TOBGROUP provides comprehensive pouch cell battery PACK production line solutions. Custom design, assembly, and testing services for various applications. Complete services from design to production with performance optimization.
TOBGROUP is dedicated to providing global customers with highly flexible, precise, and reliable high-volume pouch cell battery pack production line for applications including power batteries, energy storage systems, and consumer electronics. Leveraging in-house developed smart equipment and digital factory technologies, we deliver end-to-end mass production solutions from cell to Pack for various battery systems—liquid, solid-state, sodium-ion, and more—helping customers achieve cost reduction, efficiency improvement, and zero-defect delivery.
● Production Scale: 50,000 – 200,000 PACKs/month (supports phased capacity expansion)
● Cell Compatibility: Pouch cells (thickness: 3–20 mm, length: 80–350 mm, width: 60–200 mm)
● Core Processes Covered:
Intelligent Cell Sorting → Automated Cleaning & Plasma Treatment → Laser Cutting & Bending → Multi-Station Automatic Stacking → Laser Welding (Galvo/Fiber) for Busbars → Online Vision Inspection → BMS Integration & FPC Welding → Module Assembly & Fastening → Leak Testing → Charge-Discharge Testing → Thermal Management Integration → EOL Integrated Testing → Full-Process MES Traceability
TOBGROUP Pouch Cell Battery PACK Production Line Standard Configuration with Full Customization Support
|
Parameter Item |
Standard Specification / Range |
Customization Options |
|
Standard Capacity |
100,000 PACKs/month |
50K – 200K PACKs/month (scalable) |
|
Compatible Cell Dimensions |
L120–250mm, W70–150mm |
L80–350mm, W60–200mm (custom shapes supported) |
|
Automation Rate |
≥ 95% |
Manual stations configurable as needed |
|
Welding Yield |
≥ 99.8% (Al/Cu busbars) |
Supports ultrasonic/laser welding, riveting |
|
MES Data Trace Points |
500+ |
Extendable to 1500+ (material batch/equipment parameters) |
|
Changeover Time |
≤ 15 minutes |
Quick-change fixtures + automatic recipe recall |
|
Energy Consumption Density |
≤ 0.8 kWh/PACK |
Optimized via energy management system |
|
Delivery Lead Time |
26–40 weeks |
18–52 weeks (depending on customization) |
TOBGROUP Pouch Cell Battery PACK Production Line: A Benchmark in Smart Manufacturing & Zero-Defect Management
● Full-Automation Integration:
(1) Utilizes robotic cluster scheduling systems (AGVs + 6-Axis Robots + Collaborative Robots) to enable automated material handling, precise grasping, and flexible assembly.
(2) Automation rate ≥ 95% for key processes (welding, stacking, inspection), reducing labor costs by 60%.
● AI-Driven Quality Assurance:
(1) Five-layer quality inspection: 3D vision dimensional inspection + online weld penetration monitoring + infrared thermal imaging temperature control + X-ray internal defect screening + EOL big data performance analysis.
(2) 100% real-time defect interception, process CPK ≥ 1.67.
● High-Flexibility Mixed Production:
Modular design supports production of multiple Pack types (long blade, prismatic, custom-shaped) on the same line, with changeover time ≤ 15 minutes.
● Full Lifecycle Cost Control:
(1) 30% reduction in energy consumption (smart start-stop + IE4 high-efficiency motors).
(2) 50% extended lifespan for key components (ceramic welding protection, wear-resistant guide rails).
(3) Smart consumable early warning system reduces downtime losses.
● Industry 4.0 Data Closed Loop:
(1) MES + SCADA systems collect 2,000+ parameters in real time for material traceability, equipment OEE analysis, and quality root cause investigation.
(2) Seamless integration with customer ERP/WMS for a transparent digital factory.
From Planning to Production: TOB Full Support
|
Phase |
Core Service Content |
|
Needs Analysis |
Analyze product specs (energy density/cycle life/IP rating), capacity goals, facility conditions, investment budget |
|
Pouch Cell Battery PACK Production Line Design |
Provide process flow diagrams, 3D equipment layout models, logistics simulation, smart warehouse solutions, energy efficiency reports |
|
Custom Equipment Supply |
Deliver core equipment: automatic sorting machines, laser welding stations, robotic stacking stations, EOL testers, MES systems, etc. |
|
Smart Factory Integration |
On-site installation by TOB engineers, multi-system commissioning, process parameter finalization, trial production yield validation |
|
Technology Transfer |
Operator training (equipment/MES/maintenance), process documentation (PFMEA/CP/SOP), quality control system setup |
|
Continuous Optimization |
Remote maintenance support, spare parts supply, ramp-up guidance, technology upgrade solutions |
Core enablers of technological implementation
Actionable insights from planning to execution
Modular equipment + quick-change fixtures, with product recipes pre-set in MES. Digital twin ensures first-pass yield ≥ 99% after changeover.
Three safeguards: adaptive welding parameter compensation, real-time penetration/plasma monitoring, and AI vision 100% inspection.
Preventive maintenance, uninterrupted AGV material supply, parallel workstations with buffers, and remote diagnostics (AR-assisted repair).
Yes! Inert atmosphere glove box integration, solid electrolyte interface treatment, low-temp welding, and stress-free stacking for sulfide/oxide systems.
3D vision positioning + flexible suction cups with force-controlled robotic adaptive correction. Positioning accuracy ±0.1 mm.
TOBGROUP delivered a 3000F 60138 supercapacitor pilot line with full equipment, materials, and on-site commissioning support.
TOBGROUP designed a Na-ion battery lab line producing 18650S, 32138S, 32140S cells for advanced research and development.
TOBGROUP delivered a full-cycle 5MWh pouch cell production line for Li-ion and Na-ion, enabling European energy storage production.
