About BatteryLine Pro
Battery Assembly Line Manufacturer for Module and Pack Plants
One part of the battery industry: the plant floor between a pallet of finished cells and a tested pack on its way out. The layout is drawn to your building, most of the machines standing on it are designed and built in our own hall, and the line is signed off station by station against criteria written before anything ships.
LedgerSince 2016
Company ledger
- Assembly equipment since
- 2016
- Turnkey lines since
- 2019
- Engineers
- 26
- Assembly hall
- 6,000 m²
- Full-line pre-assembly bays
- 3
- Line segments delivered
- 40+
- Countries shipped to
- 12
Every figure on this page is attached to a way of measuring it, agreed before the line runs.
What this company is
The Company Behind the Lines
Module and pack assembly lines for plants that receive finished cells and ship tested packs. Three tiers run at 4 to 8, 8, and 12 to 15 PPM, each laid out against the building it will stand in rather than against a standard drawing.
Nine of the workstations on those lines are our own designs, drawn, built and powered up in our own hall before they ship. That one fact is behind most of what we can do and a reseller cannot: a layout redrawn to your column grid, an envelope checked against your cell the same day, and acceptance criteria written by the engineers who set the machine parameters.
Where we sit
Our Place in the Battery Chain
Equipment since 2016, complete turnkey lines since 2019. Those two dates matter more than a founding year: the first years were single machines dropped into other people’s lines, which is where the station-level parameters came from, and the turnkey work since taught us to hold a takt across 32 stations rather than at one.
Cell manufacturing
Mixing through to formation is a different class of equipment in a different building. Cells arrive here finished, on a tray, with a code on them.
Module and pack assembly
Thirty-two stations between the incoming tray and line-off. Layout, machines, commissioning and the acceptance set all come from one engineering team.
Your own customer
The integrator or vehicle maker who receives the pack and asks for its test record. What they ask for is what the end-of-line gate has to produce.
What has shipped
Delivered Record and Three Ways to Buy
Segments rather than lines is the honest unit, because much of the work is one part of an existing plant: a module segment holding back a pack segment that was already sized correctly. Three ways to buy come out of the same catalogue and the same engineers.
A complete line
One project, one layout, one acceptance plan covering both segments.
A single workstation
One machine dropped into a line you already run, quoted against the part it handles.
A segment rebuild
One segment replaced while the rest of the plant keeps running.
2016 → 2019
Single machines into other people’s lines for three years, then complete lines. The first period is where every station-level parameter came from.
Supply scope
Scope From Cell Arrival to Line-Off
Four segments, and every station we sell sits inside them.
Off the tray, scanned, sorted
Cells come off the incoming tray, each one is scanned and tested, and a rejected cell leaves a gap that is refilled before the group moves on.
Grouped to finished module
Grouping, cleaning, taping, stacking, pressing, addressing, welding and testing, until a finished module comes off the end.
Enclosure to closed pack
Enclosure and cooling plate loading, gluing, module insertion and fixing, wiring, closing and testing.
Released with its record
The pack is released with its test record attached to it, which is the document your own customer will ask you for.
Holding a narrow scope is a design decision. The engineer who sets a press force knows what the welder downstream needs from the stack, and whoever writes the acceptance criterion for module testing has commissioned the sorting station that fed it.
Who we build for
Buyers We Build Lines For
Five groups, and the difference between them is which input is already fixed before the layout starts.
C&I storage pack plants
A pack count per project high enough that takt and headcount decide the business case, usually with the cell already chosen.
- Fixed first
- Cell
Grid-scale integrators
A containerised system design, liquid cooling, and a pack drawing fixed by the project rather than by them.
- Fixed first
- Pack drawing
Residential storage makers
Five to 30 kWh, air cooling, and a cost target that normally lands on the semi-automatic tier.
- Fixed first
- Cost target
EV module and pack suppliers
A pack drawing fixed by their customer and a takt fixed by the vehicle line, so the layout bends rather than the takt.
- Fixed first
- Takt
Plants already running a line
Arrives as a bottleneck rather than a project: a hand-welding step that cannot hold takt, a missing test gate, a gluing station setting the pace for everything behind it.
