AYK Energy opens Chinese factory in a bid to become top marine battery maker

With the opening of the 5,000 m² factory, AYK is setting its sights on becoming the world’s leading marine battery maker. The company’s founder Chris Kruger said the new factory will massively ramp up production capacity using a new automated manufacturing system, to 300 MWh a year, with the ability to scale up to 1 GWh a year.

“The new AYK factory will seriously disrupt the marine battery market,” he said. 

Mr Kruger said the automated factory is the first of its kind and can be replicated with plans to open factories in Europe and America in 2024 in line with demand to serve the inland waterways market in those locations. AYK is one of the first manufacturers to secure type-approval for its lithium, iron, phosphate (LFP) cells instead of nickel, manganese, cobalt (NMC) cells. 

“This immediately slashes our costs which we can pass on to our customers. LFP is also safer than NMC, evidenced by countries such as China which does not allow NMC cells to be used for any application that involves transporting people,” added Mr Kruger. 

AYK Energy will build its range of seven class-approved batteries at the factory, including its Aries model aimed at electric ferries, tugs and barges, and Orion models aimed at OSVs, drill rigs and hybrid tugs. 

Mr Kruger said AYK will also expand production of containerised batteries from the factory. “From here, we can build the highest quality, safest and lowest cost class-approved batteries in the world. Our team is drawing on all our experience of working on marine batteries for 15 years, including pioneering the first-ever marine type-approved battery.” 

Containerised batteries have the benefit of being easy to install on deck without taking space below deck and incurring complex battery-room safety requirements. 

AYK Energy said the retrofit process is simple and does not require the vessel to be out of service for long. Batteries can also be swapped with fully charged replacements quickly at shore side charging centres. And the containerised system is future proofed. When a new, more powerful battery technology is developed, or a different form of power is introduced, the container can be adapted for that purpose.

AYK Energy has built and shipped more than 25 MWh of batteries to Europe over the last year.

One of the first projects supplied from the Zhuhai factory will see AYK supply Holland Shipyards Group with batteries for a zero-emissions machinery retrofit on the container vessel FPS Waal, operated by Future Proof Shipping. 

The ship’s diesel engines will be replaced with PEM fuel cells, storage for their hydrogen fuel, two AYK high-density DNV-approved Aries 88 lithium batteries and an electric drive train. Mr Kruger said the order is the first time AYK batteries will be used alongside fuel cells, making it a landmark contract for the company.