Redwood Scales Pack Manager for Repurposed EV Battery Storage

Redwood Materials is scaling production of its proprietary Pack Manager technology, which enables electric vehicle (EV) battery packs from different manufacturers to operate together in stationary energy storage systems. In a technical update published on 4 November 2026, the company confirmed that its production line is manufacturing more than 1,000 Pack Manager units per week. The technology supports Redwood's battery energy storage systems (BESS), which repurpose EV batteries for applications including data centres and industrial facilities.

The Pack Manager acts as a bidirectional DC-DC converter, connecting individual battery packs to a shared electrical system while managing differences in chemistry, voltage and battery condition. It allows packs from manufacturers such as General Motors, Rivian and Volkswagen to operate within the same storage installation without requiring identical electrical specifications. Each pack is connected through an independent converter rather than directly to other batteries, enabling the system to manage individual performance limits while maintaining a stable power supply.

 

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Redwood's technology supports battery packs operating across voltage ranges from approximately 400 volts to 800 volts. Its integrated battery management software communicates with each pack's existing control system, continuously monitoring voltage, current and battery health. This allows batteries in better condition to contribute more power while limiting the demands placed on older or degraded packs. Individual units can also be disconnected for maintenance or replacement without shutting down the entire storage system. According to Redwood, each Pack Manager is designed for a service life of at least 15 years and uses passive cooling without moving parts or liquid cooling systems.

The technology is already operating in Redwood's energy storage installation supporting an AI data centre operated by Crusoe. The project combines 12 MW of solar generation with 63 MWh of repurposed battery storage at Redwood's Nevada campus. The company reported operational availability exceeding 99% since commissioning, with an earlier joint announcement confirming 99.2% availability over seven months. The system demonstrates how second-life EV batteries can support electricity-intensive computing infrastructure while extending the useful life of battery materials.

Redwood is now automating additional manufacturing processes to increase Pack Manager production as demand for stationary storage grows. The company is targeting applications including peak demand management, industrial energy supply and data centre infrastructure. By integrating batteries from multiple manufacturers into a single storage system, Redwood aims to reduce reliance on newly manufactured batteries while providing a scalable alternative for energy storage deployment.

 

Source: Redwood Materials