Custom battery packs

Custom battery packs and battery packs

In our own assembly department at our head office in Amsterdam, we produce custom-made battery packs and battery packs. Indeed, it is possible that the range of batteries and batteries from the various brands in our range does not perfectly meet your needs. An appropriate solution is required and we can offer it.

At Elfa, we produce custom-made battery and battery packs for a specific application in your situation. Requirements such as dimensions, voltage, capacity, connector but also the seal are produced the way you want it. This also includes battery packs for emergency lighting fixtures. These battery and battery packs are made from brands such as Saft, Tadiran, Panasonic and Varta.

We can also copy batteries that you have previously used, but which are no longer available, for example, as a battery pack. It then fully meets the specifications you have set. Elfa has been working closely with the world's best manufacturers for years and can produce battery and battery packs made of various chemical compositions.

Advice from our specialists

Various battery types

Custom packs are made by Elfa for various types of batteries. These are NiCd, NiMH, Li-ion, LiFePO4, alkaline and lithium. Details about the different battery packs will be discussed here.

1. NiCd

NiCd batteries provide excellent performance at low temperatures and are economically priced, so that the cost per cycle is low. The battery packs that we produce at Elfa are robust, fast-charging with little stress, and easy to store and transport without legal restrictions. NiCd battery packs are ideal for industrial and professional applications. Furthermore, the NiCd battery packs have the following benefits:

• High cycle time with good maintenance;
• Long shelf life;
• Suitable for medical and safety applications.

2. NiMH

NiMH batteries (Nickel metal hydride batteries) are easy to maintain due to their low memory effect. They contain no heavy metals, making them environmentally friendly. With a longer lifespan, rechargeable, and wide applicability, NiMH batteries are popular. They have a 30-40% higher capacity than standard NiCd batteries and are easy to store and transport.

They are widely used in cordless tools, communication devices, emergency lighting, and backup power. Furthermore, NiMH batteries are ideal for a variety of industrial and household applications. NiMH battery packs also have these advantages:

• Long life and reloadability;
• Less sensitive to memory effect;
• Environmentally friendly and easy to recycle.

3. Li-ion

For lithium-ion battery packs batteries from various brands are used. A popular variant is Panasonic's 18650 battery. This is because the Panasonic 18650 is highly reliable and offers excellent costs per kilowatt hour. Li-ion battery packs are widely used in medical devices, industrial applications, military equipment and robots, among others.

To ensure efficient and safe operation of rechargeable lithium batteries, a Battery Management System (BMS) is required. This is because a good BMS monitors and controls the discharge and charging of rechargeable lithium batteries. Elfa includes this in the production of all rechargeable lithium battery packs.

In addition to a BMS, a custom Li-ion pack can include battery holders, a PCB, PCM, cell balancing board, or other components. Lithium-ion packs include the following benefits:

• Long life;
• High energy density;
• Low self-discharge;
• No memory effect;
• High power.

4. LiFePO4

LiFePO4 battery packs require no maintenance thanks to the integrated Battery Management System. They can be mounted in any position and do not require ventilation. They can be fully discharged and have a lifespan of five times that of lead-acid batteries. They are commonly used in electric vehicles, energy storage, medical devices, emergency lighting, and backup systems.

LiFePO4 battery packs perform well at low temperatures and are non-flammable, environmentally friendly and lightweight. Other benefits include:

• Maintenance-free and flexible installation;
• 100% deep unloading possible;
• High energy density and long life;
• Lightweight and safe;
• Applicable in extreme temperatures from -45°C to +70°C, LiFePO4 battery packs are ideal for a variety of applications where reliability and safety are critical.

5. Alkaline

Alkaline battery packs are known for their durability and reliability, ideal for devices that require a constant flow of energy, such as smoke detectors and medical devices. Made of zinc and manganese dioxide, alkaline batteries provide long-lasting energy and longer life compared to zinc-carbon batteries.

They are commonly used in smoke detectors, audio equipment, emergency lights, and flashlights. They maintain a strong position in the market because of various advantages:

• Long life and cost effective;
• Consistent energy supply, essential for professional applications;
• Low risk of leakage, making them safe in critical environments;
• Environmentally friendly, without harmful metals such as lead or cadmium.

6. Lithium

Lithium battery packs use lithium metal or lithium compounds as anode and are known for their high energy density, ideal for compact, energy-intensive devices. They perform well at both very low and very high temperatures. With a higher voltage per cell (approximately 3.6 V), they provide more energy than standard alkaline batteries. Lithium batteries are meant to be discarded after discharge.

They are used in military applications, IoT devices, portable tools, and medical devices. The benefits are as follows:

• Long life with low self-discharge rate;
• High energy density for more energy in a smaller space;
• Reliable at extreme temperatures;
• Constant voltage for reliable performance;
• Lightweight, ideal for portable devices;
• These features make lithium battery packs ideal for use in a wide range of applications where reliability and efficiency are critical.

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Our own production locations for customized batteries and batteries

In our own assembly department in Lijnden, we make battery and battery packs in accordance with strict procedures and safety regulations. Hundreds of packs are made here every week.

In order to guarantee the necessary capacity, Elfa has more than one production location. In addition, we have partnerships with several battery manufacturers across Europe. As a result, we always have sufficient capacity, no order is too big. By the way, Elfa has ISO 9001 and ISO 14001 certifications.

Case study: Making industrial tools more sustainable

In September 2023, Elfa partnered with Tech Innovators BV to convert diesel-powered industrial tools to electric propulsion. For this purpose, Elfa supplied modular LiFePO4 battery modules that perfectly integrated with the existing systems, making a smooth transition possible. This progressive approach has resulted in:

• Reduction of operational costs;
• Reducing environmental impact;
• Reduction of CO2 emissions.

Thanks to this successful partnership, Tech Innovators BV has positioned itself as a leader in sustainable technology, with ambitious plans to roll out these solutions on a larger scale and inspire other sectors with their green strategy.

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The step-by-step plan for your own battery pack or battery pack

To request a customized battery pack or battery pack, we use a simple step-by-step plan.

Option 1: Send a sample pack

Send us an example of the desired battery pack to make the process as fast and accurate as possible (e.g. for the connector or dimensions). Before sending the sample pack, please report your request via: info@elfa.nl. In addition, include the following information:

• Contact person name
• Telephone number
• Customer reference
• Number of packs

Then send the pack to Elfa, citing your reference.

Option 2: Photos and Specs

If sending the sample pack is not possible, please send:

• 3 photos of the battery pack
• 3 photos of the connector
• 3 specifications (including legible label)

Send this with your details to info@elfa.nl.

Option 3: Fill in specifications

If options 1 & 2 are not possible, please write an email with all the specifications and details about the contact person and send it to info@elfa.nl. Questions? Contact us by mail or phone.

More info about our custom battery pack and battery packs

Do you have any further questions or would you like more information about Elfa making battery packs and battery packs? Then contact us! We are happy to help you and answer any questions you may have. The easiest way is to fill out the contact form below. We will contact you as soon as possible. By the way, you can also reach us by email.