Battery Energy Storage Solutions (BESS) & Manufacturing Process

Why Battery Storage Matters for Africa

Africa faces three key challenges:

Unstable power grids – Load shedding and blackouts disrupt industries and households.
Energy access gap – Over 600 million Africans lack reliable electricity.
A lack of energy storage capacity for renewably produced power.

Battery Energy Storage Systems (BESS) solve these challenges by:

afrivolt™ BESS Solutions

By leveraging the vast experience of our global tier-1 technical partner, we manufacture… advanced lithium-ion cells designed for stationary storage applications:

Address a Rapidly Growing Market

Forecasted 70GWh demand by 2030 is driven by:

Making energy sustainable

Coming soon

Container energy storage system

Distributed micro grid energy storage outdoor cabinet

How battery cells are manufactured

Battery cells power everything from smartphones to electric vehicles (EVs). Their production involves multiple precise steps to ensure safety, efficiency, and longevity. The process begins with making the core materials, assembling them into a functional cell, and finally testing and packaging them for use.

Step 1: Electrode Manufacturing (Making the Core Materials)

This step involves preparing the battery’s anode and cathode, which store and release energy.

Control Points:
- Material Purity – The active materials (like lithium, nickel, and graphite) must be high quality.
- Mixing & Coating Uniformity – Ingredients are blended into a slurry and coated onto metal foils. Any inconsistencies affect performance.
- Drying & Thickness Control – The coated materials must be dried evenly and kept at precise thicknesses to ensure proper energy storage.

Step 2: Cell Assembly (Building the Battery cell)

Once the electrodes are ready, they are cut, stacked, and assembled into a battery cell.

Control Points:
- Electrode Cutting & Alignment – Poorly cut electrodes can cause internal shorts or inefficient energy flow.
- Separator Placement – A thin separator prevents short circuits; improper placement can lead to safety risks.
- Electrolyte Filling – The electrolyte (which allows lithium ions to move) must be filled accurately to avoid defects.

Step 3: Formation & Aging (Activating the Battery)

Cells go through charging and discharging cycles to form a stable battery structure.

Control Points:
- Controlled Charging Cycles – Initial charges must be carefully controlled to prevent damage.
- Leak Testing & Gas Formation Checks – Any unexpected gas buildup or leakage signals a defect.
- Performance Testing – Voltage, capacity, and resistance are measured to ensure the battery meets specifications.

Step 4: Final Inspection & Packaging (Quality Assurance)

The finished cells are tested for defects, labeled, and packaged for shipping.

Control Points:
- External Defect Checks – Any visible damage, swelling, or irregularities are flagged.
- Final Electrical Testing – Ensures each cell delivers the expected energy output.
- Safe Packaging – Cells must be packed to prevent physical damage or short circuits during transport.

Battery manufacturing is a precise process with strict quality control at every step. Any small defect can lead to performance issues or even safety hazards, making these control points critical.

Headquarters: Cape Town, South Africa
General Inquiries: info@afrivolt.net
Careers: hr@afrivolt.net