TOBGROUP helps speed up the move of battery technology from labs to real-world use by offering a high-quality pouch cell pilot line solution setup. Our pouch cell pilot line adopts the concept of “Modular Design, Mass Production Alignment.” While ensuring process stability and data reliability, it also incorporates necessary flexibility to help customers efficiently complete technology transfer and significantly reduce mass production risks.
TOBGROUP helps speed up the move of battery technology from labs to real-world use by offering a high-quality pouch cell pilot line solution setup. We work on process scale-up checks, small-batch steady output, gathering mass production details, and market entry samples. Acting as a trusted industrial link for advanced systems like liquid lithium-ion batteries, solid-state batteries, sodium-ion batteries, lithium-sulfur batteries, and others.
Our pouch cell pilot line solution follows the concept of Modular Design Mass Production Alignment. While taking care of process stability and data reliability it also involves the required flexibility to assist customers in completing technology transfer efficiently and reducing mass production risk dramatically.
● Pouch Cell Pilot Line Capacity: 500 - 3000 cells/day (Supports phased expansion to meet verification needs at different scales)
● Specification Compatibility: Thickness 3mm - 12mm, wide range of length and width (Typical examples: 70x100mm, 100x150mm, 120x180mm, etc., customizable)
● Focused Systems: Process scale-up for liquid lithium-ion (LFP, NCM, High-Nickel, etc.), solid/semi-solid-state batteries, sodium-ion batteries, lithium-sulfur batteries, and other new systems.
● Core Process Coverage: Continuous slurry preparation (including high-viscosity/dry process), continuous/precision coating, high-precision calendering, high-speed die-cutting, automatic stacking/winding, high-reliability sealing, precision liquid injection/solid electrolyte integration, advanced formation, capacity grading and sorting, comprehensive testing, and data traceability.
Standard configuration parameters of pouch cell pilot line, supporting deep customization.
|
Parameter Item |
Standard Configuration/Range |
Customization Range Description |
|
Standard Capacity |
1000 cells/day |
500 - 3000 cells/day (Depending on configuration & process) |
|
Supported Cell Thickness |
4mm - 10mm |
3mm - 12mm |
|
Supported Cell Size (LxW) |
100x150mm |
Flexible customization (e.g., 70x100mm, 120x180mm) |
|
Typical Floor Area |
~ 150 - 300 m² (Including environment) |
Optimized based on configuration, scale & plant conditions |
|
Supported Core Systems |
Liquid Li-ion (LFP, NCM), Na-ion |
Solid/Semi-solid-state, Li-S, Dry/Mixed-process Electrodes |
|
Key Process Modules |
Continuous Slurry, Coating, Calendering, Die-cutting, Automatic Stacking, Sealing, Injection/Integration, Formation, Grading, Testing, MES |
Modules can be added/removed/strengthened as needed (e.g., continuous dry process, prelithiation, special post-processing) |
|
Automation Level |
High automation for key processes (Coating, Calendering, Stacking, Sealing, Testing), semi-automatic for some steps |
Can be upgraded to higher automation (e.g., AGV logistics, fully automatic sorting) |
|
Data Acquisition Points (MES) |
200+ (Core parameters & test data throughout the process) |
Expandable to 500+ |
|
Environmental Control |
Dry Room (≤ 20% RH), Local ISO Class 7 (10,000-class) |
Customized based on system (e.g., inert atmosphere glovebox/room) |
|
Typical Delivery Time |
20 - 30 weeks |
16 - 36 weeks (Depending on customization level & scale) |
TOB GROUP Pouch Cell Pilot Line: Bridging the Critical Gap Between R&D and Mass Production
● Mass production-oriented modular design: Process units (such as continuous coating and calendering, and automatic stacking, sealing, testing) adopt the modular design approach which is very close to that of the specifications under mass production scenarios supporting flexible combination and also supporting phased construction. While ensuring stable operation it offers provision for moderate adjustment in certain key process windows (like formulation, parameters, dimensions) effectively verifying process robustness.
● Platform for͏ Scaling Cutting-Edge Technologies: Goes into and optimizes advanced processes fit for pilot scale: solid electrolyte large-scale processing (powder pressing/film integration), continuous dry/mixed-process electrode making, prelithiation process checking, high-consistency sealing (high vacuum, high temperature/pressure control), special formation regimes, and more. This gives strong support to the indust͏ri͏alization of next-generation battery technologies.
● A full Manufacturing Execution System (MES) comes standard with real-time monitoring, recording, and subsequent analysis of all key parameters during the whole process (viscosity, solid content, areal density, thickness, tension, temperature, pressure, vacuum level, voltage/current curves). This enables even traceability of the process on a very detailed level and analytical correlation between performance and process capability evaluation-CPK-in standardized reporting that accelerates mass production parameter locking.
● Core equipment selection, process parameter design, and control logic of the pouch cell pilot line highly align with mass production standards. Key parameters verified that can be extrapolated to the mass production lines are calendering density, coating speed & accuracy, injection/integration precision, sealing yield, and formation efficiency. This delivers a very high probability of significantly shortening the mass production ramp-up cycle which reduces investment risk.
● High Reliability and Stability: Equipment shall adopt the industrial grade standard which focuses more on the durability of continuous operation, i.e., OEE ≥ 85%. Stable and reliable pouch cell pilot line production data shall be ensured and provide a strong basis for mass production decisions.
