Setting up a cell grading line is a critical milestone for any lithium-ion battery manufacturer aiming to deliver safe, consistent, and high-quality battery packs. With the right system, manufacturers can grade thousands of cells daily, ensuring only matched cells go into assembly—drastically reducing failure rates and increasing battery life.

Semco Infratech, India’s trusted name in battery manufacturing equipment, offers high-performance cell grading machines that are fast, accurate, and built for production scalability. If you're planning to set up your own grading line, here’s a clear step-by-step guide to do it efficiently with Semco systems.

Step 1: Assess your production requirements

Before selecting a system, evaluate the following:

• Daily grading volume (e.g., 5,000 cells/day)

• Type of cells (cylindrical, prismatic, pouch)

• Available floor space

• Power and network infrastructure

• Cell testing parameters (voltage, capacity, internal resistance)

Share this information with Semco’s technical team—they will recommend the right configuration (64, 128, or 256 channels) tailored to your production scale.

Step 2: Choose the right Semco cell grading machine

Semco offers a range of high-speed Lithium-Ion Cell Grading machines with:

• Multi-channel architecture for parallel testing

• High-accuracy sensors for voltage, capacity, and IR

• Integrated auto-sorting for matched cell grouping

• Smart software with real-time monitoring and data export

Select a model that aligns with your current needs but also allows future upgrades. Semco’s modular design ensures scalability.

Step 3: Prepare your site for installation

Once the machine is finalized, prepare the site:

• Ensure 3-phase power or specified voltage availability

• Keep the area dust-free, temperature controlled, and dry

• Allocate ergonomic workstations and material flow areas

• Install stable tables or racking for cell trays

• Arrange proper LAN or Wi-Fi connectivity for software

Semco provides a checklist before delivery to ensure smooth installation.

Step 4: Machine delivery and physical setup

Semco’s team will deliver and install the machine at your site. During installation:

• Channels are calibrated and tested

• Auto-sorting bins are aligned as per grade thresholds

• Barcode scanner and optional printer setup is done

• Machine is positioned to allow smooth cell loading/unloading

• Operator console and software interface are configured

Installation is typically completed within 2–3 working days.

Step 5: Software setup and grading profile creation

Semco’s engineers will install the grading software and:

• Set up voltage, capacity, and IR thresholds

• Configure batch codes and data logging settings

• Customize sorting rules as per your cell specifications

• Train operators to enter, run, and monitor tests

You’ll also be shown how to export reports and maintain traceability with barcode integration if needed.

Step 6: Trial grading and fine-tuning

Before production begins:

• Run a sample batch of cells to validate sorting accuracy

• Adjust thresholds based on results

• Test data output, sorting logic, and reporting

• Verify repeatability across channels

This ensures that your grading line is optimized for actual production and yields reliable, consistent results.

Step 7: Start full-scale grading operations

With setup complete, you can begin full-scale grading. Operators load cells, initiate tests via the touchscreen interface, and sorted cells are automatically directed to the appropriate bins. Real-time test data can be monitored and saved for QA or compliance records.

Semco’s machines are designed for 24/7 industrial use with minimal maintenance and downtime.

Step 8: Support, maintenance, and expansion

Semco provides:

• Preventive maintenance plans

• Remote diagnostics and upgrades

• Spare part availability within India

• On-call engineering support for any issues

If your grading needs increase, you can easily upgrade channels or add another machine thanks to Semco’s scalable system design.

Conclusion

Setting up a Semco cell grading line is a smooth, structured process with the right planning and support. From machine selection to production startup, Semco’s team ensures every step is optimized for speed, accuracy, and long-term reliability.

For Indian battery manufacturers looking to lead in quality and scale, Semco Infratech offers the perfect grading solution—robust machines, local service, and proven performance. Start strong. Grow confidently. Grade better with Semco.