Overview of Our Battery PACK Manufacturing Line
At Xiaowei New Energy, we design and build automatic battery pack production lines engineered for the full spectrum of lithium‑ion applications — from EV battery packs to energy storage systems (ESS), UPS, and general‑purpose lithium batteries.
Our turnkey PACK manufacturing solutions integrate every stage — cell sorting, module welding, BMS installation, performance testing, and final packaging — ensuring reliability, traceability, and scalability.
The PACK line can be seamlessly integrated with our Battery Cell Production Line, offering a one‑stop cell‑to‑pack solution for customers building complete lithium battery factories.
YOUR RELIABLE PARTNER FOR ONE‑STOP BATTERY
PRODUCT LINES
Lithium Battery Pack Assembly Lines
| Image | Name / Process / Description / Application | Core Equipment | Capacity |
|---|---|---|---|
|
Automatic Line Cylindrical Battery Pack Assembly Line
Process: Full Automatic Assembly
Description: High-capacity fully automated line for mass production. Application: Mass Production |
|
8,000-12,000 packs/day |
|
Full-auto Line Cylindrical Battery Pack Assembly Line
Process: Full Automatic Assembly
Description: Fully automated line for large-scale battery production. Application: Large Scale Production |
|
10,000-15,000 packs/day |
|
Manual Line Cylindrical Battery Pack Assembly Line
Process: Manual Assembly
Description: Entry-level line with manual assembly and testing. Application: Small Batch Production |
|
1,000-2,000 packs/day |
Lithium Battery Pack Assembly Lines
Automatic Pack Line
Full-auto Pack Line
Manual Pack Line
Automated Battery PACK Production Process
The Battery PACK production process is generally divided into three main sections: Cell Test & Load, Battery Module Assembly, and Battery PACK Assembly.
Each stage transforms individual battery cells into complete PACK systems through precise, automated operations.
Depending on the cell type — cylindrical, prismatic, or pouch — and the target application, the process and technical requirements may vary.
The following five steps outline the standard workflow of a Battery PACK Production Line:
1. Cell Sorting & Grading
Automatic cell sorting by voltage, internal resistance, and capacity ensures only matched cells enter the PACK assembly. This step maximizes consistency and performance across each battery pack.
2. Module Assembly
Cells are grouped and stacked into modules using precision alignment and welding systems. Compatible with cylindrical, prismatic, and pouch cells, the system achieves high throughput and stable yields.
3. PACK Welding & BMS Integration
Each module is connected via laser or ultrasonic welding, followed by the installation and testing of the Battery Management System (BMS). Full data traceability and MES connectivity guarantee quality control.
1. Cell Sorting & Grading
Automatic cell sorting by voltage, internal resistance, and capacity ensures only matched cells enter the PACK assembly. This step maximizes consistency and performance across each battery pack.
2. Module Assembly
Cells are grouped and stacked into modules using precision alignment and welding systems. Compatible with cylindrical, prismatic, and pouch cells, the system achieves high throughput and stable yields.
3. PACK Welding & BMS Integration
Each module is connected via laser or ultrasonic welding, followed by the installation and testing of the Battery Management System (BMS). Full data traceability and MES connectivity guarantee quality control.
4. Performance Testing & Aging
Every PACK undergoes performance, safety, and ageing tests, including voltage, capacity, and thermal evaluation. Automated testing benches and ageing chambers ensure long‑term stability.
5. Final Assembly & Packaging
The final stage integrates enclosure assembly, labeling, and automatic conveyor packaging, preparing each pack for safe shipment or downstream installation.
If you are planning a turnkey pack production project, our team can design, build, and deliver a fully integrated line tailored to your capacity, budget, and product requirements.
Contact us for fast project evaluation and a customized turnkey solution.
Mechanical arm automatic feeding
Scanning, OCV sorting, and gluing
Pre stacking of battery cells
Upper plate, extrusion, and steel strip sleeve
Module launch
Polarity detection and polarity addressing
Laser cleaning
Manual installation of CCS
Laser welding
Manual inspection after welding
Insulation withstand voltage and internal resistance test
Module transfer line
Cleaning of the box online
Cleaning the bottom of the box and installing the liquid cooling plate
Module in shell
Glueing
Install fastener accessories
Module in box
Module tightening
Insulation test
Installation of high-voltage wiring harness
Installation of low-voltage wiring harness
EOL testing
Upper cover installation fastening
Leak test
Final inspection labeling
Battery pack offline
Core Equipment in the PACK Line
The Battery PACK production line integrates a range of specialized equipment designed for precise assembly, welding, testing, and packaging operations.
Each machine plays a critical role in ensuring process accuracy, product consistency, and production efficiency across every stage of PACK manufacturing.
Below is a list of commonly used machines for your reference:
🟢 Cell Loading Machine
🟢 Cell Polarity Reversing Machine
🟢 Module Stacking Machine
🟢 Laser Cleaning Machine
🟢 Laser Welding Machine
🟢 Module Insulation & Hi‑pot Testing Machine
🟢 Cooling Plate Air Tightness Testing Machine
🟢 Cooling Plate Glue Dispensing Machine
🟢 Pack Air Tightness Testing Machine
🟢 Cell OCV (Open Circuit Voltage) Testing Machine
Why Choose Xiaowei New Energy As Your Supplier
High automation & throughput
Our PACK lines integrate conveyors, vision systems, robotic welding and automatic testing to reduce manual intervention.
