60138 Dry Electrode Supercapacitor Production Line

Designed and delivered a dry electrode supercapacitor production line for industrial energy storage applications.

Project Details

TOBGROUP provided a turnkey dry electrode supercapacitor production line for a North American customer, covering process design, equipment manufacturing, material supply, and on-site commissioning to support stable, scalable industrial production of 60138 cylindrical supercapacitor cells.

Project Type

Battery Product Line

Origin

North America

Surface Area

3000-4000 m²

Date

2021

Project Overview

This project involved the design and implementation of a 60138 cylindrical supercapacitor production line based on dry electrode technology for a North American energy storage manufacturer. The customer aimed to transition from laboratory-scale validation to stable industrial production while maintaining tight control over electrode structure, process consistency, and product reliability.

TOBGROUP delivered a fully integrated solution, including factory layout planning, dry electrode process development, customized production equipment, auxiliary systems, and the complete supply of electrode materials and consumables. The production line was engineered to support continuous manufacturing while minimizing solvent usage, reducing environmental load, and improving electrode density uniformity.

Special emphasis was placed on process compatibility between dry electrode preparation, electrode lamination, cell assembly, and formation, ensuring consistent electrochemical performance across batches. TOBGROUP’s engineering team provided on-site installation, commissioning, and technical training, enabling the customer to achieve a smooth ramp-up from pilot production to stable output.

The project demonstrates TOBGROUP’s capability to translate emerging electrode technologies into reliable, industrial-grade manufacturing systems, supporting advanced energy storage applications such as grid stabilization, regenerative braking, and high-power backup systems.

Ⅰ. Clients Requirement

The customer’s key technical and operational requirements included:

Dry Electrode Process Integration	Eliminate solvent-based slurry coating Reduce drying energy consumption and environmental impact Maintain electrode mechanical integrity and adhesion
60138 Cylindrical Supercapacitor Compatibility	Stable electrode winding and alignment Precise control of electrode thickness and density High consistency in cell assembly
Scalable Production Capacity	Transition from pilot-scale validation to continuous industrial production Modular equipment design to support future capacity expansion
Process Stability and Yield Control	Minimize electrode defects during dry mixing and lamination Ensure repeatability across multiple production batches
Full Technical Support and Material Supply	One-stop sourcing for equipment, materials, and consumables On-site technical training for operators and process engineers

Ⅱ. TOBGROUP Solution

TOBGROUP developed a customized dry electrode supercapacitor production line manufacturing solution, addressing both current production needs and long-term scalability.

Key Solution Components:

Factory & Line Engineering	Formation & Aging Systems
Complete factory layout planning based on material flow and safety requirements Optimized zoning for dry electrode preparation, cell assembly, and testing	Supercapacitor-specific formation protocols Controlled aging and grading equipment
Dry Electrode Process Equipment	Material & Consumable Supply
Dry material mixing and fiberization systems Precision dry electrode forming and lamination units Controlled calendering systems for electrode density adjustment	Activated carbon, conductive additives, binders Current collectors, separators, electrolyte materials Process consumables and spare parts
Cell Assembly Line (60138 Format)	Commissioning & Training
Electrode slitting and winding systems designed for dry electrodes Automated can insertion, sealing, and electrolyte filling Inline inspection and quality monitoring systems	On-site installation and process validation Operator and engineering team training Ongoing technical support for process optimization

Ⅲ. Equipment & Materials List

It covers the entire production process of the 60138 dry electrode supercapacitor production line

Category	Equipment / Material
Dry Electrode Preparation	Dry Mixer, Fiberization Unit, Powder Feeding System
Electrode Forming	Dry Electrode Laminator, Calendering Machine
Electrode Processing	Slitting Machine, Electrode Winding Machine
Cell Assembly	Can Insertion System, Sealing Machine
Electrolyte System	Electrolyte Filling & Vacuum Impregnation Unit
Formation & Testing	Supercapacitor Formation System, Aging Cabinets
Quality Control	Thickness Gauge, Weight Inspection System
Materials	Activated Carbon, Conductive Additives, Binders
Consumables	Current Collectors, Separators, Process Accessories