#prismatic cell

The future of clean energy and electric mobility in India relies on one powerful component: the lithium-ion battery. At the heart of high-performance battery packs are Prismatic Cells—widely used for their energy density, flat design, and pack assembly efficiency. But to ensure long-term performance and safety, these cells must be precisely sorted before being assembled. That’s where Semco Infratech delivers unmatched value, offering highly accurate, fast, and scalable Prismatic Cell Sorting solutions built for India’s battery manufacturing industry.

Why prismatic cell sorting matters

In a lithium-ion battery pack, even minor inconsistencies between cells can lead to imbalance, reduced capacity, overheating, or failure. Before integration, every Prismatic Cell must be tested for key parameters like voltage, internal resistance, and temperature. Based on these results, they need to be sorted into matched groups—this process is known as Prismatic Cell Sorting.

For modern Battery Manufacturers in India, this is no longer a manual task—it requires automation, speed, and precision. That’s why top manufacturers choose Semco Systems.

Semco Infratech: setting the standard in cell sorting

Semco Infratech, India’s most trusted supplier of battery production equipment, offers advanced Prismatic Cell Sorting machines that simplify and accelerate production. Designed for Indian conditions and high-volume factories, Semco’s systems deliver accurate results, reliable performance, and full integration into your battery assembly line.

Whether you're manufacturing cells for electric vehicles, grid storage, or industrial applications, Semco provides solutions that ensure consistent quality and efficiency.

Key features of Semco’s prismatic sorting systems

Semco’s Prismatic Cell Tester and Sorting Machines come with industry-leading features:

Multi-parameter testing Each cell is tested for voltage, internal resistance, and temperature—ensuring accurate Prismatic Cell Grading.

High-speed sorting mechanism Handles hundreds of cells per hour, automatically classifying them into performance-based categories.

Barcode scanning and traceability Each cell’s data is logged and linked to its barcode, allowing for traceable sorting and improved quality control.

Smart software interface Easy-to-use touchscreen interface allows technicians to monitor and control operations in real time.

BMS compatibility Works seamlessly with BMS test equipment for a complete cell-to-pack testing workflow.

Built for Indian battery manufacturers

Semco’s sorting systems are trusted by leading Lithium Battery Manufacturers in India because they are:

Cost-effective and scalable

Rugged and durable for local factory environments

Easy to integrate with existing systems

Supported with on-ground technical service

Semco also offers installation, operator training, and maintenance to ensure smooth operation and long-term performance.

Enabling consistent battery quality at scale

In today’s competitive energy market, quality cannot be compromised. With Semco’s Prismatic Cell Sorting machines, manufacturers can:

Improve production speed

Ensure accurate cell grouping

Reduce pack rejection rates

Maintain global safety and performance standards

Powering India’s clean energy future

As India aims to become a global leader in battery manufacturing, automation and precision will be key. Semco Infratech is proud to support this mission by equipping Lithium Ion Battery Manufacturers in India with high-performance sorting systems that simplify complex processes and deliver consistent results.

India’s clean energy revolution is being fueled by advancements in lithium-ion battery technology, where Prismatic Cells are emerging as a cornerstone for EVs and renewable energy storage systems. These cells offer higher energy density, better space utilization, and improved safety—making them ideal for sustainable applications.

The growing adoption of Lithium Ion Prismatic batteries has created a strong demand for precise manufacturing and testing solutions. At the heart of this shift lies advanced BMS test equipment, ensuring accurate monitoring and protection of battery packs. Alongside, Prismatic Cell Testers help manufacturers evaluate voltage, capacity, and internal resistance with high accuracy.

To enhance consistency and performance, automated Prismatic Cell Sorting and Prismatic Cell Grading systems are being deployed. These solutions ensure only the best-matched cells are assembled together, reducing failure rates and boosting efficiency.

By integrating such smart technologies, India is not only advancing its clean energy ambitions but also building a robust and self-reliant battery manufacturing ecosystem. These innovations are paving the way for a cleaner, greener, and energy-secure future—powering everything from electric mobility to grid-level storage with confidence and precision.

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Early batteries were in jars,but mass production changed the packaging to the cylindrical design.The year 1896 pioneered the large F cell for lanterns;the D cell followed in 1898,the C cell in 1900,and the popular AA was introduced in 1907.Design criteria and cost considerations required new battery formats that offer distinct advantages over the cylindrical design.How many kinds of battery cells do you know?Here you can get some information.

Cylindrical Cell

The cylindrical cell continues to be one of the most widely used packaging styles for primary and secondary batteries.The advantages are ease of manufacture and good mechanical stability.The tubular cylinder has the ability to withstand internal pressures without deforming.Typical applications for the cylindrical lithium battery cell are power tools,medical instruments and laptops.Nickel-cadmium offers the largest variety of cell choices,and some popular formats have spilled over to nickel-metal-hydride.To allow variations within a given size,manufacturers use fractural cell length,such as half and three-quarter formats.Figure 1 shows a cross section of a cell.