- Fixed first
- The building
How a project opens
Five Documents In, Three Back
Cell datasheet
Format and dimensions with tolerances, so the gripper and fixture question is answered on day oneModule configuration
Series and parallel count, which sets the stack, the press length and the busbar patternPack drawing
Enclosure, cooling plate and interfaces, which decide the gluing path and the pack station countTarget takt
PPM, or annual output we can convert into one, which picks the tierFloor plan
Clear height, floor loading and utility entry points, marked on the plan of the bay itselfBack within 24 hours: a tier recommendation with the reason behind it, a layout drawn against that floor plan, and the labelled station list for both segments.
Our own designs
Nine Workstations of Our Own Design
Nine workstations on a BatteryLine Pro line are our drawings rather than bought-in machines with our plate on them. What that ownership buys you is written under each one.
Cell tray unloading
Grippers drawn around your tray pitch and cell face, five cells to a pick.
Cell testing and sorting
Reject and refill logic set by us, so a gap never travels downstream into a group.
Stacking and pressing
Force read through the stroke rather than sampled at the end of it.
Terminal addressing
One vision set locates the terminal and reads its polarity in the same look.
In-line busbar welding
Recipes stored per busbar geometry and called by the part that arrives.
Module end-of-line testing
Thresholds written by the group that owns the test physics, not by a salesman.
Cooling plate gluing
Bead path and metered volume, with the curves handed up to your MES.
Module conveying
Stop and lift units positioned for the station in front of them. It carries modules and their fixtures, including the handover into the pack segment, and never finished packs.
Off-line gantry welding
Four-axis welding kept off the takt, so the line never waits for it.
Who draws and who travels
Twenty-Six Engineers, Four Disciplines
Almost a third of the team spends its year on other people’s floors, and what they bring back is what the mechanical group redraws. Field commissioning is a permanent group here, not a role a sales engineer picks up when a shipment lands.
| Discipline | What it owns | Engineers |
|---|---|---|
| Mechanical | Layout, frames, grippers, fixtures | 8 |
| Electrical and control | Test stations, controllers, remote diagnostics | 6 |
| Laser and vision process | Weld recipes, addressing, inspection thresholds | 4 |
| Field commissioning | Installation, acceptance, operator training | 8 |
Before a crate is closed
Three Full-Line Pre-Assembly Bays
The machines are built in a 6,000 square metre hall, and three of its bays are reserved for something most equipment suppliers have no use for. A complete line is stood up in the bay in its shipping configuration, powered up, and run before a single crate is closed.
- Faults that only appear when 32 stations share a controller are found in our building rather than in yours.
- The commissioning engineers arrive at your plant having already seen this specific line running.
- A supplier that buys its stations in has nothing to pre-assemble, because it does not own the mechanical design that makes the stations index to each other.
When the line runs in your plant for the first time, it is the second time it has run — which is why we accept being measured on how a line behaves at start-up, not only on how each machine behaves alone.
Ownership of the numbers
Envelopes and Acceptance Criteria
The compatibility envelopes we quote are ours to set, and that is a different thing from knowing them.
| What is bounded | Envelope |
|---|---|
| Cell | 100–220 mm wide × 100–220 mm high × 20–80 mm thick |
| Module | 400–1200 × 100–300 × 100–250 mm |
| Press length, BLP-SP | 300–1100 mm |
Those numbers exist because our mechanical group drew the grippers, fixtures and addressing programmes that produce them. So when a cell lands 5 mm outside an envelope, the question is not whether it fits: it is which fixtures and programmes change, who changes them, and whether the takt moves. Four items follow the part and four do not, and the split is on the battery module assembly line page.
One author, three documents
Layout, station list and acceptance set come from one party here. The engineers who set the press force and the weld recipe also write the criterion each station is signed off against, and they sign their own work at your site.
Three authors, three documents
Where those three documents come from different suppliers, the criteria drift toward what each machine can prove about itself rather than what the line has to deliver at the end of a shift. The acceptance page covers how they are agreed.
What a line is made of
Five Technologies a Line Is Built From
Each discipline owns its own stations, its own parameters and the criteria those stations are accepted against.
Laser process
A 6 kW source welding busbars in line on BLP-W6, with BLP-WG covering off-line work.
- Wavelength
- 1070 nm
- Power
- 1000–6000 W
- Stability
- 3%
Vision and robotics
BLP-UL picks five cells at a time; BLP-AD locates the terminal and reads polarity.
