Pack and ESS assembly lines, delivered turnkey.
Montavo plans, builds and commissions assembly lines for energy storage battery packs, residential storage systems and C&I cabinets. One partner from the first feasibility study to a line running at rate, documented to the EU Machinery Regulation.
Lines for the products that store energy, not the cells inside them.
We focus on everything after the cell: module and pack assembly, system integration and end-of-line testing for three product families.
Energy storage battery packs
Rack-mount LFP packs for utility and C&I systems, from cell sorting and stacking to laser welding and EOL testing.
Explore pack lines
Residential energy storage
Wall-mounted and stackable home batteries and all-in-one units, with BMS integration, enclosure assembly and ageing.
Explore residential lines
C&I energy storage cabinets
Outdoor liquid-cooled cabinets: pack racking, high-voltage cabling, thermal and fire systems, PCS integration and system test.
Explore C&I linesFrom the first spreadsheet to the thousandth pack
Most projects stall at the hand-offs between consultant, equipment vendor, integrator and installer. We remove the hand-offs and carry every stage ourselves.
Preliminary assessment
Market, product, site and supply-chain review to define what the plant should make.
Financial modelling
CAPEX, OPEX, unit cost and payback scenarios that hold up with lenders and boards.
Line & factory design
Process flow, takt, layout, automation level and utilities, in 2D and 3D.
Equipment manufacturing
Build, integration and factory acceptance testing of every station.
Transport & logistics
Crating, export documentation and delivery to site.
Installation
Mechanical, electrical and IT installation by our own site teams.
Commissioning & ramp-up
Site acceptance, process validation, operator training and yield ramp.
Operational support
Spare parts, remote diagnostics, upgrades and continuous improvement.
When you need it, we also join your product R&D and design reviews, and deliver customized product designs and complete process packages. See all services
Build your line before you buy it
Pick a product, walk the line station by station and set each one to fully automated, semi-automated or manual. Investment, capacity and headcount update live, and the 3D model changes with you.
- Equipment and function details for every workstation
- Live total investment, annual capacity and labour requirement
- Animated product flow with bottleneck highlighting
- Send your configuration to our engineers in one click
One accountable partner for the whole plant
Single point of accountability
One contract and one team own capacity, yield and schedule, from design to ramp-up.
Product-aware line design
We design lines around your product, and help shape the product so it is easy to build.
Bankable numbers
Investment and unit-cost models built from real station data, ready for lenders and boards.
Right-sized automation
Fully automated, semi-automated or manual, station by station, matched to local labour cost and volume.
Thinking on ESS manufacturing
Manual, semi-automated or fully automated? Choosing the right automation level for an ESS pack line
Full automation is not always the right answer. How to decide, station by station, where robots pay back and where skilled operators are the better investment.
Read articleBuilding a bankable business case for an ESS pack assembly plant
Lenders and boards want more than a capacity figure. The building blocks of a financial model that survives due diligence, and the assumptions that matter most.
Read articleFrom cell to cabinet: the critical process steps in C&I energy storage assembly
A walk through the process chain of a liquid-cooled C&I cabinet, and the steps where quality is won or lost.
Read articlePlanning an energy storage factory?
Tell us what you want to build and where. We will come back with a first line concept, an investment range and a realistic timeline.