Supercapacitor Pilot Line | Tabless Supercapacitor Fabrication | ARCI Hydrabad

A complete tabless supercapacitor pilot line delivered through end-to-end engineering and close client collaboration.

We partnered with the client to deliver a fully functional pilot-scale line for tabless supercapacitor manufacturing, including process engineering, equipment setup, hands-on demonstrations, and prototype validation.

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Project Overview

The Super Capacitor Fabrication Project was executed through a highly collaborative engagement with the client. The project began with detailed technical discussions to fully understand the client's performance goals, process expectations, facility layout needs, and equipment requirements.

Based on these inputs, our team created a complete project roadmap—covering workflow design, equipment selection, utility planning, safety guidelines, training needs, and commissioning steps.

Throughout the 3.5-month execution period, we maintained continuous communication via progress meetings, design reviews, on-site coordination, and weekly reporting. This ensured full transparency, alignment with technical objectives, and timely decision-making.

The result was a fully operational pilot line with all instruments installed, demonstrated, and handed over to the client. The developed process successfully produced validated tabless supercapacitor prototypes ready for scale-up.

What We Delivered

1. Full Equipment Installation & Demonstration

• Installed all pilot-line instruments, including mixing, coating, drying, calendering, assembly, and testing systems.
  
• Conducted hands-on demonstrations and operator training for every instrument.
  
• Provided SOPs, safety protocols, operational documentation, and troubleshooting guidelines.
  
  

2. Complete Process Design

• Developed the entire process flow for tabless supercapacitor fabrication.
  
• Optimized slurry mixing, electrode coating, drying parameters, and calendering.
  
• Implemented tabless cell architecture to minimize resistance and improve heat management.
  
  

3. Pilot Line Commissioning

• Integrated all instruments into a smooth, modular production pipeline.
  
• Established quality checkpoints and operational safety standards.
  
• Conducted multiple trial runs to verify stability and repeatability.
  
  

4. Prototype Fabrication & Testing

• Fabricated tabless supercapacitor prototypes directly from the pilot line.
  
• Performed ESR, capacitance, leakage current, and cycle-life testing.
  
• Submitted a complete performance validation report to the client

Key Achievements

• Fully commissioned supercapacitor pilot line delivered within 3.5 months.
  
• Complete installation and demonstration of all manufacturing equipment.
  
• High-performance tabless supercapacitor prototypes successfully produced.
  
• A scalable, repeatable manufacturing process ready for future expansion.
• Smooth client collaboration from initial planning to final handover.

Applications Use

• Electric vehicles and transportation systems
  
• Renewable energy and grid-support solutions
  
• Industrial peak-power management
  
• Backup and emergency power systems
  
• IoT devices and pulse-power electronics

Key Points

• Tabless Supercapacitor Format
  
• End-to-End Pilot Line Setup
  
• Full Equipment Installation
  
• Demonstration & Operator Training
  
• Complete Process Design
  
• Prototype Cell Fabrication
  
• Performance Validation Tests
  
• 3.5-Month Delivery Timeline
  
• Client-Centric Engagement
• Scalable Manufacturing Capability

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