EV battery remanufacturing company Samsar Resources has repurposed 1,000 Nissan Leaf battery packs for new energy storage applications, marking a milestone in its battery reuse programme. The U.S.-based company said it has returned more than 25 MWh of battery capacity to use through the programme.
Samsar operates a battery remanufacturing facility in Sugar Land, Texas, where it dismantles Nissan Leaf battery packs, evaluates individual cells and modules, and refurbishes components for further use.
Battery Remanufacturing Program Expands
Samsar said it reached the 1,000-pack milestone after three years of remanufacturing activity. The company processed 20 Nissan Leaf battery packs in 2022 and increased production to more than 300 packs in 2025.
The company expects to reach a total of 2,000 remanufactured battery packs in 2027.
Rather than treating the removal of a battery pack from a vehicle as the end of its useful life, Samsar evaluates the remaining capacity and condition of individual components. The company said its process can capture around 90% of the value of each battery pack.
The process involves dismantling battery packs into modules before conducting quality control at the cell level. Components that meet the company’s requirements can then be remanufactured for use in different applications.
Batteries Used Beyond Electric Vehicles
Samsar said its remanufactured batteries can be deployed in stationary energy storage systems as well as marine and worksite power applications.
The company considers Nissan Leaf battery packs particularly suitable for remanufacturing because of their air-cooled architecture and what it describes as well-understood lifetime performance.
Guillermo Garcia, founder and CEO of Samsar Resources, said the company initially had to develop its processes without an established industry model.
“When I joined the team in 2022 we didn’t know if this was going to work. We had this amazing opportunity with Nissan to do something with all the thousands of batteries that were coming out of old Nissan Leafs every year. But every process we developed, every step in building a factory for re-manufacturing EV batteries was new. There was no playbook. It was a lot of sweat, tears, and late nights.”
Second-Life Applications for Leaf Batteries
The reuse of Nissan Leaf batteries is also being explored in other energy storage projects. Earlier this year, electrive reported that 12 decommissioned 30-kWh Nissan Leaf battery packs were being repurposed in a stationary energy storage system at the Port of Vigo in Spain.
Samsar’s 1,000-pack milestone adds to efforts to extend the useful life of EV batteries after they are removed from vehicles, with remanufacturing providing an alternative application for components that retain usable capacity.
