CASE STUDY – EV Manufacturing with Skillet Brush Cleaning System

When a Swedish automotive manufacturer began installing a new production line dedicated to fully electric vehicles, maintaining a completely debris-free environment became mission-critical. 

The Challenge

In March 2025, we were approached by a company tendering for a major project at the Swedish manufacturing facility. The requirement was to design, develop, and manufacture a bespoke skillet cleaning system for a brand-new production line dedicated to fully electric vehicle (EV) production.

Unlike a previous project delivered for Nissan, where debris build-up interfered with light guards and caused line stoppages the challenge here was significantly more critical.

In EV production, foreign debris must never come into contact with the vehicle battery due to the risk of puncture. Even minor contamination could compromise safety and halt production.

To mitigate this risk, the manufacturer required a fully integrated, custom-engineered skillet brush cleaning system capable of maintaining a clean production environment while ensuring continuous and safe line operation. 

Our Approach

Following an initial discovery call, Cottam’s R&D team developed tailored design concepts for both the Pre-Trim and Trim production lines. A site visit to the Swedish facility enabled the team to assess installation points, understand line constraints, and collaborate directly with their engineers to confirm integration requirements. This ensured the final design aligned with the manufacturer’s operational, safety, and maintenance standards.

On 1st September 2025, the manufacturer’s engineers visited Cottam HQ to review the first brush assemblies. A full-scale mock-up skillet was built to demonstrate how the system would operate in the production environment, highlighting integration, ease of maintenance, brush removal, and durability.

Replicating the real application gave the customer confidence in the system’s performance and long-term reliability.

Delivery

Following the successful HQ visit and design approval, the Cottam team moved quickly to meet the tight project deadlines.

The final brush systems were:

  • Manufactured in-house
  • Packed using bespoke, protective packaging produced internally
  • Quality-checked and prepared for export

The complete system was shipped to Sweden on 22nd September 2025, ready for integration into the manufacturers new EV production line.

“This project began as an evolution of our existing cleaning system, but through early discovery discussions it became clear that a more advanced, tailored solution was required.  

With two production lines operating differently configured skillets, the challenge called for close collaboration, flexibility, and innovative thinking. 

From the outset, we worked side by side with the customer — holding regular design meetings, sharing CAD models, and openly exchanging ideas to refine the concept. Detailed site visits and surveys ensured every aspect of the solution was aligned with real operating conditions. 

Together, we developed innovative approaches to manufacturing large-format brush assemblies, introducing bespoke jigs and fixtures to guarantee quality and repeatability. On-site testing and proving gave confidence that the system would perform exactly as intended. 

Customer inspection visits prior to shipment further reinforced trust and transparency throughout the process. Hosting the team in Newcastle provided not only the opportunity to review the finished equipment, but also to strengthen the partnership in a more informal setting. 

This project is a strong example of how technical expertise, open collaboration, and a shared commitment to quality deliver successful, long-term outcomes.” 

NICK PALFREYMAN - HEAD OF PRODUCT AT COTTAM

Conclusion

Through close collaboration, detailed site assessments, and rigorous testing, Cottam delivered a bespoke skillet brush cleaning system tailored to the manufacturer’s EV production line. The final solution ensures a debris-free environment, supporting both operational efficiency and the strict safety requirements of electric vehicle manufacturing.

This project demonstrates how Cottam’s engineering expertise and collaborative approach enable the development of reliable, application-specific solutions for critical production environments.

“The frames and brushes met (and exceeded) our expectations when it comes to maintainability and design. We are very happy with the solution for pre-trim and being able to remove the brushes in an effective way to be able to run cars through the line.” 

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