Warsaw, Mazovia cell grading plant
How Warsaw — Mazovia Grading Centre decides reuse or refining for every module — test sequence, grade bands, outputs and the sites that feed it.
Throughput
17,000 TPA
Process stages
6
Feeder sites nearby
6
Operating since
2022
From intake to grade assignment
- 1
Intake & safety triage
Packs are logged, thermally imaged and screened for swelling, coolant ingress or venting before entering the bench area.
- 2
Controlled de-energising
Residual energy is discharged to a safe state of charge with regenerative load banks and recorded per serial number.
- 3
Module-level capacity test
Full charge-discharge cycling at C/3 establishes usable capacity, internal resistance and cell-to-cell balance.
- 4
EIS fingerprinting
1 mHz–10 kHz impedance sweeps separate SEI growth, lithium plating and contact resistance degradation modes.
- 5
AI optical inspection
Machine-vision inspection of busbars, welds and cell cans flags mechanical defects that block second-life reuse.
- 6
Grade assignment
Grade A (≥85% SOH), B (75–85%), C (65–75%) and D routes are assigned, with D-grade material released to refining.
Acceptance criteria
| Criterion | Requirement |
|---|---|
| Accepted feed | Whole packs and modules from intake yards and fleets |
| State of charge | Below 30% on arrival, recorded per serial |
| Condition | Damaged units declared and routed to quarantine |
| Documentation | Manifest with serials, chemistry and prior history |
Grade bands and routes
| Grade | Route |
|---|---|
| Grade A (85%+) | Grid-tied and commercial storage builds |
| Grade B (75–85%) | Telecom backup and solar buffering |
| Grade C (65–75%) | Low-duty backup, short warranty |
| Grade D (<65%) | Discharge and refining feed |
Why Warsaw, Mazovia
Poland has become one of Europe's major centres for battery cell and component manufacturing, and Warsaw is a hub for logistics and fleet operations in central Europe. The grading centre opened on ulica Poleczki in 2022 to serve Poland and neighbouring countries, giving central European customers a closer alternative to sending material to western Europe for testing. Cross-border loads are handled routinely.
At 17,000 TPA, it grades passenger and commercial packs, electric bus packs from city transport operators, and modules and production material from regional manufacturers. Reusable modules are passed on for second-life builds, while material below threshold is sent for black mass production. Grade reports are issued for every pack tested, and regional manufacturers use the centre to assess rejected and end-of-line material before deciding what to do with it.
Permitting
EU Battery Regulation (EU) 2023/1542 and the Polish Act on Batteries and Accumulators
The centre operates under Polish environmental permits and the EU Battery Regulation (EU) 2023/1542. Transport follows ADR dangerous-goods rules, and cross-border movements follow EU waste shipment requirements.
Technical strengths
Central European base
Serves Poland and nearby markets without long hauls west.
Manufacturing support
Handles material from the region's battery production.
Bus pack grading
Tests packs from urban electric bus fleets.
Sites that feed Warsaw, Mazovia
Packs and modules arrive from these intake sites.
Warsaw, Mazovia plant: technical questions
How long does grading take?
Standard passenger modules are graded within about five working days of intake; large-format bus and truck packs take longer because of disassembly.
What tests are run on each module?
A full capacity cycle, DC internal resistance, impedance spectroscopy and optical inspection of busbars, welds and cans.
Does Warsaw serve countries outside Poland?
Yes, including neighbouring central European markets, subject to waste shipment rules.
Can bus batteries be graded in Warsaw?
Yes, with advance booking for large packs.
Damaged or defective packs are handled under a separate quarantine protocol — flag them in the form and the team calls you back the same day.
Need modules graded?
Share pack counts, chemistry and condition for a grading slot and indicative value split.