Lead acid batteries come in flooded and dry formats; portable versions are packaged in a prismatic design resembling a rectangular box made of plastic.Some lead acid systems also use the cylindrical design by adapting the winding technique,and the Hawker Cyclone is in this format.It offers improved cell stability,higher discharge currents and better temperature stability than the conventional prismatic design.

The established standards for nickel-based batteries did not catch on with lithium-ion and the chemistry has established its own formats.One of the most popular cell packages is the 18650 battery,as illustrated in Figure 2.Eighteen denotes the diameter and 65 is the length of the cell in millimeters. The Li-manganese version 18650 has a capacity of 1,200-1,500mAh;the Li-cobalt version is 2,400-3,000mAh.The larger 26650 cells have a diameter of 26mm with a length of 65mm and deliver about 3,200mAh in the manganese version.This cell format is used in power tools and some hybrid vehicles.

Cylindrical cells include a venting mechanism that releases excess gases when pressure builds up.The more simplistic design utilizes a membrane seal that ruptures under high pressure.Leakage and subsequent dry-out may occur when the membrane breaks.The re-sealable vents with a spring-loaded valve are the preferred design.Cylindrical cells make inefficient use of space,but the air cavities that result with side-by-side placement can be used for air-cooling.

Button Cell

Smaller devices required a more compact cell design,and in the 1980s the button cell met this need.The desired voltage was achieved by stacking the cells into a tube.Early cordless telephones,medical devices and security wands at airports used these batteries.Button cells,also known as coin cells,offer small size and ease of stacking but do not allow fast charging.Most commercial button cells are non-rechargeable.

Although small and inexpensive to build,the stacked button cell fell out of favor,and newer designs reverted to more conventional battery configurations.A drawback of the button cell is swelling if charged too rapidly.Button cells have no safety vent and can only be charged at a 10- to 16-hour charge.However,newer designs claim rapid charge capability.Most button battery cells in use today are non-rechargeable and can be found in medical implants,watches,hearing aids,car keys and memory backup.Figure 3 illustrates the button cells with accompanying cross section.

Prismatic Cell

Introduced in the early 1990s,the prismatic cell satisfies the demand for thinner sizes and lower manufacturing costs.Wrapped in elegant packages resembling a box of chewing gum or a small chocolate bar,prismatic cells make optimal use of space by using the layered approach. These cells are predominantly found in mobile phones with lithium-ion.No universal format exists and each manufacturer designs its own.If the housing design allows a few millimeters extra in a cell phone or laptop,the manufacturer designs a new pack for the sake of higher capacity.High volume justifies this move.

Prismatic cells are also making critical inroads into larger formats.Packaged inwelded aluminum housings,the cells deliver capacities of 20 to 30Ah and are primarily used for electric powertrains in hybrid and electric vehicles.Figure 4shows the prismatic cell.The prismatic cell requires a slightly thicker wall size to compensate for the decreased mechanical stability from the cylindrical design,resulting in a small capacity drop. Optimizing use of space makes up this loss.Prismatic cells for portable devices range from 400mAh to 2,000mAh.

Pouch Cell

In 1995,the pouch cell surprised the battery world with a radical new design.Rather than using a metallic cylinder and glass-to-metal electrical feed-through for insulation,conductive foil tabs welded to the electrode and sealed to the pouch carry the positive and negative terminals to the outside.Figure 5 illustrates such a pouch cell.The pouch cell makes the most efficient use of space and achieves a 90 to 95 percent packaging efficiency,the highest among battery packs.The pouch pack finds applications in consumer,military,as well as automotive applications.No standardized pouch cells exist;each manufacturer builds the cells for a specific application.

Pouch packs are commonly Li-polymer.Its specific energy is often lower and the cell is less durable than Li-ion in the cylindrical package.Swelling or bulging as a result of gas generation during charge and discharge is a concern.Battery manufacturers insist that these batteries do not generate excess gases that can lead to swelling.Nevertheless,excess swelling can occur and most is due to faulty manufacturing,and not misuse.Some dealers have failures due to swelling of as much as three percent on certain batches.Manufacturers say that an inflated cell is safe.Figure 6 shows a swelled pouch cell.

To prevent swelling,the manufacturer adds excess film to create a "gas bag" outside the cell.During the first charge,gases escape into the gasbag,which is then cut off and the pack resealed as part of the finishing process.Expect some swelling on subsequent charges;8 to 10 percent over 500 cycles is normal.Provision must be made in the battery compartment to allow for expansion.It is best not to stack pouch cells but to lay them flat side by side.Prevent sharp edges that could stress the pouch cell as they expand.