NextStar Energy completes Windsor battery pack line

NextStar’s pack line completes the domestic battery supply chain that Canada has long sought but rarely achieved in practice NextStar Energy has begun production on a new battery pack production line at its Windsor, Ontario facility, completing full cell-to-pack vertical integration at a single facility for the first time. The third production phase, added alongside existing cell and module operations, responds to the growing global demand for energy storage systems (ESS) and expands the company’s product range. The Windsor facility, Canada’s first and only commercial-scale battery manufacturing facility, recently celebrated its official grand opening and will begin commercial cell production in November 2025. The facility reached one million cells in February 2026, and the new packaging line allows NextStar Energy, now wholly owned by LG Energy Solution, to source all battery products from one place, deepening its role in the North American supply chain. NextStar Energy Chief Executive Danies Lee said in a statement: “Adding package manufacturing means we can now get batteries from cell to module or finished package in Windsor. This expansion reflects our commitment to capitalizing on the rapid growth of the ESS market and is also a meaningful step to strengthen Canada’s position in the global battery supply chain.” Why this matters: Full cell-to-pack vertical integration is a meaningful competitive step. At this stage, most battery manufacturers are running cell or pack lines; Combining both in a single facility reduces logistics complexity, increases yield visibility throughout the production chain, and strengthens NextStar’s position as the sole supplier for ESS customers. The shift towards ESS over automotive is a signal worth watching. NextStar was launched as Canada’s first commercial-scale battery plant with an implicit automotive supply chain logic; Leading the expansion of the packaging line with ESS demand shows that LG Energy Solution is reading grid storage as the more immediate growth vector in North America.

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