Warehouse Challenges for Solar and Battery

Industry challenges
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Controlled Environment - Manufacturing of Photovoltaic cell, core of solar panels and Li-ion batteries are highly sensitive to moisture and particle contamination and needs ISO and ESD compliant cleanroom environment, else may result in reduced efficiency, corrosion and quality.
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Process & Operational flows - Segregated ageing, testing, and Just in Time supply intensifies complexity to battery manufacturing, often causing material movement delays, idle production lines, further resulting into increased operating costs.
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Complex Material racking - Custom-shaped solar panels and batteries of varying weights demand specialised storage racks, leading to increased handling complexity and inefficiencies in warehouse operations.
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ESD Risk - Production of new energy cells and battery are highly vulnerable to electrostatic discharge. It can result to short circuits, toxic exposure and thermal runaway resulting in fire or explosion.
Industry challenges
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Storage Density - Gigafactory-scale production asks for compact, high-density storage and adaptable layouts. Shortage of buffer zones between coating, pressing, and testing stages results into space and inventory bottlenecks.
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Storage and traceability - Proper storage and tracking of millions of micro-cells and segregating batteries like lithium iron phosphate (LFP) and nickel manganese cobalt (NMC) to avoid risks of reactions is complicated, leading to recalls, and non-compliance.
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Return & Recycling Risks - End-of-life batteries and solar panels create fire, leakage and compliance dangers. Mishandling during reverse logistics slows down recycling, adds storage burden and affects sustainability goals.

Automation Solutions for Solar and Battery

Buffer Storage

Material Movement

ASRS

Conveyors and pallets

AI-enabled Software

Digital Twin

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Addverb shuttles enable high density buffer storage for in-process goods for the processes like cutting, calendering, ageing, etc. ensuring a continuous supply to subsequent production lines. These buffer storage helps to maintain strict compliance in a cleanroom environments, where space is at a premium.

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Addverb’s heavy duty AMR robots, with special attachments and varied load capability up to 2500 Kgs assures accurate handling of solar panels and battery packs, minimising damage risks and enabling accurate, large-scale handling in safe human robot environment.

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High-density ASRS like Stacker Cranes maximize gigafactory floor space, providing vertical storage and modular racks for varying chemistries and product sizes of up to 2500 kgs. Transfer Cars facilitate cranes to switch aisles smoothly and ensures flexibility in dynamic production environments.

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Anti-static conveyors with co-ordinated turntables transport pallet and crates with electrolytes and PV cells in production zones, maintaining safe zone-to-zone automated transfer line for flexible routing, preventing contamination and ensuring ESD safety compliances.

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Addverb’s AI enabled software, WMS assures batch-level tracking across millions of micro-cells and chemistries, preventing mix-ups, assuring compliance, traceability and giving manufacturers real-time visibility of inventory.

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Our digital twin platform lets you onboard new customers with confidence by combining real-time data from existing operations with projected data from incoming customers. This realand simulated coexistence helps you test, analyze, and optimize in the virtual world before execution in the real one.

Solutions Finder

Your biggest challenge?
Damages during intra-warehouse material movement
Appropriate handling necessary to reduce the risk of damage during storage
Temperature-controlled environment to protect sensitive material
Unforeseen events disrupting supply chain and affecting order fulfilment
Compliance with storage and handling regulations is a must to avoid legal issues

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Driving a change with sustainable automation

Why Choose Addverb?

Transforming Industries with Automation

Battery and Solar warehouse automation benefits renewable industry by improving operational efficiency, safety and accuracy while saving cost and enhanced traceability.

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Frequently Asked Questions

  • What factors determine the cost of automating a semiconductor warehouse or cleanroom?

    The cost depends on the required automation modules, contamination control level (ISO class) and type of automated transport systems (like AMRs, FOUP/FOSB storage). Since semiconductor operations have stringent ESD and cleanliness requirements, solutions are highly customized. For an exact cost estimate, please get in touch with our experts here.

  • How long does it take to implement automation in a semiconductor environment?

    Implementation timelines depend on cleanroom layout, throughput required, and integration with existing MES and fab systems. Modular solutions such as FOUP transport Mobico or automated Vertex can go live in phases within months. Stepwise deployment ensures zero contamination risk and seamless handover across cleanroom zones.

  • How can digital twin simulation help optimize semiconductor logistics?

    Addverb’s digital twin models wafer flows, FOUP transfers, and buffer storage under varying throughput scenarios. This helps fabs test layout efficiency, predict bottlenecks, and validate system capacity before deployment, reducing commissioning time and ensuring flawless integration with fab operations.

  • How do Addverb’s solutions ensure contamination-free and ESD-safe handling?

    All our cleanroom AMRs and robotic systems use anti ESD materials and have smooth movement for handling fragile components of semiconductor production. Integrated sensors monitor particle count and ESD parameters in real time, ensuring contamination-free transport of wafers, and critical components.

  • Can Addverb automation scale with fab expansion or new process lines?

    Yes. Our modular automation like FOUP transfer AMRs, Wafer disk ASRS can be easily scaled or reconfigured as new bays, or process lines are added. Our Seamless software integration ensures synchronized wafer flow and real-time updates across MES and warehouse control systems.