Multi‑format compatibility
Support cylindrical, prismatic, pouch cells for EV, ESS, UPS and other lithium‑ion battery projects.
Seamless integration with cell line
Our PACK lines can smoothly dock with upstream battery‑cell production workflows.
Full data traceability & quality control
Serial numbers, test records and BMS logs support full‑cycle traceability and product reliability.
Customised layout & flexible design
Custom‑tailored for your factory space, output targets, optimize layout and CAPEX efficiency.
Global export & after‑sales support
Complete export logistics, overseas service and operator training for worldwide clients.
Why Choose Xiaowei New Energy As Your Supplier
High automation & throughput
Our PACK lines integrate conveyors, vision systems, robotic welding and automatic testing to reduce manual intervention and increase consistency.
Multi‑format compatibility
Supporting cylindrical, prismatic, and pouch cells, our lines are built to handle EV, ESS, UPS and general lithium‑ion battery formats.
Seamless integration with cell line
As we also provide cell production solutions, our PACK lines are engineered to integrate smoothly with upstream cell‑production workflows.
Full data traceability & quality control
Every pack produced can be tracked with serial numbers, test data, ageing results and BMS logging, supporting L & T reliability.
Customised layout & flexible design
We customise our solutions to your factory footprint, output requirements and product mix, ensuring optimal layout and CAPEX efficiency.
Global export & after‑sales support
With decades of experience in foreign‑trade manufacturing, we handle export logistics and provide international service and training.
| Capability | Benefit to You |
|---|---|
| Full production line supply | Simple procurement, single accountability |
| Pack + BMS co-design | Fast launch, fewer failures |
| Lean automation solutions | Lower labor cost, higher consistency |
| Global on-site support | Smooth installation & ramp-up |
| Standard + customized equipment | Fits both new & upgrade projects |
Customisable Your PACK Line Solutions
Every production project is unique. Whether you’re building a new facility or upgrading an existing one, we provide:
- Turnkey design from concept to commissioning
- Factory layout planning including material flow and lean automation
- Complete equipment supply — conveyors, welders, sorters, testers, ageing chambers
- Software integration — MES/SCADA, data trace systems, traceability modules
- On‑site installation, commissioning and operator training
- Ongoing maintenance & spare‑parts services
How to Quickly Define Your PACK Production Line Requirements
To help us provide the most suitable PACK production solution, please prepare the following key information about your project. This ensures accurate recommendations and faster responses.
- Cell Type: Cylindrical, prismatic, or pouch?
- Cell Specifications: Dimensions, capacity, voltage, and other key parameters.
- Target PACK: Size, capacity, voltage, and series/parallel configuration.
- Daily Production Volume: Expected output per day.
- Application: Energy storage, electric vehicles (EV), or other uses.
Battery PACK Solutions for Multiple Industries
EV Battery Packs
High‑energy traction packs for electric vehicles.
Energy Storage PACKs
Modular systems for solar and grid storage.
UPS & Telecom PACKs
Compact, high‑reliability backup batteries.
Lithium Battery PACKs
Flexible solutions for power tools, e‑bikes, and industrial systems.
FAQ About Our Battery PACK Production Line
Q: What types of battery cells are compatible with your PACK production lines?
A: Our production lines support cylindrical, prismatic, and pouch lithium‑ion cells. They cover applications for EV, energy storage, UPS, power tools and other battery PACK projects.
Q: Can you deliver a full turnkey PACK assembly solution?
A: Yes. We provide full turnkey services including concept design, factory layout, complete equipment supply, MES/SCADA software integration, on‑site installation, commissioning and operator training.
Q: Is the production line customizable for my factory space and output target?
A: Absolutely. We adjust line layout, equipment configuration and production capacity according to your factory footprint, daily output requirements and product mix to optimize CAPEX efficiency.
Q: Does your PACK line support full‑cycle data traceability?
A: Yes. Every finished battery pack stores serial number, test records, ageing data and BMS log information, supporting full data traceability for product reliability testing.
Q: Can your PACK equipment integrate with upstream cell manufacturing workflows?
A: Yes. Since we also supply cell‑making equipment, our PACK assembly lines are engineered for smooth docking with upstream cell production workflows.
Q: What after‑sales support do you provide for overseas customers?
A: We handle export logistics, provide remote & on‑site guidance, operator training, long‑term maintenance and spare‑parts supply for global clients.
Q: What key information do I need to prepare for an initial project quotation?
A: Please confirm cell type, cell specifications, target PACK parameters, daily production volume and end‑use application, this helps us give accurate and fast proposals.
Q: Can your line handle both new‑plant construction and old‑plant upgrading?
A: Yes. Our solutions work for both brand‑new factory builds and existing production‑line renovation & capacity expansion projects.
Q: What main equipment is included within a standard PACK assembly line?
A: It includes conveyors, robotic welding stations, sorting equipment, testing stations, ageing chambers, vision inspection systems and supporting software modules.
Q: How high is the automation level of your PACK production solution?
A: Our high‑automation lines reduce manual intervention heavily. Robotic welding, vision inspection and automatic testing improve production consistency and throughput.