Sep 17, 2025
High-Tech in the North: Stack Production at the Hamburg Site
In 2024, Quest One opened its company headquarters – the Gigahub – in Hamburg, a central development and production site for PEM electrolyzer stacks. With the start of series production, the availability of green hydrogen is increasing. Stacks are the technological heart of an electrolyzer, which produces green hydrogen by splitting water into oxygen and hydrogen using renewable electricity. As such, they play a key role in ramping up the future hydrogen economy.
Highly automated manufacturing, combined with a strong focus on research and development, makes the Hamburg facility a key site within the green hydrogen value chain.
Site Manager Jens Werner Schwarz and his team developed and commissioned this state-of-the-art production site in a record time of just 18 months. In Hamburg, the combination of stack engineering, testing, and process development enables short innovation cycles with high product quality.
Building and leading a newly established site means keeping the big picture in mind while never losing sight of the details. Continuously evolving processes and giving innovation the space it needs – all while putting collaboration at the center of our actions. I believe that a culture of learning from mistakes and genuine teamwork makes us efficient – only then can we create an environment where progress and community go hand-in-hand.
— Jens Werner Schwarz, Site Manager Quest One Hamburg & Vice President Operations Stack
Stack Production at Gigawatt Scale
At the Gigahub, two parallel production lines handle the stacking, pressing, and testing of stack components under cleanroom conditions. Many steps that were previously done manually are now automated. This reduces the production time of a stack by approximately 75 percent. Automation also increases efficiency and precision: quality-relevant parameters such as tightness, electrical properties, and mechanical stability are checked directly during production and digitally documented. All process data, test values, and image material are stored in the system – ensuring complete traceability.
Each stack is provided with a complete data trail – including image data from the production process. This ensures the highest quality and transparency all the way to delivery.
— Jens Werner Schwarz
All manufacturing steps, test protocols, batch information, and material data are assigned to an individual stack record. Additionally, a visual and manual final inspection is carried out by qualified professionals. A central KPI dashboard is planned to display the real-time production status for everyone to reference in to stay on target.
To ensure performance, electrochemical conditioning is carried out under real operating conditions. The hydrogen generated during quality testing is collected in mobile trailers and made available to regional customers.
Research & Development with Responsibility: Advancing Stack Technology
With around 160 employees with a mix of engineers, technicians, and PhD-level experts, the Hamburg site has a strong technical focus. In-house training programs support employee retention.
More than 70% of the staff in Hamburg work in research, development, and technical roles. In dedicated labs for electrochemical, chemical, and electrical analysis, the next generation of stacks is being developed: more powerful, more compact, and easier to integrate.
Key research areas include:
- Scaling to the next stack generation
- Material handling and robotics
- Digitalization and condition monitoring
- Development of recycling strategies
- Particular focus on recovering valuable raw materials
This interplay makes the Gigahub a technology driver, innovation lab, and production center. With a clear focus on growth, automation, and recyclability, it lays the foundation for a scalable and internationally competitive hydrogen economy.
Modern Infrastructure with a Sustainability Focus
The Gigahub includes modern production and logistics areas, specialized labs, cleanrooms, and a three-story office building. The hall space covers around 10,000 square meters, with about one-third dedicated to R&D, testing, and prototyping.
Sustainability is a core principle. The site has been awarded Gold status by the German Sustainable Building Council (DGNB) and aims to achieve the highest DGNB certification level, Platinum, in 2025. This is supported by features such as intelligent building automation, green roofs with a 2-MW photovoltaic system, heat recovery from testing, in-house hydrogen production, and charging stations for e-bikes and electric vehicles.
The site also promotes accessible workspaces designed for growth and long-term use, accommodating up to 430 employees, approximately 320 in office areas and 110 in production and labs under a single-shift operation, and the potential to be expanded into a multi-shift system over time.
Interface to Overall Production: Two Sites, One System
Although Hamburg operates independently in production, the finished electrolyzers are created in collaboration with the Augsburg facility. There, the stacks from Hamburg are delivered just-in-sequence, integrated into containers, and undergo final assembly and system testing. Coordination is managed centrally via order management: delivery times, packaging, transport specifications, temperature control, and testing are precisely and demand-driven between the sites.
The two facilities also closely coordinate on technical development, especially regarding installability, maintenance accessibility, and interface design. Regular workshops and exchange formats ensure that stacks and overall systems remain optimally aligned, including for the planned new stack generation.
Looking ahead to the international hydrogen market ramp-up, Schwarz feels well prepared:
“In the future, stacks will also be delivered directly to construction sites for large-scale plants to accomodate new requirements for transport, storage, and logistics. With flexible processes, high quality standards, and optimal collaboration between Augsburg and Hamburg, we are perfectly equipped for this.”
