Why Whole Pack Utilization (WPU) is the Best Second-Life Solution for EV Batteries

Technology
Written By Junxing HUANG

As the world shifts towards electrification, the question of what happens to electric vehicle (EV) batteries at the end of their first life has become increasingly urgent. While recycling technologies are advancing, Whole Pack Utilization (WPU) is emerging as the most efficient and sustainable solution for second-life applications. Here’s why:

1. Avoiding Higher Dismantling Costs

The cost of dismantling EV battery packs is higher than simply producing new batteries.

  • New battery prices continue to fall, making cell-level recycling less cost-effective.

  • Disassembling packs requires expensive equipment, labor, and production line adjustments.
    By reusing the whole pack directly, WPU bypasses these unnecessary costs and inefficiencies.

2. Enhanced Safety in Second-Life Applications

One common concern about second-life batteries is safety. WPU addresses this directly:

  • Packs already meet automotive-grade standards for safety and reliability.

  • With automotive-grade battery management systems (BMS) in place, the packs ensure better monitoring, consistency, and control.
    This makes WPU even safer than some newly produced low-cost batteries on the market.

3. Coping with the Revolution of EV Packaging

Modern EVs are increasingly adopting large, one-piece battery modules, such as CTP (Cell-to-Pack) and CTC (Cell-to-Chassis) blade batteries.

  • These designs are difficult and expensive to disassemble for cell-level reuse.

  • WPU eliminates the need for dismantling, directly integrating full packs into second-life energy storage systems (ESS).

4. Meeting Huge Energy Storage Demands

The global energy storage market is expanding rapidly.

  • By 2025, global storage needs are expected to reach 170 billion EUR (300 GWh).

  • Distributed, large-scale ESS powered by second-life batteries can play a critical role in meeting this demand.
    WPU enables fast deployment of second-life lithium-ion batteries (LiB) at scale.

5. Ensuring Compliance with ESS Regulations

Regulations for second-life energy storage are becoming more stringent.

  • Only WPU can consistently meet National Energy Administration requirements for cell uniformity and safety.

  • This ensures that second-life energy storage systems are compliant and reliable.

6. Facilitating Recycling After End-of-Life (EOL)

Even after their second life, batteries must eventually be recycled. WPU makes this easier:

  • Whole pack handling reduces the risk of explosion or pollution during dismantling.

  • Once their storage life is over, packs processed via WPU can still enter the recycling chain more safely and efficiently.

Conclusion

Whole Pack Utilization (WPU) is more than just a second-life option—it’s the most practical, safe, and cost-effective pathway for EV batteries.

By avoiding high dismantling costs, ensuring safety, aligning with modern EV pack designs, satisfying regulatory requirements, and facilitating end-of-life recycling, WPU stands out as the future-proof solution to power the next wave of global energy storage.

The transition to a sustainable energy future depends not only on producing new batteries but also on how we maximize the value of existing ones. WPU provides the bridge—delivering both economic and environmental benefits in the journey toward a circular battery ecosystem.

Junxing HUANG