Energy5.02.2025

Inside South Africa’s biggest battery factory

MyBroadband recently got a tour of Freedom Won’s impressive factory in Edenvale, one of the three biggest battery assembly plants in South Africa.

Freedom Won was founded by Lizette Kriel and Antony English in 2011 and was one of the country’s earliest adopters of batteries with lithium iron phosphate (LiFePO4) chemistry.

LiFePO4 has a more stable structure than lithium-ion, providing greater cycle life and better safety.

The company had to work hard to convince the general public and valuable commercial clients that the technology was far better and more cost-effective over the long term than lead-acid, the prevailing chemistry for backup energy storage at the time.

Freedom Won has become one of South Africa’s most sought-after battery brands, with a wide range of models for home, business, commercial, and industrial applications.

According to a recent Jaltech Fund Management survey of 288 solar installers and engineering, procurement, and construction companies in South Africa, it was the most widely preferred battery brand in the country.

Around 30% of respondents said they prefferred Freedom Won’s batteries, double the 15% share of second-placed SunSynk.

Freedom Won’s premium batteries are assembled using the latest components and manufacturing processes.

Its primary offering is its Lithium To Energy or LiTE range, with capacities ranging from 5kWh to 800kWh. For commercial and utility-scale installations, its new Megatower series supports up to 5,900kWh capacity.

Freedom Won also offers a custom marine battery for below deck operations and general-purpose mobile applications, with capacities from 5kWh to 30kWh.

The company’s batteries are assembled at a 48,000m2 facility in Modderfontein, Edenvale, previously used by Pick n Pay as a distribution centre.

When considering space occupancy, it is the largest battery assembly plant in the country.

It produces roughly 150 megawatt-hours (MWh) of storage every month, which works out to about 1,800MWh or 1.8 gigawatt-hours (GWh) in a year.

However, the facility is capable of manufacturing up to 3.5GWh capacity in a year, the most of any battery assembly plant in South Africa.

There are roughly 340 employees at the plant working across its various operations — including cell welding, battery assembly, research and design, and troubleshooting and repairs.

South Africa has no battery cell manufacturing capability, so local assemblers must import this component from countries like China, which have established strong supply chains for critical cell minerals such as lithium, cobalt, nickel, and manganese.

However, Freedom Won told MyBroadband that around 50% to 60% of its battery packs are made in South Africa.

Testament to its belief in its own products is that the facility runs off a 2MWh Freedom Won battery system connected to a massive rooftop solar power system, which caters for a substantial part of the facility’s electricity demand.

Below are images from our Freedom Won factory tour in January 2025, with captions describing the basic flow of the assembly process.

Battery cell packaging and laser welding

Wooden crates containing imported lithium-ion cells on Freedom Won’s factory floor, the core “ingredient” in battery storage.
Battery cells taken out of their crates.
More battery cells.
Freedom Won uses laser welding to bind the cells together and ensure optimal operational stability.
The Lwandle Beam, one of the two laser welding machines.

Battery enclosures

Freedom Won’s aluminium battery casings or enclosures — custom-fabricated in another building at the same facility — stand ready to be loaded with cells and other components.
The battery enclosures come in many different shapes and sizes to accommodate various capacities and configurations.
Battery enclosure for Freedom Won’s new more energy-dense batteries.

Battery assembling

Storage boxes for all the smaller components that go into the battery enclosures.
Plant workers assembling some of the larger batteries generally used by commercial customers.
A closer view at the battery assembly process.
Assembled batteries are charged and tested before the enclosure is closed up.
Numerous inverters help feed renewable electricity from batteries being tested.
More battery cells getting charged before the labelling and packaging process begins.
Factory workers assembling some of Freedom Won’s newer, more energy-dense batteries.
A module enabling remote controlling capabilities on Freedom Won’s batteries.

Battery packaging

Labelled Freedom Won Lite batteries being prepared for storage in wooden crates with high-density foam.

Troubleshooting and repairs

Freedom Won’s troubleshooting section. Considering it has roughly half a million batteries in rotation, the number under service was impressive.

From start to finish

Empty enclosure for the 800/640kWh HV+ battery.
Completed Freedom Won 800/640kWh HV+ battery.
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