Project Overview
TOBGROUP designed, manufactured, and commissioned a 5MWh Pouch Cell Production Line for a European energy technology company. The project addressed the client’s strategic goal of entering the European energy storage market with a production facility capable of handling multiple chemistries, formats, and production scales. The turnkey solution included modular plant planning, custom-engineered equipment, process integration, and training for local operators, ensuring the client achieved rapid ramp-up and independent operation.
The 5MWh Pouch Cell Production Line is designed to support both conventional lithium-ion chemistries and emerging sodium-ion systems, with pre-installed interfaces for potential solid-state electrode adoption. Advanced automation covers the entire process chain, including precision slurry mixing, dual-side electrode coating, high-speed stacking, electrolyte filling under low-dew-point conditions, formation, and automated PACK assembly. Each process stage incorporates in-line monitoring and quality control systems to ensure consistent performance and safety.
The plant incorporates modular steel-structure construction with frost-proof foundations and explosion-proof zones, enabling operation in sub-zero ambient conditions while maintaining high reliability. The dry room is controlled at a dew point of -45°C, and the entire facility is designed for zero-incident commissioning. The line’s flexible configuration supports over ten different cell formats and small-batch production, enabling the client to adapt to changing market demand while maintaining a comprehensive yield of 98%.
TOBGROUP engineers also implemented VR-based training modules and a three-month on-site practical training program for the client’s technical team. This ensures that local staff can independently manage production, troubleshoot equipment, and maintain optimal process conditions. Future-proofing measures, including interfaces for next-generation chemistries and modular equipment upgrades, provide a clear path for technology evolution without major downtime. This facility has become a benchmark in European energy storage manufacturing for its combination of flexibility, safety, and high-quality output.
Ⅰ. Clients Requirement
The client required a highly flexible, multi-chemistry 5MWh pouch cell production line capable of rapid deployment in European conditions. Key priorities included strict energy density and capacity targets, precise cell dimensions, adaptability for both Li-ion and Na-ion chemistries, environmental resilience, high yield, and local team operational independence. Safety and compliance were also critical.
| Requirement Category | Specific Requirements |
| Project Name | 5MWh Pouch Cell Production Line |
| Battery Types | Li-ion pouch, Na-ion pouch |
| Cell Size | Custom (max 300×200×12 mm) |
| Nominal Capacity | 10–50Ah ±5% (expandable 5–100Ah) |
| Energy Density | Li-ion: 200–360Wh/kg, Na-ion: 130–250Wh/kg |
| Material Systems | Li-ion: NMC cathode + Si-C anode, Na-ion: Na+ hard carbon |
| Key Process Steps | Slurry mixing → dual-side coating → high-speed stacking → electrolyte filling & formation → PACK assembly |
| Annual Production Capacity | 5MWh (~100,000 cells) |
| Environmental Requirements | Dry room at -45°C dew point, equipment operational at -30°C |
| Production Flexibility | Support >10 cell formats, rapid small-batch changeover |
| Local Operation | Train local staff for independent production and maintenance |
Ⅱ. TOBGROUP Solution
TOBGROUP provided a full turnkey 5MWh pouch cell production line solution tailored to the client’s needs, integrating modular plant design, advanced automation, and pre-configured future-proof technology. Localized training, VR-assisted operational simulations, and robust safety systems ensured high-yield production, operational independence, and compliance with European standards while maintaining flexibility for multiple chemistries and cell formats.
| Solution Area | TOBGROUP Implementation |
| Turnkey Plant | • Modular steel-structure plant design with frost-proof foundations & explosion-proof zones, shortening construction by 40%
• Customized cold-resistant coating machine (±1 μm precision, 70–550 mm width, 10 substrate types) • High-speed stacking machine (0.3 s/piece) • Dry electrode pilot section reducing solvent usage by 30% |
| Core Technology | • TOB BMS with online diagnostics and thermal runaway early warning
• Solid-state electrode interface pre-installed for future upgrades |
| Local Support | • On-site engineering team for 3-month practical training, 2 months production ramp-up support
• VR-based operational simulation, reducing fault response time to 15 minutes |
Ⅲ. Equipment & Materials List
The 5MWh pouch cell production line incorporates precision-engineered equipment across all stages, from electrode preparation to PACK assembly. Each system is selected for accuracy, reliability, and adaptability to multiple chemistries. Equipment includes advanced slurry mixers, dual-side coating machines, high-speed stacking, laser welding, X-ray monitoring, low-dew-point filling, and flexible PACK lines to ensure consistent high-quality output and operational safety.
| Process Stage | Equipment | Key Technical Highlights |
| Electrode Manufacturing | Twin-screw slurry mixer | Vacuum degassing ≥99.5% efficiency |
| Dual-side extrusion coating machine | Substrate tension fluctuation ≤0.5% | |
| Cell Assembly | High-speed multi-station stacking machine | Yield ≥99.2% |
| Laser welding integrated unit | Welding strength ≥150 N/mm² | |
| X-ray alignment monitor | Ensures precise electrode alignment | |
| Electrolyte Filling & Formation | Low-dew-point filling system (-45°C) | Dew point controlled ≤-45°C |
| High-precision capacity grading system | Voltage detection accuracy ±0.5 mV | |
| PACK Assembly | Modular automated PACK line | Flexible 1P10S~4P20S configurations |