From Concept to Consistent Production, TOB Accompanies the Whole Tech Transfer Process
● Deep Dive Requirements Discussion: Extensive discussion of the technology roadmap (liquid/solid/sodium-ion, etc.), target product performance, challenges during process scale-up, expected capacity, yield targets as well as budget planning.
● Tailored Line Design: Offers general pouch cell pilot line process flow design based on mass production experience detailed equipment layout diagrams (including logistics, environmental control), 3D plant planning as well as supporting (power, drying/cleanliness, exhaust) solutions.
● Selection and Supply of Main Equipment: Such as continuous mixer, double-side coater, calender, automatic stacking machine, high-speed die cutter, vacuum sealer, electrolyte filling system, formation & grading machine which shall be of pilot requirements based on precise selection modification and supply thereof.
● Professional Integration & Commissioning: TOB will bring on site its senior engineering team to carry out the installation of all equipment, set up the line integration, linkage commissioning, process parameter initial setting and multi-batch sample trial production verification which makes sure that the line attains its design performance target (capacity and yield as well as stability).
● Process Handover & Training: Step-by-step training on equipment operation and maintenance as well as process optimization & adjustment, quality control, safety measures, and usage of the MES system which will empower the technical team of the customer to own pouch cell pilot line operation abilities.
● Continual Process Support: Process optimization recommendation provision as well as mass production transition consulting support with any necessary onsite support needed for client success.
Core enablers of technological implementation
Actionable insights from planning to execution
● Pouch Cell Lab Line: Core goals are material screening, formulation optimization, basic process exploration, and small sample preparation. Small capacity (<200 cells/day), extreme emphasis on flexibility and equipment modularity, low automation (mainly manual/semi-automatic), lower investment. Suitable for early-stage R&D.
● Pouch Cell Pilot Line: Core goals are process scale-up verification, small-batch stable production, locking mass production parameters, and collecting sample market feedback. Medium capacity (500-5000 cells/day), balances stability, reliability, and moderate flexibility, achieves high automation in key processes, equipment specifications close to mass production, complete data system (MES). Essential for technology transfer.
● Pouch Cell Production Line: Core goals are large-scale, high-efficiency, low-cost, stable, and consistent production. Large capacity (tens of thousands+ cells/day), high emphasis on stability, efficiency (OEE), and cost, highly automated and continuous full process, highly integrated and dedicated equipment, massive investment.
● Equipment selection near mass production: The core process equipment, e.g., coater, calender, stacker, and sealer, uses pilot models with the same principle and technical route of the major mass production equipment to ensure mechanism consistency.
● Control logic as that of mass production: Equipment control system (PLC/SCADA) and the strategy for monitoring process parameter control (e.g., PID control, closed loop feedback) adopt standards for mass production.
● Depth, and Breadth of Data: Collects full-process high-density process data through the MES system and conducts rigorous Statistical Process Control SPC, and CPK analyses thereby ensuring that the parameter windows verified have mass production feasibility.
● Infusion of Process Know-How: Mass production experience is what the TOB team has; this experience introduces mass production thinking and best practice into pilot line design, commissioning, and process setting.
Space:
● Basic setup (covering main processes & MES) needs more than 150 - 300 square meters (not counting offices and storage). Think about how the equipment will be placed, how materials move, access for upkeep, and room for growth later on.
Environment:
● Very Low Humidity: Main sections (for making electrodes, putting parts together, and before adding liquid) need a dry area with less than 20% moisture in the air (dew point less than -30°C).
● Cleanliness: It is recommended to attain ISO Class 7 (10,000-class) or better cleanliness for the key areas of electrode coating, stacking, and sealing.
● Special Atmosphere: For sodium-ion batteries or for some kinds of solid-state batteries (sulfide-based), this means that certain processes must run inside an inert atmosphere glovebox or room (e.g., Argon).
● Infrastructure: Stable and sufficient power supply (considering equipment peak power), compressed air, cooling water (required for some equipment), exhaust systems (solvents, dust), fire protection facilities.
● Core Process Package Delivery: Provides basic process steps (SOP) and starting parameter frames according to the target system such as liquid LFP/NCM, Na-ion, some solid-state paths.
● In-Depth Commissioning & Optimization Support. TOB engineering group directs in machine start and parameter set leads several runs of sample trial making and process tuning so that the line can reach the signed capacity, yield, and stability aims.
● Mass Production Transition Consulting: Based on pilot verification data, this includes providing mass production line planning and equipment selection advice together with key parameter transition plans.
● Long-Term Collaboration & Support: Optional technical support agreement that may include continuous process optimization as well as troubleshooting support, maintenance guidance, and personnel re-training, among others.
● Material Assurance: TOB supplies various cathode/anode materials and electrolyte/solid electrolyte precursors, separators, aluminum laminate film auxiliary materials, etc. required for pilot scale so as to assure production continuity.
● Time: Normally takes between 6 and 12 months after the signing of the contract to reach stable operation, depending on customization degree of equipment, complexity of the equipment, readiness of the plant, and commissioning depth.
● Cost: Pouch cell pilot line investment is much greater than lab line— typically several million to tens of millions of RMB — determined by such factors as target capacity and automation level, complexity of supported battery systems (solid-state demands are higher), and choices of equipment brand and configuration.
● Standards in the construction of environmental control (dry room, clean room, inert atmosphere). Depth of software system (MES). Scope of process support and commissioning services.
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.
