Samsar Resources announced on September 15, 2026, that it has remanufactured its 1,000th battery pack from a Nissan Leaf electric vehicle. The company said it has returned more than 25 MWh of battery capacity to service instead of sending the packs directly for recycling.
At its factory outside Houston, Texas, Samsar disassembles used EV battery packs into modules, conducts cell-level quality control and refurbishes components as needed. The resulting modules are supplied for second-life applications in sectors including marine, security and work-site energy storage.
EV batteries are typically removed from vehicles when their remaining capacity falls within a threshold of 80% to 90%. Although this is commonly described as end of life, the remaining capacity can still support applications with different performance requirements. Samsar said Nissan Leaf packs are suited to its remanufacturing process because of their air-cooled architecture and documented lifetime performance.
The company remanufactured 20 Nissan Leaf packs in 2022. By 2025, its annual processing volume had increased to more than 300 packs. Samsar said its approach captures 90% of the value of each pack by separating it into modules and applying cell-level testing. The company expects to reach a cumulative total of 2,000 remanufactured packs sometime in 2027.
Samsar Remanufactures 1,000 Nissan Leaf Battery Packs
Samsar scaled Nissan Leaf battery remanufacturing, returning usable capacity to service instead of sending it directly to recycling.
Operational depth underpins the gain: over 18 years of experience, including nearly four years directing 65 employees across three departments.
Samsar was founded by Steve Hellman, founder of Mobility Impact Partners, to develop batteries designed for remanufacturing and to recover value from used lithium battery systems. The company promotes design for remanufacturing, which considers future servicing, repair and component reuse when batteries are initially developed.
Source: EIN Presswire
