Asahi Kasei Project Eagle - Phase I

The Story

Powering the future of mobility, Project Eagle – Phase I marks the launch of North America’s first wet-process lithium-ion battery separator manufacturing facility. With an annual output capacity of 700 million m² of Hipore™ separator film, the plant will play a pivotal role in the EV and hybrid vehicle supply chain.

The facility will feature a base building and outdoor equipment area, supporting the full production cycle—from raw material storage and mixing to extrusion, stretching, coating, and inspection. Advanced utility systems will include a 1 MW generator, steam and refrigeration plants, and a 13.8kV step-down substation for connection to the grid.

Site preparation spanned 180 acres, with over one million cubic metres of earth moved and steel piles driven 35 metres deep to establish a robust foundation. The plant’s design integrates high-performance separator technology, emphasizing uniform pore structure, porosity, and puncture resistance.

Outdoor infrastructure will support critical operations such as distillation, warehouse and logistics, VOC control, and emergency systems, reinforcing the facility’s role as a cornerstone in Ontario’s growing battery ecosystem.