“Our current R&D focus is on: module and PACK processes for largeformat cells (587Ah, 628Ah and above), high-precision laser welding with automatic post-weld inspection, machine vision for polarity checking and positioning, automated liquidcooling-plate assembly and leak testing, AGV flexible logistics and scheduling, the MES data closedloop and Industry 4.0 transparent production, and containerised energy storage system integration”
Sunka Lead provides automated and semi-automated production solutions for prismatic, cylindrical, pouch and blade batteries. How do you customise your production lines for different battery formats and customer requirements?
We customise our lines by combining platform-based design, modular configuration and non-standard custom engineering. We maintain mature production platforms for four battery formats — prismatic, large/small cylindrical, pouch and blade — and for each customer project, our three dedicated R&D teams (product process, mechanical structure, and PLC & MES) work together to adapt the line to the cell specification, module structure, PACK enclosure size, welding process and required throughput. Our lines are compatible with mainstream cells from 100Ah up to 1175Ah, covering common models from CATL, EVE Energy, Hithium, Gotion and other leading brands, and support rapid model changeover. From requirement research, scheme design and trial validation through to installation and commissioning, customers receive customised and continuous service throughout.
Your solutions cover cell processing, module assembly, laser welding, PACK assembly, EOL testing and MES traceability. How does this end-to-end approach help battery manufacturers improve production efficiency and quality?
We deliver an end-to-end integrated line: starting from incoming-cell inspection (OCV testing, barcode scanning, sorting, thickness measurement, cleaning and tape application), through the module stage (stacking, pressing and strapping, CCS busbar installation, laser welding, post-weld inspection, insulation/Hi-Pot and EOL testing, and DCIR testing), to the PACK stage (module loading into the enclosure, liquid cooling plate assembly and leak testing, busbar connection, BMS harness installation, PACK airtightness testing and final PACK EOL testing). The entire chain is designed, built and delivered by one team, which removes the interface and handover losses between multiple equipment vendors. At the same time, MES runs through the whole process and provides real-time traceability — one code, one product. The practical results: a line qualification rate of at least 99.8%, a final yield of at least 99.9%, and a whole-line equipment failure rate controlled within 3% [figures to be confirmed].
Sunka Lead offers dedicated production lines for EV batteries, C&I energy storage and residential energy storage. How are the production requirements different across these applications?
The requirements differ clearly across the three applications. EV power batteries demand high takt, large volume and automotive-grade quality traceability; here we deploy our high-end 20–24 PPM AGV lines with cell-level traceability and fully automated inspection at every process step. C&I energy storage centres on liquid-cooled, large-format PACKs — for example 587Ah and 628Ah cells in 1P52S and 1P104S configurations — which place higher demands on automated handling, leak testing and high-current charge/discharge testing; we have also extended into containerised energy storage system integration. Residential storage products are more standardised with moderate volumes, where changeover flexibility and cost-performance matter most; we offer 6–10 PPM semi-automatic and automatic lines. Configuring takt, material flow and inspection depth on one common technology platform is the key reason we can deliver quickly in all three markets.
How is Sunka Lead integrating robotics, AGV material handling and MES traceability into its battery manufacturing solutions?
Robotics and AGVs are deeply integrated into our lines. Six-axis robots handle repetitive, heavy-duty tasks such as cell loading, automatic stacking and module loading into the enclosure; AGVs — with magnetic-strip or QR-code navigation options — provide flexible material flow between the module and PACK sections, working in tandem with double-speed chain conveyors. Our MES follows a layered architecture: the enterprise layer integrates SRM, ERP, CRM and cloud data platforms; the management layer consists of MES, production e-dashboards and PLM; the control layer connects equipment through HMIs, servo drives and a Siemens PROFINET industrial network; and the execution layer collects OCV, IR, DCIR, EOL, leak-test, laser-welding, vision-inspection, pressure and torque data in real time. Line status is fully transparent and every product is traceable.
Your website highlights more than 70 product patents and a dedicated R&D and production base. What areas of battery manufacturing automation are currently receiving the most attention from your R&D team?
We operate three specialised R&D teams — product process, mechanical structure, and PLC & MES — supported by an equipment prototype R&D centre, a machine vision laboratory and a welding laboratory, jointly developed with partner universities. Our current R&D focus is on: module and PACK processes for large-format cells (587Ah, 628Ah and above), high-precision laser welding with automatic post-weld inspection, machine vision for polarity checking and positioning, automated liquid-cooling-plate assembly and leak testing, AGV flexible logistics and scheduling, the MES data closed-loop and Industry 4.0 transparent production, and containerised energy storage system integration. The company holds more than 70 product patents [to be confirmed], most of which have been built around these directions.
With ISO 9001 certification and 100% equipment inspection before delivery, how does Sunka Lead ensure reliability and consistency across its customised production equipment?
Reliability comes from standardised process management. We strictly follow ISO 9001, ISO 14001 and our occupational health & safety management systems, embedding standardisation across design, manufacturing, assembly, commissioning and delivery. Key processes follow standard work instructions, and every machine undergoes complete factory acceptance testing before shipment — including functional verification, no-load and loaded trial runs, and safety interlock checks [the “100% inspection before delivery” wording to be confirmed]. Projects are managed in five stages: requirement planning, R&D and manufacturing, installation and commissioning, acceptance and handover, and after-sales. For service, we commit to responding within 1 hour, arriving on site within 4 hours for urgent faults, and within 12 hours for major failures; equipment is covered by a 1-year free warranty plus lifetime maintenance, one set of original wear parts for key equipment, and full-lifecycle preventive maintenance.
Sunka Lead has offices in Hong Kong, India and Wuxi. What are your key priorities for expanding your global presence and supporting battery manufacturers in emerging energy-storage markets?
Our three offices play distinct roles: Hong Kong serves as our overseas business and cross-border platform; Wuxi focuses on intelligent logistics and flexible integration; in India, we have offices in Delhi and Ahmedabad and a factory in Noida (built with a local partner), providing local sales, installation, commissioning and after-sales support. As the global energy-storage market grows rapidly, we are prioritising emerging markets such as India and Southeast Asia. Our strategy is local teams, fast response, lines customised to local cell brands and certification standards, and turnkey delivery plus operator training so that customers can ramp up production quickly. Our vision is to become a world-renowned lithium-battery automation equipment supplier.