- Payload
- 220 kg
- Reach
- ≥2650 mm
- Addressing
- ≤0.2 mm
Servo force and metering
BLP-SP reads force through the stroke; BLP-GL meters adhesive volume and holds the bead path.
- Press force
- 0–8000 N
- Bead path
- ±2 mm
- Volume
- 5%
Electrical test
BLP-CS measures every incoming cell; BLP-EOL runs insulation and hipot on every finished module.
- Insulation
- DC 1000 V
- Floor
- ≥500 MΩ
- Hipot
- DC 2800 V
Transfer and fixturing
BLP-CV decides whether the other four hold their numbers, by locating each module for the station in front of it.
- Load
- ≥200 kg
- Speed
- ≤20 m/min
- Carries
- Modules
Send the drawings
Send Your Cell and Pack Drawings
A tier recommendation, a layout drawn to your floor plan and a labelled station list come back within 24 hours.
The irreversible station
Three Rules That Lock a Weld Recipe
Busbar welding is the one station on a module line whose output cannot be undone. Three rules hold it, and all three are enforced by the machine rather than promised in a document.
A recipe belongs to a geometry, not a shift
Parameters are stored per busbar geometry and called by the part that arrives at the station. A geometry with no locked recipe does not run: the station refuses it. That is an interlock, and it is the reason a new busbar variant cannot quietly enter production on yesterday’s settings.
A recipe earns its lock on your material
Pull testing destroys the joint it tests, so it can never be performed on a production module. Parameters are proved on sample joints made from your own busbar and terminal material, pulled until the 1000 N floor is met with margin, and the power, speed, focus and beam pattern that produced those samples are locked for that geometry.
Production joints are then judged on the two measurements that survive the part: penetration of 1.0 mm or more and bead width of 1.5 mm or more, read at the post-weld inspection station immediately behind the welder.
The operator does not hold the recipe
Weld parameters are not adjustable from the station in production, because a joint welded on adjusted parameters no longer matches the sample the criterion was proved against. Where a line lets a shift leader tune power to clear a backlog, every joint made that afternoon has left the evidence chain, and nobody finds out until resistance climbs in the field months later.
- The locked recipe for each busbar geometry
- The sample pull-test results it was proved against
- Penetration and bead width for every production joint
A joint outside either measurement is marked at inspection and the module leaves the flow before manual re-inspection and module end-of-line testing, carrying the station’s record of what it found. The rework decision on your side is then made against a measurement rather than an opinion. The station itself is on the busbar welding station page.
The unit of description
Two Station Sequences We Quote Against
Every station in both sequences is labelled AUTO, SEMI-AUTO or MANUAL, and the labelled list is in your hands before anything is signed rather than discovered during commissioning. The labelling is done by the commissioning group, who are the people who will stand at those stations with your operators, and it is not adjusted to make a quotation read better.
AUTO
Runs inside the takt with no operator standing at the station.
SEMI-AUTO
Machine cycle, operator loads or unloads. Counted in the headcount.
MANUAL
Done by people. Most of the pack segment sits here on every tier.
The sentence most suppliers avoid
The Manual Shape of Pack Assembly
Applied honestly, that labelling discipline produces a sentence most equipment suppliers would rather not write: the pack segment is predominantly manual on every tier. The standard tier carries a single automatic station in that segment, enclosure floor gluing.
- Module insertion and fixing
- Series copper busbar installation
- BMS installation
- MSD and connector installation
- Harness dressing
- Cover installation and tightening
- Front panel installation
Why it stays manual
Each of those steps changes shape with the pack variant: a different harness route, a bracket moved, a connector repositioned. Automating them means dedicated tooling per variant, written off the day that variant is superseded, while 12 to 14 people absorb a drawing change on the day it lands.
Why the headcount is quoted
Those figures appear in the quotation next to the equipment figure, because they set your shift roster and your labour cost for as long as the line runs. A quotation describing the same pack segment as fully automatic is describing tooling that does not yet exist for your variant list.
| Tier | Cells | Module | Pack |
|---|---|---|---|
| BLP-P8S | 4 | 4 | 12–14 |
| BLP-P15 | 4 | 3 | 12–14 |
How the numbers work out against a target output is on the battery pack assembly line page.
