In response to the challenges posed by the European Union’s new battery regulations, a global leader in EV battery systems has partnered with Lead Intelligent Equipment (hereafter referred to as LEAD) to jointly develop a comprehensive logistics solution that complies with EU standards, successfully implemented in the European market.
The EV battery systems provider is renowned for its products’ high energy density, long lifespan, and high safety, widely applied in the electric vehicle sector. In recent years, as the company’s overseas business has expanded, the need for a logistics solution that meets EU standards has become urgent, particularly to comply with the new EU battery regulations.
EU Regulations Drive Companies to Seek Solutions for International Expansion
The new EU Battery Regulation (EU) 2023/1542 came into force in February 2024, requiring that batteries from electric vehicles exported from China to Europe be returned to the country of production for disposal. Starting in February 2025, EV batteries sold in the EU market must provide carbon footprint declarations. By 2027, batteries exported to Europe must hold a “Battery Passport” that meets EU standards. These regulations have forced companies to build local factories in Europe to enhance their competitiveness in the market.
Although the EV battery systems provider had an established lithium-ion battery logistics solution, this was their first attempt at international expansion, which brought challenges in product certification, industry regulations, customs clearance, overseas staffing, and on-site operational management. LEAD, a global leader in intelligent manufacturing solutions for new energy, offers a comprehensive one-stop solution covering consultation, design, manufacturing, installation, training, and subsequent upgrades. LEAD has already created leading smart factory solutions for renowned companies such as CATL, EVE Battery, SVOLT, and Tesla. Due to LEAD’s outstanding capabilities in lithium-ion battery intelligent manufacturing, the provider selected LEAD to deliver a compliant logistics solution after careful consideration of the challenges.
Customized Smart Logistics: Four Key Systems for Support
LEAD provided the client with four major smart logistics systems tailored to the client’s plant layout and production processes, forming a comprehensive customized logistics solution.
Overhead Transfer System
The client’s products include a wide range of battery cell structural components, which need to be transported over long distances across various production stages. Traditional methods couldn’t meet the need for efficient, stable transport. LEAD pioneered the use of an aerial suspended platform combined with an overhead conveyor system to address these challenges. The system integrates dispatching control, roller conveyors, rotating tables, and transport pallets, enabling seamless production capacity matching and long-distance, uninterrupted transport across multiple stages, effectively utilizing vertical space.
Mid-Section Logistics Transport System
In the lithium-ion battery production process, coordination difficulties exist between various machines in terms of battery cell flow and equipment loading/unloading, which hampers efficient assembly. LEAD’s mid-section logistics system integrates scheduling control, double-layer conveyors, vertical lifts, pallet escape, lifting and transfer mechanisms, and cell transfer mechanisms. The system ensures smooth flow of materials between machines and processes, meeting the client’s need for high-efficiency assembly.
Formation and Aging Logistics Storage System
During the formation and aging stage, it’s critical to ensure the safe and reliable transport of charged battery cells, efficient material handling, and compliance with EU export standards. LEAD’s solution includes a formation logistics dispatching system and capacity logistics dispatching system, incorporating safety measures such as flexible robotic grippers, multiple detection switches, and mechanical-electrical safeguards. The system also supports full lifecycle traceability and efficient material handling, meeting EU standards with an efficiency of 20 PPM on a single line.
Sorting and Packaging System
With a variety of battery cell specifications, grades, and batches, sorting and packaging them manually is inefficient and labor-intensive. LEAD’s system uses 3D vision technology and MES integration to automate the sorting, scanning, and packaging processes. This system significantly enhances production efficiency, saving over 20 workers per shift on a 20 PPM line.
This project has recently been successfully launched as the client’s first battery factory in Europe, marking a key milestone in their international expansion.
The project leader from the client company remarked: “LEAD’s solution enables full automation of operations from raw material storage, intelligent unpacking, formation and aging processes to sorting and packaging. It has reduced manpower by over 25%, and our production efficiency and system stability have exceeded expectations, substantially lowering overseas labor costs and reducing labor risks.”
As lithium-ion battery production expands globally, compliance with logistics regulations for overseas operations has become essential. The trends of fewer workers, high safety, quick installation, and fully intelligent processes are key for global product delivery. LEAD has enhanced logistics efficiency across multiple facets, including information, resources, production, and inventory management, providing a platform for transparent, real-time, and flexible management that better meets customers’ lean production and management requirements. Looking ahead, LEAD will continue to focus on customer needs, drive innovation in technology, and enhance the customer experience with valuable solutions and faster, better support services, helping the global lithium battery industry reach new heights.
