No products in the cart.
Fully Automatic Pouch Cell Mass Production Line
Our pouch cell mass production line is a complete solution for high volume pouch battery manufacturing. This fully automatic pouch cell manufacturing line delivers 24 PPM, 99.8% first‑pass yield, and 1 GWh annual capacity. PPCELL provides turnkey services from factory planning to technology transfer – backed by 15+ years of battery equipment experience.
Quote Now
Pouch Cell Mass Production Line – High Volume Pouch Battery Manufacturing with Fully Automatic Pouch Cell Manufacturing Line
1. What Is a Pouch Cell Mass Production Line?
A pouch cell mass production line is an integrated, fully automated system for producing lithium polymer pouch cells at industrial scale. It handles all steps from raw electrode foils to finished, graded cells ready for module assembly. Our line is designed for 24/7 continuous operation with minimal manual intervention, ensuring high consistency, low defect rates, and full traceability.
2. High Volume Pouch Battery Manufacturing – Core Performance Metrics
| Parameter | Value |
|---|---|
| Production speed | 24 cells per minute (PPM) |
| Annual capacity (single shift) | 500,000 cells/year |
| Annual capacity (3 shifts) | Up to 1.5 GWh (depending on cell size) |
| First‑pass yield | ≥99.8% |
| Final yield | ≥99.9% (with rework) |
| Equipment OEE | ≥98% |
| Changeover time (cell size) | <1 hour |
| Number of operators per shift | 3-5 |
| Machine uptime | 98.5% (excluding planned maintenance) |
3. Fully Automatic Pouch Cell Manufacturing Line – Complete Process Flow
Our fully automatic pouch cell manufacturing line is divided into six main sections:
3.1 Electrode Preparation Section (from roll to sheet)
A. Slitting
Precision slitting of coated anode/cathode rolls into narrow strips.
Parameters: Width accuracy ±0.05 mm, burr ≤6 μm, speed 1‑70 m/min.
B. Notching / Tab Forming
Laser or mechanical notching to create electrode tabs.
Parameters: Notch position tolerance ±0.1 mm, tab width accuracy ±0.05 mm.
C. Vacuum Drying
Removes moisture before assembly.
Parameters: Vacuum ≤ -0.095 MPa, temperature RT‑150°C, 24h vacuum retention ≥95%.
D. Electrode Stacking (Z‑fold or Sheet Stacking)
Our standard is Z‑fold stacking with CCD vision alignment.
Parameters: Alignment accuracy ±0.3 mm, stack thickness 3‑20 mm, stacking speed 0.8‑1.2 seconds per layer.
Alternative winding section available for cylindrical‑type pouch cells.
3.2 Cell Assembly Section
E. Ultrasonic Tab Welding
Welds anode and cathode tabs to the electrode stack.
Parameters: Frequency 40 kHz, weld strength ≥15 N/mm (destructive test), electrode life >500,000 welds.
Dual‑head welding for multi‑tab cells optional.
F. Pouch Forming
Deep drawing of aluminum laminate film into a pocket.
Parameters: Forming depth ≤10 mm, corner radius ≥2 mm, no wrinkles or cracks.
G. Side & Top Heat Sealing
Seals three sides of the pouch before electrolyte filling.
Parameters: Temperature RT‑250°C ±2°C, sealing pressure 0.2‑0.6 MPa, seal width 5‑10 mm, seal strength >30 N/15mm.
3.3 Electrolyte Filling & Vacuum Sealing
H. Vacuum Filling
High‑precision electrolyte injection under vacuum.
Parameters: Vacuum level ≤ -0.095 MPa, filling accuracy ±0.5% of target weight, filling volume 5‑150 ml adjustable.
Servo‑controlled ceramic pump with ±0.2% pump accuracy.
I. Wetting / Soaking
Temperature‑controlled chamber for electrolyte absorption.
Parameters: Temperature 25‑85°C, soaking time 2‑24 hours (programmable).
Vacuum‑pressure cycles to accelerate wetting.
J. Final Vacuum Sealing
Seals the remaining side of the pouch after degassing.
Parameters: Vacuum ≤ -0.095 MPa, seal temperature RT‑250°C ±2°C, helium leak test <1×10⁻⁶ mbar·L/s.
3.4 Formation, Aging & Grading
K. Formation
Initial charge/discharge cycles to activate the cell and form SEI layer.
Parameters: Voltage 0‑5V ±0.05% FS, current 0.2‑10A ±0.05% FS, 512‑2048 channels per cabinet.
Hot‑press formation (optional) with pressure 700‑5000 kg, temperature RT‑80°C.
