Industry solution
Battery pack and energy-storage manufacturing lines
ZeroLine plans and delivers production lines for lithium-ion energy-storage modules and PACKs, from incoming cell sorting to end-of-line testing, built by partner factories in Wuhan and run before they ship. Our reference is the Stratavolt 8 PPM prismatic line: 21 stations, about 2.46 GWh a year with 314 Ah cells. Busbar laser welding comes from Maxwave Laser.
- Reference line takt, counted in cells
- 8 PPM
- A year with 314 Ah cells, 20 h × 300 days, 85% OEE
- ≈ 2.46 GWh
- Prismatic cells the reference line is designed around
- 314–587 Ah
- Starting price of the reference line
- RMB 2 m+
Scope
What a line includes
-
Power
Cell incoming and sorting
- Depalletizing and code reading
- OCV and internal-resistance testing
- Grading and sorting
- Cell surface cleaning and insulation
-
Power
Module stacking and welding
- Gluing and stacking
- Compression and strapping
- Busbar laser welding
- Weld inspection by vision
-
Power
PACK assembly
- Module placement into the pack
- Harness, BMS and high-voltage parts
- Liquid-cooling plates and thermal pads
- Screw-driving and lid closing
-
Power
Test and traceability
- Module and PACK end-of-line test
- Insulation and hi-pot
- Air-tightness test
- MES with per-cell traceability
-
Make
Lasers for the line
- Fiber lasers for busbar and terminal welding
- Laser cleaning before welding and gluing
- Laser marking of cell and pack codes
-
ZeroLine
Plant and utilities
- Layout for your building
- Compressed air, power and extraction lists
- Conveyors and logistics
- Operator training plan
How it runs
How a line project runs
- 01
Cell and target
You share the cell datasheet, module and PACK drawings, and the GWh you need.
Week 1
- 02
Line concept and price
Takt, station list, layout for your building, staffing and a priced proposal.
Weeks 2–4
- 03
Design and build
Detailed design, fixtures for your cell, build at the partner factories in Wuhan.
Typically 3–5 months
- 04
Acceptance in Wuhan
The line runs your cells before it is crated. You watch the acceptance test live or on video.
1–2 weeks
- 05
Install and ramp up
Our engineers install, commission and train your team on site, then stay through ramp-up.
Typically 6–10 weeks
Projects
Typical projects
The scope, scale and schedule of projects like this. Ask us for references in your country.
- Typical scope
8 PPM energy-storage module and PACK line
A fully specified prismatic line for a storage integrator moving PACK assembly into its own market.
- Output
- ≈ 2.46 GWh a year (314 Ah)
- Stations
- 21 in three segments
- Footprint
- 55 × 9 × 3.5 m
- Schedule
- ≈ 5–7 months to production
- Cell test and sorting
- Stacking and busbar laser welding
- PACK assembly
- EOL and air-tightness test
- MES
- Installation and ramp-up
Typical markets · Gulf states, India, Southeast Asia
- Typical scope
Semi-automatic PACK line for C&I storage
A smaller line with manual and semi-automatic stations, for commercial and industrial storage cabinets at lower volume.
- Output
- ≈ 0.2–0.5 GWh a year
- Stations
- ≈ 10–14
- Staff
- ≈ 12–20 per shift
- Schedule
- ≈ 3–5 months to production
- Cell sorting
- Manual stacking with fixtures
- Laser welding station
- PACK assembly
- EOL test
- Operator training
Typical markets · Africa, Latin America, Central Asia
Services
Services that come with it
- Factory acceptance and inspection Nothing ships before it has run. You watch the test, then you pay.
- Installation and training Engineers on your site until it runs at rate, and a team that can run it after.
- Spare parts and support Spare parts, video support, service partners and upgrades for the life of the equipment.
- Payment terms and trade finance Letters of credit, payment after acceptance, and insured deferred terms.
FAQ
Questions buyers ask
How much does a battery PACK assembly line cost?
The Stratavolt 8 PPM prismatic ESS line starts at RMB 2 million and the price depends on line specification, configuration and quantity. Semi-automatic lines for lower output cost less. Send your cell datasheet and target capacity for a matched configuration and a firm quote.
How much can one line produce a year?
Annual GWh = takt in cells per minute × 60 × hours per day × days per year × OEE × cell energy. At 8 PPM with 314 Ah cells, 20 hours a day, 300 days and 85% OEE, that is about 2.46 GWh; with 587 Ah cells at the same takt, about 4.6 GWh.
Can the line take larger cells later?
The reference line is designed around 314 Ah prismatic cells with 587 Ah in mind. Moving to a new cell format usually means new fixtures and grippers rather than a new line. We check this at the concept stage.
Do you build lines for cylindrical or pouch cells?
Yes, through partner factories that specialise in them, for e-mobility, telecom backup and small storage packs. Share the cell and pack drawings and we propose the station list and takt.
Can you supply the cells and BMS as well?
We can source cells, BMS, harnesses and enclosures from partner factories and qualify samples on your line before volume orders. Many customers keep their own cell supplier; the line is built for the cell you choose.
Start a project
Plan your pack line
An empty plant, a part, a network or a product idea. Tell us where you are starting. An engineer replies with a plan and a quote.
- Emailsales@zerolineai.com
- WhatsApp+44 7762 362563
- OfficeWuhan, Hubei, China