In a recent development, International Power Supply (IPS), based in Bulgaria, announced that its new automated battery energy storage system (BESS) manufacturing facility will require approximately 85% fewer employees per gigawatt-hour (GWh) of production capacity. This advancement marks a significant shift in the manufacturing landscape for energy storage systems.
IPS CEO Alexander Rangelov stated in an interview with Energy-Storage.news that their facility features a ‘cell-to-system’ production process, which is the first of its kind in Europe. The current manufacturing setup employs around 30 workers for every GWh of annual capacity. However, the new facility is designed to operate with only 45 employees total for a planned capacity of 10GWh, meaning the labor requirement per GWh will drop to about 4.5 workers.
This automation initiative could lead to substantial cost savings and increased production efficiency in the BESS sector. Rangelov emphasized that most assembly tasks do not necessitate specialized skills, as the processes are simplified to allow for easier workflow. The only area requiring advanced electrical engineering expertise is during the final testing phase, which involves handling high voltages and power levels.
The facility is set to reach an initial capacity of 3GWh by the end of 2025, with plans to expand to 4GWh once construction of an adjoining site is completed. As the industry evolves, IPS is also in the design phase for a larger facility that aims to achieve a 10GWh production capacity.
This move towards automation aligns with the broader trends in the renewable energy sector, where efficiency and cost reduction are critical for scaling up production. With this new approach, IPS is positioning itself as a leader in the evolving landscape of energy storage manufacturing.
