Project Overview
TOBGROUP designed and delivered a 3000F 60138 supercapacitor pilot line for an Indian energy technology company focusing on high-capacity energy storage devices. The project targeted the manufacturing of cylindrical supercapacitors with a nominal capacity of 3000F, while retaining flexibility for other capacitance and capacity configurations. The 60138 supercapacitor pilot line was engineered to support multiple cylindrical formats, including 4680, 38130, 60130, 60138, 66160, and 80180, enabling broad experimental validation and pre-commercial development.
The 60138 supercapacitor pilot line adopts a winding-based manufacturing process optimized for full-tab electrode structures. This design significantly reduces internal resistance (IR), improves power density, and extends cycle life—critical performance metrics for supercapacitors used in regenerative braking, grid buffering, and industrial power stabilization. The production workflow covers electrode preparation, winding, cell assembly, electrolyte filling, sealing, aging, and electrical performance testing, ensuring complete process continuity from raw materials to finished cells.
TOBGROUP provided not only the full set of production and testing equipment, but also the complete material system required for supercapacitor manufacturing, including activated carbon-based electrodes and compatible hybrid materials such as LFP, NCM, NCA, and LCO for research and comparative evaluation. All equipment was configured with modular layouts, allowing the client to scale production capacity from tens of units per day to pilot volumes of up to 2000 cells per day.
During project execution, TOBGROUP dispatched experienced engineers to the customer’s facility for installation, commissioning, and process optimization. On-site support continued until the production line reached stable operation and consistent output. Following handover, TOBGROUP established a long-term after-sales service framework, including remote diagnostics, spare parts supply, and process support, ensuring reliable and continuous operation of the 60138 supercapacitor pilot line. This project demonstrates TOBGROUP’s capability to deliver technically complex energy storage pilot lines with strong engineering depth and long-term operational reliability.
Ⅰ. Clients Requirement
The client required a flexible 60138 supercapacitor pilot line capable of producing high-capacitance cylindrical cells with low internal resistance and long cycle life. Key requirements included support for full-tab structures, multiple materials and formats, scalable daily output, and strong on-site engineering support to ensure stable commissioning and long-term operation.
| Parameter Category | Specific Requirements |
| Battery Type | Full-tab structure to reduce internal resistance and improve cycle life |
| Battery Materials | Activated Carbon, LFP, NCM, NCA, LCO |
| Cell Formats | 4680, 38130, 60130, 60138, 66160, 80180 |
| Design Capacity | 1000F, 2000F, 3000F, 6000F |
| Nominal Capacity | 6Ah, 10Ah, 26Ah, 60Ah |
| Main Process | Winding process |
| Daily Production Capacity | 10–2000 cells/day |
| Facility Area | 100–10,000 m² depending on daily output |
Ⅱ. TOBGROUP Solution
TOBGROUP delivered a turnkey supercapacitor pilot solution integrating equipment, materials, commissioning, and after-sales service. The line was designed for full-tab structures, multi-format compatibility, and scalable output. On-site engineers ensured stable operation, while modular design and long-term service support guaranteed production continuity and future expansion capability.
| Solution Area | Implementation Details |
| Pilot Line Design | Modular production layout supporting multiple cylindrical formats and scalable output |
| Core Process | Winding-based process optimized for full-tab electrode structures to minimize IR |
| Material System | Full supply of activated carbon and hybrid electrode materials for performance comparison |
| Equipment Supply | Complete set of supercapacitor production and testing equipment |
| On-site Commissioning | TOBGROUP engineers dispatched for installation, tuning, and stable ramp-up |
| After-sales Support | Remote diagnostics, spare parts, process optimization, and long-term technical service |
Ⅲ. Equipment & Materials List
The pilot line integrates precision equipment covering electrode preparation, winding, assembly, filling, sealing, aging, and testing. All systems are selected for reliability, flexibility, and compatibility with high-capacitance supercapacitor structures. The equipment supports both activated carbon and hybrid material systems, ensuring consistent performance validation and stable pilot production.
| Process Stage | Equipment | Key Function |
| Electrode Preparation | Slurry mixing and coating system | Uniform electrode formation |
| Electrode Processing | Calendering and slitting machines | Thickness and dimension control |
| Cell Assembly | High-precision winding machine | Full-tab structure winding |
| Assembly Line | Cell casing and assembly system | Mechanical integration |
| Electrolyte Filling | Automated filling equipment | Accurate electrolyte dosing |
| Sealing | Cell sealing machine | Hermetic sealing |
| Aging & Testing | Electrical testing systems | Capacitance, IR, and cycle testing |
| Quality Control | Sorting and inspection equipment | Performance consistency |
