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BK Energies technician, seen from behind in a company T-shirt, facing a long line of Power Pro units in the integration building

Production

Two production centres. One standard.

BK Energies has two production centres in China: Luoyang and Lianyungang. There we integrate LFP cells with BMS, power conversion, protections, cooling and fire suppression to deliver 100% operational BESS.

See the processTalk to our engineers
2
production centres in China
8
integration and test stages
5
product levels, from cell to container
1,000+
PV, BESS and hybridisation projects
BK Energies technician next to an all-in-one unit bearing the BK logo, in the integration building

Integrators

We integrate, test, commission and operate. One technical team.

How we work

We design in Asturias. We integrate and test in China. We operate wherever your system is.

We are energy storage system integrators: we bring cells together with every other component and take responsibility for the complete system, from engineering to operation.

  1. 01

    Design and engineering

    Asturias

    System engineering, cell and component selection, electrical schematics and EMS configuration.

  2. 02

    Integration and testing

    Luoyang · Lianyungang

    Cells, BMS, power conversion, protections, cooling and fire suppression. Testing at every stage and a final FAT.

  3. 03

    Commissioning and operation

    Spain · Europe · Latin America

    Installation, site testing, commissioning and 24/7 operation with our EMS.

LuoyangLianyungangOviedoMadrid
Map showing the production centres in Luoyang and Lianyungang (China), the head office in Oviedo (ASIPO III, Llanera) and the sales office in Madrid (Tarancón, Cuenca).

Drag to rotate

Two production centres

Luoyang and Lianyungang. Headquartered in Asturias.

We have two production centres in China. Both work with the same process, the same checks and the same documentation, and engineering decisions are made in Oviedo.

Production · China

Headquarters and offices · Spain

Same process
The eight integration stages and their checks are identical at both centres.
Same traceability
Serial number for every pack, rack and system, with a record of each test.
Engineering in Spain
Design, showroom and technical service in Oviedo (ASIPO III, Llanera).

The production line

Eight stages from a cell to a site-ready system.

This is how every unit moves through our production centres in Luoyang and Lianyungang. Every station has its own check, and every check is recorded.

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01 / 08

Cell

Cell receipt and inspection

Robotic loading of LFP cells, open-circuit voltage and internal impedance measurement, and grading into homogeneous groups.

  • OCV
  • Internal resistance
  • Visual inspection
  • Grading into groups

Production flow

From cell to operational system, in eight stages.

Every stage has its check and every check leaves a record. The result is a system traceable from cell batch to commissioning.

  1. BK technician in a company T-shirt measuring LFP cells on a pallet in the receiving area01

    Stage 01

    Cell receipt and inspection

    Every batch of LFP cells arrives with its documentation. We measure open-circuit voltage and internal impedance, check the physical condition and group cells with matching behaviour so the pack runs balanced from the very first cycle.

    • OCV
    • Internal resistance
    • Visual inspection
    • Grading into groups
  2. Busbars laser-welded onto the terminals of a row of cells02

    Stage 02

    Stacking and laser welding

    Cells are stacked in their frame and joined with laser-welded busbars. Terminals are cleaned beforehand and every joint is inspected afterwards: a poor weld means resistance, heat and shorter service life.

    • Terminal cleaning
    • Busbar laser welding
    • Joint inspection
  3. Open battery pack showing the BMU board, sensor wiring and power connectors03

    Stage 03

    BMU and BMS interconnection

    We fit the sensing harness and BMU to each pack. The BMS reads every cell voltage and the temperature at several points, balances the charge and protects the whole assembly in real time.

    • Sensor continuity
    • BMU communication
    • Balancing
  4. BK operator assembling an LFP cell module at the assembly bench04

    Stage 04

    Pack assembly and testing

    We close the pack with its enclosure, liquid cooling plates or air ducts, and connectors. Before leaving the line it passes its end-of-line test: insulation, dielectric strength and, for liquid-cooled packs, circuit leak-tightness.

    • Insulation
    • Hi-Pot
    • Leak tightness
    • Pack EOL test
  5. Open battery cabinet with two columns of integrated packs and their wiring05

    Stage 05

    Rack integration

    Packs are connected in series inside the rack alongside the high-voltage control box: contactors, fuses, current measurement and the rack BMS that coordinates every pack.

    • Tightening torque
    • Polarity
    • Rack insulation
  6. BK technicians testing open battery cabinets in the test area06

    Stage 06

    Functional and quality testing

    Every rack and every system is tested in operation: BMS, PCS and EMS communications, tripping of protections and alarms, and charge and discharge cycles to verify capacity and balancing.

    • Communications
    • Protection
    • Cycling
    • Burn-in
  7. Three technicians wiring battery cabinets on the integration line07

    Stage 07

    Final BESS assembly

    We integrate power conversion, protection switchgear, cooling, fire detection and suppression, and our EMS. The complete system then passes its factory acceptance tests (FAT).

    • PCS
    • Protection
    • Fire suppression
    • EMS
    • FAT
  8. Packed BESS units and a forklift in the dispatch area08

    Stage 08

    Packing and dispatch

    Each unit leaves packed for sea or road transport, with Class 9 dangerous goods documentation and a quality dossier tracing every test.

