What Zesar does

Zesar is an Istanbul-headquartered, family-owned industrial machinery manufacturer specializing in equipment and process technologies for lead-acid battery production. Its product catalog spans plate production (paste mixing, grid casting, pasting, flash drying, curing chambers, plate cutting and brushing), assembly line equipment (enveloping/stacking, cast on strap, intercell welding, short circuit testing, heat sealing, air leakage testing, terminal burning), finishing line machinery (acid filling, second-lid sealing, washing, high-rate discharge testing, hi-voltage leakage testing, terminal brushing), and formation solutions (battery formation water baths, acid/gel filling). Three patents (turntable, lead run-away mold, jig box designs) and the internally developed EVOLINE low-cost automated assembly line with Robotic Transfer System underpin the technical differentiation. The company has delivered a turnkey battery manufacturing facility project since 2014, extending the model from individual machine sales to full plant integration, supplemented by spare parts, training, and know-how transfer services.

Name

Zesar

Legal name

Zesar

Website

https://zesartech.com

Company type

Private

Founded year

2002

Operating status

Operating

Headcount range

51–100 employees

Short description

Zesar is a Turkish, family-owned manufacturer of industrial machinery for lead-acid battery production, supplying plate, assembly, finishing, and formation equipment plus turnkey plant projects to battery manufacturers in over 20 countries.

Ownership category

akta.pro rank

Product category

Battery Manufacturing Equipment

NAICS

Battery Manufacturing (335910)

akta.pro primary industry

Battery Modules & Packs (Industrial/Commercial pack assembly) (IMAGAHAB)

Keywords

• Lead-acid battery equipment
• Battery manufacturing machinery
• Turnkey battery projects
• Plate production machines
• Battery assembly line

Headquarters

HQ city

Umraniye

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Supply Chain, Operations, Infrastructure, Technology or R&D, Marketing or Sales

Revenue model

1. Battery Manufacturing Equipment Sales: Sale of industrial machinery for lead-acid battery manufacturing, including single machines and complete production lines. Equipment includes plate production machines, assembly line equipment, formation solutions, and finishing line machinery. Revenue is generated through one-time capital equipment purchases with optional spare parts and technical support services.
2. Turnkey Projects: Complete battery manufacturing facility design and installation services, including all equipment, integration, and commissioning. Delivered first turnkey project in 2014.
3. Spare Parts and Components: Supply of replacement parts and components for Zesar machines and customer-specific needs
4. Technical Support and Training: Technical assistance, training sessions for production, maintenance, and engineering teams
5. Battery Manufacturing Know-How: Technical knowledge transfer and consulting services for battery manufacturing from basic to specialized production

Go-to-market motion1 record

Distribution channels1 record

Marketing channels4 records

Core offering

Zesar manufactures and supplies industrial machinery and process technology for lead-acid battery production, covering plate production, assembly, formation, and finishing lines. It sells both single machines and complete turnkey battery manufacturing facilities to battery producers worldwide.

Product overview

Zesar is a manufacturer of industrial battery manufacturing equipment offering a comprehensive portfolio of machinery for lead-acid battery production. The product portfolio spans three main production lines: Plate Production (paste production, grid casting, pasting, flash drying, curing chambers, and plate cutting/brushing), Assembly Line (enveloping/stacking, cast-on-strap, intercell welding, short circuit testing, heat sealing, air leakage testing, terminal burning, height checking, and coding), and Finishing Line (acid filling/leveling, second lid sealing/testing, washing/drying, high-rate discharge testing, hi-voltage leakage testing, and terminal brushing/greasing). The company also provides Formation Solutions including water baths and acid/gel filling machines. Zesar supplies individual machines as well as complete turnkey battery manufacturing projects.

