagnostic, and process data
  • Early anomaly notifications
  • Manual, automated, quarantine, or specialist routing
  • Operator guidance during disassembly
  • Foundation for recovery-value estimates
Best-fit customers

Built for recyclers scaling from expert judgement to industrial intelligence.

Especially relevant for teams processing mixed EV battery packs, damaged batteries, unknown feedstock, or plants preparing for robotic and semi-automated disassembly.

Recycler
Pre-treatment
Black mass
OEM take-back
Insurance risk
Why now

Regulatory deadlines are forcing the hand.

EU, China, and US rules are tightening recovery and traceability together. Recyclers need intake intelligence that scales before volumes arrive.

Feb 2027

Digital battery passport mandatory for EV batteries. Removability rules tighten under EU Battery Regulation.

Dec 2030

70% recycling efficiency for lithium-based batteries — up from 65% in 2025 (EU Annex XII).

End 2031

80% Li and 95% Co, Ni, Cu material recovery targets take effect.

Apr 2026

China mandatory EV battery recycling framework takes effect — throughput pressure on global supply chains.

US IRA

Domestically recycled critical minerals count toward EV tax credits — incentivising faster, traceable recovery.

~1M+/yr EU

Age-based end-of-life packs in Europe by 2030 (Statista / IEA). Scenario range 0.4–1.1M; global ~1.2M. Every pack needs a safety and routing decision at intake.

Insights

Early warning must start before the temperature spike.

Technical insight for EV battery recyclers: thermal runaway is a chain of evidence — not a single flame or sensor — turned into intake and routing actions.

Open technical insight →
Hazards

Do not conflate three risks

External fire, vent-gas deflagration, and toxic exposure need different controls. Flame intensity is a poor proxy for overall severity.

Larsson · Baird · Feng Read insight → Sensing

A sequence, not a threshold

Thermal and voltage help but lag or go missing on damaged packs. Gas, pressure, acoustic and context can reveal earlier change — with placement and qualification caveats.

Gardner · Shi · Mei · Alsewailem Read insight → Intake

Evidence → site action

Connect, fuse, decide, act, learn — route to process, hold, stop, or quarantine. Assistive decision support, not a replacement for certified plant safety.

Guardian + Intake logic Read insight →

Dr Marek Kostrzewa · 21 July 2026 · Full technical insight

FAQ

Designed for low-friction industrial adoption.

Do we need to buy new sensors?

No. The platform is designed to be hardware-agnostic. The pilot starts by mapping the sensors, diagnostics, machines, and process data you already have. Additional sensors can be recommended only where they clearly improve the use case.

Is this a replacement for certified safety systems?

No. Guardian is a battery anomaly detection and risk-scoring layer that assists the client's safety-response process. It supports, and does not replace, certified safety systems, plant procedures, and regulatory obligations.

Why start with Guardian + Intake?

Because safety and intake routing are the most immediate operational bottlenecks. They are easier to pilot, easier to measure, and create the data foundation for Yield.

When should we add Yield?

After the pilot has started connecting intake signals, process results, and recovery outcomes. Recovery-value estimates become more useful when they can learn from your own battery feedstock and process data.

Can I try the Virtual Lab?

The Virtual Lab is invitation-only for pilot partners. Request access via the contact form; we unlock credentials after a short intake call. The Lab is for evaluation and pilot preparation — not certified safety control or live plant monitoring.

Virtual Lab

Explore the Virtual Lab — access on request.

A controlled workspace for pilot partners to review sensing workflows, twin scenarios, and intake decision prototypes before plant deployment. It is a development and evaluation environment — not live plant monitoring and not a certified safety system.

Access locked

What you can review after access is granted

  • Twin and simulation scenarios used to scope intake decisions
  • Sensor-pattern exploration for pilot design (site-specific modalities)
  • Operator workflow concepts and dashboard prototypes from discovery

We do not publish a public Lab login. Credentials are issued after a short intake call with pilot candidates.

Request Lab access → See the pilot offer

The Lab supports pilot preparation and evaluation. It does not claim production fire detection, thermal-runaway prevention, or replacement of plant safety systems.

Prefer email? Write to [email protected] with subject “Virtual Lab access request”.

Guardian + Intake Pilot

Ready to start a focused intake pilot?

Apply for a focused pilot and build your first data-driven intake intelligence layer in 8–12 weeks.

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Reference:

[email protected]

We reply within two business days and can book a 30-minute intake assessment call.

One line, one workcell, or one site — dashboard concept, decision model, event log, and rollout business case in 8–12 weeks. No sensor lock-in.