TOBGROUP provides complete supercapacitor production line for mass manufacturing. We deliver custom production lines with comprehensive support services. End-to-end solutions from factory design to employee training.
TOBGROUP is dedicated to providing global clients with large-scale mass supercapacitor production line solutions for high-performance supercapacitors (electric double-layer capacitors/pseudocapacitors). Targeting applications such as power-type energy storage, start-stop systems, and regenerative energy recovery, we integrate materials science, precision manufacturing, and digital control technologies to establish a high-efficiency, low internal resistance, and long-life mass production system. This system accommodates various structures including wound, coin, and large industrial modules.
Core Value:
● Full-stack technology coverage: from active carbon/graphene material processing to high-consistency electrode preparation and ultra-low internal resistance assembly processes.
● Mass production-level reliability: Industrial 4.0 standard equipment supporting 7×24 hours continuous operation.
● Precise cost control: optimized material utilization, energy consumption management, and automation-driven cost reduction.
● Production scale: 100,000 – 1,000,000 units/year (supports phased expansion)
● Product compatibility:
(1) Voltage range: 2.5V – 3.8V
(2) Capacity range: 100F – 10,000F
(3) Structural types: cylindrical, prismatic, coin, large industrial modules
● Core process chain:
Active carbon nanonization → highly conductive slurry preparation → ultra-thin current collector coating → multi-stage precision rolling → high-speed winding/stacking → laser welding and sealing → ultra-low moisture electrolyte filling → formation and aging → full-channel sorting and testing → automated module integration
TOBGROUP Supercapacitor Production Line Standard Configuration with Full Customization Support
|
Parameter |
Standard Configuration |
Customizable Options |
|
Annual Capacity |
500,000 units (3000F cylindrical) |
100,000 – 1,000,000 units |
|
Product ESR |
≤ 3mΩ (3000F @25°C) |
≤ 0.5mΩ (high-power type) |
|
Electrolyte Filling Accuracy |
±0.5% |
±0.2% (precision servo system) |
|
Key Equipment OEE |
≥ 88% |
≥ 92% (with predictive maintenance) |
|
MES Data Collection Points |
500+ |
1000+ (including high-speed electrochemical data) |
|
Environmental Control |
Class 10,000 (local Class 1,000) |
Full workshop Class 1,000 |
|
Typical Delivery Period |
32 weeks |
24–48 weeks (scalable based on project size) |
TOB Supercapacitor Production Line: Industrial Assurance of Power Density and Lifespan
● Ultra-low ESR design architecture:
(1) Nano-level active carbon surface modification technology enhances ion adsorption efficiency.
(2) Proprietary current collector treatment process (micro-etching + conductive coating) reduces interface impedance by 30%.
(3) Fully automated laser welding system ensures terminal contact resistance ≤ 0.1mΩ.
● High-precision closed-loop manufacturing control:
(1) Coating areal density fluctuation ≤ ±1.5% (real-time feedback via online β-ray detection).
(2) Winding alignment accuracy ±0.1mm (machine vision-guided).
(3) Moisture content control ≤ 10ppm (dual-stage molecular sieve + dew point monitoring).
● Digital twin production system:
(1) Integrated MES + SCADA systems for real-time monitoring of ESR, capacity, leakage current, and other core parameters.
(2) AI process optimization engine dynamically adjusts key variables such as electrolyte filling volume and formation time.
(3) Full lifecycle data traceability (individual product traced back to raw material batch).
● Green manufacturing technology:
(1) Solvent recovery rate ≥ 95% (integrated condensation + adsorption system).
(2) Modular design supports future upgrades (e.g., rapid switching to graphene electrodes).
TOB’s Four Major Delivery Assurance Systems
|
Phase |
Core Deliverables |
|
Joint Process Design |
Analyze customer target product (power/energy density, lifespan requirements), material selection, process route, and cost model. |
|
Turnkey Production Line |
Provide plant planning, equipment selection (including agency services for imported core equipment), and environmental control systems (Class 1000 cleanroom). |
|
Smart Factory Integration |
Deploy equipment interconnection (OPC UA protocol), customized MES system, quality alert dashboards, and energy management systems. |
|
Continuous Value Operation |
Process auditing, spare parts supply, remote diagnostics, and technical upgrades (e.g., dry electrode process implementation). |
Core enablers of technological implementation
Actionable insights from planning to execution
● Process differences:
(1) No need for graphite/silicon anode processing.
(2) Electrolyte is organic quaternary salt (non-lithium salt), requiring higher filling accuracy.
(3) Formation time shortened to 2–4 hours (no SEI film formation required).
● Equipment differences:
(1) Coaters must handle high solid content (≥ 60%) slurries.
(2) Welding equipment must meet high-current terminal requirements (Cu-Al dissimilar metal welding).
Through four-level control:
● Raw material pretreatment (active carbon pore size distribution screening).
● Coating drying gradient temperature control (prevents cracking).
● Fully automated visual inspection (electrode defect detection, winding misalignment).
● Post-filling vacuum secondary sealing (prevents electrolyte leakage).
● Power: peak load ≥ 800kW (including refrigeration units).
● Dry room: electrode workshop ≤ 30% RH, assembly workshop ≤ 15% RH.
● Floor load-bearing: ≥ 5T/m² (rolling mill area).
● Environmental protection: organic solvent recovery system (NMP/DMF).
Available supplies:
● High surface area active carbon (2000–3500 m²/g).
● Ketjen black conductive agent.
● Quaternary salt electrolyte (3.0V withstand voltage grade).
● Modified aluminum foil current collector (anti-corrosion coating).
● Electrode design: add carbon nanotubes to improve lateral thermal conductivity.
● Structural design: built-in aluminum cooling fins.
● Formation process: multi-stage gradual current activation.
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.
