Whether powering remote telecom towers or stabilizing renewable-heavy grids, stationary energy storage requires precision, safety, and scalability. Our battery pack manufacturing systems integrate robotics, vision systems, and intelligent process control to deliver consistent, reliable battery pack assembly for the most demanding applications.
Discuss your project.
BESS - Battery Energy Storage System Manufacturing Process
Below are the critical steps in the battery pack manufacturing process for BESS and containerized energy storage systems.
Cell Sorting
Automated sorting of cells based on test parameters for uniformity and quality.
Module Preparing
Grouping and arranging cells into modules with precision handling.
Multiple Module to Casing
Integrating prepared modules into protective casings.
Casing to Stacker
Automated stacking of cased modules for final assembly.
Stacks to Container
Final integration of stacks into containerized energy storage systems ready for deployment.
Our Technical Capabilities
Our battery pack manufacturing solutions are designed to meet the specific needs of stationary energy storage applications:
- Supports Large-Format Cells: Prismatic, pouch, and blade cells for BESS and containerized systems
- Modular Assembly Lines: Scalable from pilot systems to multi-MWh capacity manufacturing lines
- Integrated Quality Control: Automated cell testing (OCV, ACIR), AI-driven inspection, and thermal interface application checks
- Full Data Integration: Real-time MES connectivity, process logging, and predictive maintenance analytics
Typical Applications
- Renewable Energy Storage: Solar and wind energy integration
- Commercial & Industrial Backup Power: Data centers, factories, hospitals
- Telecom & Remote Power: Reliable off-grid operation
- Grid Balancing & Peak Shaving: Utility-scale energy storage systems
Process Overview
Our battery pack assembly automation process for energy storage includes:
01
Automated Cell
Unloading & Sorting
02
Surface Preparation
(Plasma Cleaning)
03
Insulation & Safety
Layer Application
04
Automated Cell
Testing & Classification
05
Module Assembly with
Precision Robotics
06
Final Pack Assembly
& Sealing
07
Functional Testing &
Certification
Discuss your project.
Why Battery Pack assembly automation matters for Energy Storage
The rapid adoption of renewable energy and the push for grid modernization are driving demand for large-scale, reliable Battery Energy Storage Systems (BESS) Containerized Energy Storage Systems. These solutions must deliver long cycle life, robust safety mechanisms, and maintenance-free operation.
- Large-format packs require consistent, repeatable manufacturing for stable performance
- Battery pack assembly automation ensures long-term reliability through precision engineering
- Minimizes human error when handling high-capacity cells
- Improves traceability for compliance and warranty management
Why choose Cybernetik for Energy Storage Battery Pack manufacturing
- Proven expertise in battery pack assembly automation for EVs and stationary storage applications
- Tailored solutions for diverse cell chemistries and formats
- Compliance with international safety and performance standards (UL, IEC)
- End-to-end project execution from design to commissioning
Power the future, reliably and efficiently.
Our battery pack manufacturing experts will design an automation solution for your Battery Energy Storage System (BESS) or containerized energy storage project, ensuring unmatched performance, safety, and scalability.
Speak to Our Energy Storage Specialists
0+
Systems Installed Worldwide
0+
Satisfied Customers
0+
Years of Experience
