1.5 Gwh Capacity Lithium Battery Production Assembly Line From Imported Prismatic Cell To Pack, Expandable To 3 Gwh +

A. Objective of DPR Appendix

This appendix is prepared as part of the Detailed Project Report (DPR) to present a clear, conservative, and finance‑ready technical description of the proposed lithium battery production facility. The document defines the capacity logic, scope of supply, customization flexibility, and expandability of the assembly line in a manner suitable for review by banks, financial institutions, investors, EPC partners, and statutory authorities.

The focus of this appendix is strictly on production capability and technical configuration, excluding all commercial pricing information.

B. Project Description

The proposed project involves setting up an automatic and semi‑automatic lithium battery assembly facility, starting from imported prismatic LFP lithium cells and producing finished battery modules and PACKs primarily for Battery Energy Storage System (BESS) applications.

The assembly process requires a defined combination of manpower‑assisted operations and automated equipment, exactly as per the approved scope of supply. No electrode manufacturing, cell fabrication, or raw chemical processing is included within this project scope.

C. Scope of Supply – Functional Overview

The scope of supply covers a complete and integrated cell‑to‑module‑to‑PACK assembly line, comprising the following functional stages:

Module Assembly Line Scope

• Automatic / semi‑automatic cell loading and orientation
• Online barcode scanning, OCV testing, internal resistance testing, and polarity verification
• NG segregation and buffer handling
• Cell stacking and alignment (flat stacking)
• Controlled pressing and compression
• Pole inspection through vision‑assisted photography
• Insulation withstand voltage (Hi‑Pot) testing
• Laser cleaning of welding areas
• CCS installation and verification
• Laser welding of cell tabs and busbars
• Manual post‑weld inspection and slag cleaning where required
• End‑of‑Line (EOL) electrical testing for completed modules
• Palletized conveyor transfer, buffering, and offline handling
• MES‑based traceability for defined critical process stations

PACK Assembly Line Scope

• Lower box handling and positioning
• Cooling plate air‑tightness testing
• Adhesive / sealing application with controlled dispensing
• Module placement and PACK assembly
• Intermediate and final PACK‑level inspection
• Complete PACK air‑tightness testing
• Charging and discharging validation
• Roller‑type PACK conveyor system with defined load capacity
• Offline handling and lifting for finished PACKs

The above scope ensures a complete and continuous assembly workflow from imported cells to finished battery PACKs.

D. Cell Technical Basis (Design Reference)

All production capacity calculations in this DPR are derived strictly from cell‑energy equivalent principles, independent of module or PACK aggregation assumptions.

The assembly line is designed to accommodate the above range of prismatic cell formats without fundamental changes to the production concept.

E. Supported Electrical Configurations

Based on customer, client, or buyer requirements, the line can be designed and customized to support multiple electrical series configurations, including but not limited to:

• 1P8
• 1P10
• 1P12
• 1P13
• 1P16
• Higher series configurations as required

The selected configuration determines the module voltage, while the annual energy capacity is governed by cell throughput and Ah rating.

F. Throughput and Operating Basis

The rated capacity of the facility is established on the following bankable operating assumptions:

This operating basis reflects a conservative and achievable production scenario.

G. Annual Capacity Determination (Base Case)

Cell Throughput

12 cells/min × 60 min × 8 hours × 300 days
= 1,728,000 cells per year

Energy Output (Cell‑Energy Equivalent)

Using a reference cell capacity of 280 Ah:

1,728,000 cells × (3.2 V × 280 Ah)
≈ 1.5 GWh per annum

H. Declared Base Capacity for DPR

Declared Plant Capacity:

1.5 GWh per year on a cell‑energy equivalent basis, using imported prismatic LFP cells, under single‑shift operation.

This declared capacity is conservative, transparent, and fully traceable to fundamental electrical parameters.

I. Customization and Capacity Variability Statement

Depending on customers / clients / buyers’ actual product specifications and capacity requirements, the complete assembly line can be designed and customized using imported prismatic LFP cells ranging from 100 Ah up to 314 Ah and above, with a nominal voltage of 3.2 V.

The final annual production capacity in GWh is directly determined by:

• Selected cell Ah rating
• Electrical configuration (series count)
• Actual cells‑per‑minute (PPM)
• Operating hours per day and number of shifts

Accordingly, the declared GWh output varies proportionally with operational and product parameters defined by the end customer.

J. Expansion Capability

The proposed assembly line is inherently scalable and allows future expansion through:

• Increase in daily operating hours or additional shifts
• Addition of parallel assembly lines
• Adoption of higher‑capacity prismatic cells

Under such scenarios, the facility is technically expandable to 3 GWh per year and beyond, subject to operational planning and incremental equipment deployment.

K. Bankability and Financial Suitability Statement

The capacity assessment and technical framework presented in this appendix:

• Is conservative and non‑speculative
• Is independent of selling price or revenue assumptions
• Is aligned with lender due‑diligence expectations
• Minimizes execution and over‑commitment risk

Accordingly, the proposed 1.5 GWh lithium battery assembly line represents a finance‑ready, scalable, and commercially viable manufacturing project suitable for consideration by banks, financial institutions, and strategic investors.