L. Aging
Storage at elevated temperature to stabilize cell voltage.
Parameters: Temperature 45±2°C, duration 24‑72 hours, voltage monitoring every 6 hours.
M. Grading (Capacity Sorting)
Full charge/discharge cycle to measure actual capacity.
Parameters: Discharge current 0.5C/1C, capacity accuracy ±0.5%, sorting into 10+ bins (e.g., A, B, C).
Automatic sorting into trays by bin grade.
3.5 MES Integration & Data Traceability
Every station is linked to a central MES (Manufacturing Execution System):
Barcode tracking – Each cell receives a unique ID at the start.
Real‑time data – Electrode dimensions, weld strength, seal temperature, filling weight, formation voltage/current, final capacity.
Traceability – Full history of each cell is stored and can be exported.
Remote monitoring – Optional dashboard for production managers.
3.6 Clean Room & Environmental Control
Humidity control – Dew point ≤ -40°C in dry rooms (for electrolyte filling).
Particle control – Class 100,000 (ISO 8) for assembly area; class 10,000 (ISO 7) for winding/stacking.
Temperature – 23±3°C throughout.
PPCELL can supply complete clean room design and HVAC integration.
4. PPCELL – 15+ Years Turnkey Service Provider
With over 15 years in the battery equipment industry, PPCELL offers complete turnkey solutions for pouch cell mass production line projects:
Consulting – Feasibility studies, material selection, cell design support, process optimization.
Factory planning – Layout design, clean room specifications, utility requirements (power, compressed air, N₂, dehumidification).
Equipment supply – All machines listed above, from electrode slitting to grading.
Installation & commissioning – On‑site by PPCELL engineers; typical commissioning time 4‑6 weeks.
Training – Operator training (2‑3 days), maintenance training (2 days), process engineering training (1 week).
Technology transfer – Full process documentation, QC checklists, troubleshooting guides, spare parts lists.
After‑sales support – 24/7 remote support (response <2 hours), on‑site service within 48 hours (global), spare parts warehouse.
5. Equipment Parameters Summary Table (Key Stations)
| Station | Parameter | Specification |
|---|---|---|
| Slitter | Width accuracy | ±0.05 mm |
| Burr | ≤6 μm | |
| Speed | 1‑70 m/min | |
| Notching | Notch position | ±0.1 mm |
| Output | up to 400 cells/min | |
| Stacking (Z‑fold) | Alignment | ±0.3 mm (CCD) |
| Speed | 0.8‑1.2 s/layer | |
| Tab welding | Weld strength | ≥15 N/mm |
| Electrode life | >500,000 welds | |
| Pouch forming | Depth | ≤10 mm |
| Sealing | Temperature | RT‑250°C ±2°C |
| Seal width | 5‑10 mm | |
| Electrolyte filling | Vacuum | ≤ -0.095 MPa |
| Filling accuracy | ±0.5% | |
| Formation | Voltage range | 0‑5V ±0.05% FS |
| Current range | 0.2‑10A ±0.05% FS | |
| Grading | Capacity bins | 10+ bins (e.g., A1, A2, B1, B2, C, NG) |
6. Quality Assurance & After‑Sales Support
Quality metrics (per line, after stabilization):
First‑pass yield ≥99.8% – measured over 7 consecutive production days.
Final yield ≥99.9% – includes rework of minor defects.
Equipment uptime ≥98% – excludes scheduled maintenance and material interruptions.
Warranty & service:
Warranty period – 12 months after final acceptance.
Response time – 2 hours for technical support (email/phone).
On‑site service – 48 hours (within 1000 km), 72 hours (international).
Spare parts – Recommended list included; PPCELL stocks critical components.
Training package (included):
5 days on‑site training for up to 6 people.
Topics: machine operation, maintenance, process parameter setting, quality control, safety.
Certificate of training provided.
7. Why Choose Our Production Line
| Advantage | Description |
|---|---|
| High output | 24 PPM, 1+ GWh/year – meets tier‑1 battery demand. |
| Low defect rate | 99.8% first‑pass yield reduces waste and rework. |
| Full automation | From unwinding to grading – only 3‑5 operators per shift. |
| Traceability | Full MES integration with barcode per cell. |
| Fast changeover | <1 hour between different pouch cell sizes. |
| Global support | PPCELL supports global technical services, production line customization, and personnel training. |
📥 Download the Detailed Technical Brochure to explore full specifications and integration guides.
📞 Contact Our Engineering Team for a provide confidential consulting and customized performance analysis for your specific yield goals.
Email： info@ppcell.com