NextStar Energy has begun production on a new battery pack manufacturing line at its Windsor, Ontario, facility, completing full cell-to-pack vertical integration at a single site for the first time as it expands its focus on the growing energy storage system (ESS) market.
The addition of battery pack production complements the plant’s existing battery cell and module manufacturing operations, enabling the company to produce complete battery products from a single location.
Cell-to-Pack Production Completed
The Windsor facility, Canada’s first commercial-scale battery manufacturing plant, officially opened earlier this year after commercial battery cell production began in November 2025.
The plant reached a production milestone of one million battery cells in February 2026.
With the launch of the new battery pack production line, NextStar Energy can now manufacture battery cells, modules and finished battery packs at the same facility, strengthening its role within North America’s battery supply chain.
Expanding Into the ESS Market
The new production line has been added in response to increasing global demand for battery energy storage systems, allowing the company to broaden its product portfolio beyond battery cells and modules.
“Adding pack production means we can now take a battery from cell to module or to a finished pack, all here in Windsor,” said Danies Lee, Chief Executive Officer of NextStar Energy.
“This expansion reflects our commitment to capitalizing on the rapid growth of the ESS market and is a meaningful step to strengthen Canada’s position in the global battery supply chain as well.”
Strengthening Vertical Integration
The company said full vertical integration from battery cell production through to finished battery packs reduces logistics complexity while providing greater visibility across the manufacturing process.
Producing complete battery systems at a single location also positions NextStar Energy as a single-source supplier for customers seeking energy storage solutions.
Growing Focus on Grid Storage
The investment also highlights the growing importance of stationary energy storage within the North American battery market.
While the Windsor facility was originally established to support the automotive battery supply chain, the latest expansion reflects increasing demand for grid-scale energy storage products as utilities and renewable energy developers invest in battery storage capacity.
NextStar Energy, a wholly owned subsidiary of LG Energy Solution, said the expansion strengthens both its manufacturing capabilities and Canada’s position within the global battery supply chain.