    • UN 38.3
    • Class 9
    • Quality dossier

Production lines

Five levels of integration, from cell to container.

Each level is a finished product and, at the same time, the starting point for the next. That is why we can supply anything from cells for a special project to multi-MWh containers.

  1. 01
    314AhLiFePO43.2V

    Cells

    LFP 280 – 587 Ah

    Receipt, inspection and testing of LFP cells, with serial-number traceability.

    See the range
  2. 02

    Packs

    11.5 – 46.6 kWh

    LiqPack and AirPack: stacking, laser welding, BMU, closing and end-of-line testing.

    See the range
  3. 03

    Racks

    172.8 – 372.7 kWh

    LiqRack and AirRack: packs in series with a high-voltage box and rack BMS.

    See the range
  4. 04

    Cabinets and all-in-one

    112 – 522 kWh

    BK Cabinets from 241 to 418 kWh and Power Pro from 112 to 522 kWh: battery, PCS, protections, cooling, fire suppression and EMS in one unit.

    See the range
  5. 05

    Containers

    3.34 – 6.25 MWh

    Powerbolt: racks, liquid cooling, HVAC and fire suppression in a 20-foot container.

    See the range
Line of open cabinets during rack integration and wiring
Cabinet integration
Open BESS container with integrated rack columns
Racks in containers
Cooling
Liquid or air
DC voltage
Up to 1,500 Vdc
Installation
Indoor and outdoor, IP55
Chemistry
LFP

Quality and testing

Tested at every level. And documented.

Routine tests are carried out on every unit, in line. Type tests validate the design against the industry's safety standards.

Routine tests · every pack, every rack, every system

1

Cell

  • Open-circuit voltage (OCV)
  • Internal resistance
  • Visual inspection
  • Grading into groups
2

Pack

  • Insulation resistance
  • Dielectric strength (Hi-Pot)
  • Liquid circuit leak-tightness
  • BMU communication
  • End-of-line test
3

Rack

  • Tightening torque
  • Polarity and voltage
  • Rack insulation
  • Rack BMS
4

System

  • BMS · PCS · EMS communications
  • Protections and alarms
  • Cycling and burn-in
  • FAT
5

On site

  • Incoming inspection
  • Commissioning tests
  • EMS and PPC integration
  • Handover certificate
Inside a 215 kWh unit, showing the packs, the control panel and the fire suppression system

Traceability

  • Serial number for every pack, rack and system
  • Record of every test, with date and result
  • Quality dossier that ships with the unit

Reference standards

  • UL 9540A

    Test method for thermal propagation in battery systems: what happens when a cell fails.

  • UL 1973

    Battery safety for stationary applications.

  • IEC 62619

    Safety requirements for lithium batteries in industrial applications, including stationary energy storage.

  • IEC 62933

    Electrical energy storage systems: parameters, test methods and system safety.

  • IEC 63056

    Safety requirements for lithium batteries in electrical energy storage systems.

  • UN 38.3

    Tests for the safe transport of lithium batteries: altitude, thermal, vibration, shock and short circuit.

Standards declared in our product datasheets. Scope varies by model: ask us for the certificates of the unit you are interested in.

What the type tests assess

Electrical
External short circuit, overcharge and over-discharge
Mechanical
Vibration and shock
Environmental
Thermal cycling and humidity
Thermal propagation
Induced cell failure and system behaviour

In the factory

People who know every unit inside out.

Technicians on the line, engineering in Asturias and a single technical team accountable for your project at every stage.

BK Energies technician pointing at a line of Power Pro units in the integration building
All-in-one unit line
BK operator handling an LFP cell module at the assembly bench
Module assembly
Open cabinet with two columns of integrated packs, wiring and control panel
Packs integrated into racks
Open battery pack showing the cells, busbars and BMU board
Open pack: cells and BMU
Row of finished battery cabinets in the integration building
Finished Cabinets

Logistics and commissioning

From the production line to your site.

We coordinate shipping from China, transport and delivery to site. Then our technical team installs, commissions and operates the system.

  1. 01

    China

    Release

    FAT passed, serial number and quality dossier for the unit.

  2. 02

    China

    Packing

    Transport protection and Class 9 dangerous goods documentation.

  3. 03

    China

    Transport

    By sea in containers and by road to the site.

  4. 04

    Destination

    Receipt

    Arrival inspection and unloading coordinated with the site.

  5. 05

    Destination

    Commissioning

    Installation, connection, site testing and EMS integration.

  6. 06

    Destination

    Operation

    24/7 monitoring, maintenance and technical service from Spain.

Packed BESS units and a forklift in the dispatch area
Units packed and ready for dispatch

Where we deliver

  • SpainInstallation, commissioning and technical service with our own team and nationwide coverage.
  • EuropeHybridisation and grid-connected energy storage projects.
  • Latin AmericaUtility-scale systems, with remote support from Spain.

Technical service in Spain

Workshops and warehouses stocking critical components, so replacements never wait on shipping. Remote diagnostics and a field team with nationwide coverage.

Want to see how your system is integrated?

We'll show you the process, the test documentation and units in operation. If you prefer, we can start at our showroom in Asturias.

Talk to our engineersView products