How each number is tested
Figures Tied to a Measurement
Every figure this company publishes is attached to a method for measuring it, and the method is agreed before the line runs rather than argued about afterwards.
| Figure | How it is measured | Agreed |
|---|---|---|
| 8 PPM takt | Utilisation means time utilisation multiplied by performance utilisation multiplied by first-pass yield, so both sides measure the same takt on the day it is verified. | In the acceptance plan |
| ≥99% yield | Equipment causes alone, with human factors excluded. First-pass yield is input quantity minus NG units divided by input quantity, and what counts as an equipment cause is agreed station by station in writing. | Before the acceptance run |
| ≥1000 N joint | Proved on your busbar and your terminal, on sample joints made during commissioning. Those samples are kept with the recipe they locked. | At recipe lock |
| ≥99.9% scan | Applies to readable incoming codes. Unreadable incoming labelling sits outside it, because a scanner cannot be held responsible for a code that was never printed properly. | In the acceptance plan |
| 4 m clear height | Measured under the lowest obstruction over the line run, not to the roof. Floor loading of 800 kg per square metre or more is a design input rather than a preference. | At layout |
A yield percentage quoted without that definition cannot be tested, because every disputed unit becomes an argument about attribution. Voltage and resistance accuracies are instrument specifications, testable on acceptance day against your own reference cell.
How the work is controlled
Quality System and Certification Scope
Underneath the certificates the arrangement is simple. Criteria for each station are set by the discipline that owns the physics of that station, and a deviation found at commissioning goes back to whoever wrote the criterion. It is either defended with evidence or changed on paper before the line is signed off.
- Laser and vision process owns the welder and the addressing station
- Electrical and control owns the test stations
- Mechanical owns the press and the conveyor
Available before commitment
Four Documents Before Commitment
Four documents are available to you before any commitment, and all four are the ones the line is later measured against.
The layout
Drawn to your building and your column grid, not to a standard drawingThe station list
Both segments, every station labelled AUTO, SEMI-AUTO or MANUALThe test item list
What end-of-line measures on a module and on a packThe acceptance criteria
The threshold each station is signed off against, station by stationNamed groups, not promises
Responsibility From Enquiry to Acceptance
A turnkey order covers layout design, equipment, installation, commissioning, acceptance and operator training. Each of those has a named group behind it.
Layout drawn to your floor plan
Line run, station spacing, material entry and exit, where operators stand, and where power, compressed air and nitrogen enter the building. The 8 mechanical engineers who draw it are the same people who drew the stations standing on it, so a column in the wrong place is a layout problem rather than a machine problem.
Build and pre-assembly
Machines are built in the hall, then the complete line is stood up and run in a pre-assembly bay before shipment, in the configuration it will ship in.
Installation and commissioning
Carried out by the field commissioning group. How many of those 8 engineers attend, and which disciplines travel with them, is written into the acceptance plan before shipment rather than decided when the crates land.
Acceptance on your materials
Station by station against the criteria agreed beforehand, on cells, busbars, end plates, enclosures and cooling plates from your own supply chain — a line accepted on our sample parts has proved nothing about yours. We provide the test programme, the recording and the engineers, and both sides sign the same document. The acceptance page covers the sequence and what happens if a criterion is missed first time.
After the line is signed
Training, Spares and Remote Diagnostics
Training is delivered on your line, to the people who hold the shift, and concentrates on the three things that decide whether it still performs as accepted a year later.
- Recipe management on the welding station
- Criteria setting on the sorting and end-of-line test stations
- Fixture changeover inside the envelope
A controller or vision fault can be looked at by the engineer who commissioned it before anyone books a flight. The electrical and control group holds that connection, which is why a diagnosis usually starts from the parameters as they were left at acceptance rather than from a description over the phone.
Your enquiry, ready to send
If your email client opened, it is already in the message. If nothing opened, use one of the two routes below.
Start a project
Start a Line Project
For a complete line, send the cell datasheet, module configuration, pack or enclosure drawing, target takt and floor plan, and a tier recommendation, layout and labelled station list come back within 24 hours. For a single station, send the drawing of the part it handles and the takt it has to hold.
Both routes reach the engineering team through the contact page.