Differentiator

Problem solved

Functional benefit

Products and services

• Paste Production (PSM-1000) Fully automatic paste mixing machine that combines lead oxide, water, acid, and chemicals to form battery paste, controlled by a PLC system. For lead-acid battery manufacturers.
• Grid Casting Machine (GRC A180, GRC I110) Gravity casting machine for producing lead-acid battery grids using low-antimony and calcium alloys, featuring high casting quality and long service life.
• Pasting Machine High-productivity pasting machine for all battery plate types, featuring vacuum grid feeder, pneumatic lifting system, and adjustable spatula rollers for optimized paste consumption.
• Flash Dry Oven Pre-drying tunnel with convection heating system that minimizes heating space while maximizing efficiency and energy savings for plate drying.
• Curing Chambers (CRC H180, CRC H220) Chamber designed to accelerate the curing process of lead-acid battery plates, ensuring proper drying and crystal growth with programmable temperature, humidity, and time cycles. The CRC H180 is marketed as the fastest curing chamber in the world.
• Plate Cutting and Brushing Machine (CNB-A180, CNB-I100) Machine that cuts charged or discharged panels and lugs to requested length while brushing both sides clean of paste residue, at up to 140 panels/minute.
• Enveloping & Stacking Machine Machine for wrapping plates with separators (PE, AGM, glass mat) and stacking plate groups for battery assembly, featuring programmable process control and motor-driven vacuum plate picker.
• Cast On Strap Machine (COS A500, COS L100) Machine for processing automotive and industrial batteries that casts lead straps to connect plate groups, using electromechanical rotary indexing for precise positioning, at up to 5 batteries/minute.
• Intercell Welding Machine (ICW A300, ICW A600) Machine for high-quality intercell welding of lead-acid batteries using hydraulic jaws and a microprocessor weld control system to recognize defective welding.
• Short Circuit Test Machine (SCT A300) Automatic tester for detecting assembly-level insulation defects including missing or damaged separators before/after ICW and checking welding quality.
• Heat Sealing Machine (HTS A300, HTS A600) Fully automatic machine for sealing battery lids to containers using a reliable heating system with precise positioning and recipe recall functions.
• Air Leakage Test Machine (ALT-A300, ALT-MF30, ALT-MF60, ALT-MF90) Automatic tester for detecting air leaks in battery containers or intercellular walls for automotive and truck batteries.
• Terminal Burning Machine (TRB-A300, TRB A600) Machine for bonding battery terminal pillars and lid bushes by burning under precisely controlled conditions using water-cooled mold and burner heads.
• Terminal Height Check Machine (THC A300) Machine for checking terminal height after the burning process to ensure consistent post height.
• Coding Machine (COD-A300) Machine for marking tracking codes on batteries using a dot matrix coding mechanism, supporting chain conveyor systems with up to 12 characters per second.
• Hole Punching Machine (HPM-A300) Semi-automatic machine for punching holes in empty battery boxes for qualified intercell welding, with precision height control.
• Acid Filling and Leveling Machine (AFL-A300, AFL-A600) Machine for filling the exact amount of acid into cells and sucking back excess acid, achieving +-1% filling volume accuracy and +-1mm level accuracy, at up to 10 batteries/minute.
• Second Lid Heat Sealing Machine (HTS-MF30, HTS-MF60, HTS-MF90) Fully automatic machine for sealing the second lid to the main battery cover with servo motors for lid holder and heater control.
• Second Lid Air Leakage Test Machine (ALT-MF30, ALT-MF60, ALT-MF90) Automatic test machine for ensuring no air leakage in the second lid of MF batteries, with adjustable test pressure up to 400mBar.
• Washing and Drying Machine (WND-A300) Machine for decontaminating acids left on batteries using a rotary brush system and high-capacity fans for complete cleaning and drying.
• High Rate Discharge Test Machine (HRD-A300) Quality test machine for battery reliability by discharging at high current for short periods, with rejection station and OCV/CCV/Delta V testing devices, at up to 8 batteries/minute.
• HI Voltage Leakage Test Machine Machine for detecting leaks using high voltage (max. 12kV) extended between battery terminal and container bottom to identify dielectric defects.
• Terminal Brushing & Greasing Machine (PLB/GRS A300, A600) Machine for providing a smooth terminal surface with steel brush elements and homogeneous grease dispersion using a precision grease dosing pump.
• Battery Formation Water Bath (WTB-A80, WTB-A160, WTB-A240) Fully automatic water bath for battery formation with automatic loading/unloading and synchronous water filling/drainage for homogeneous H2O temperature.
• Acid & Gel Filling Machine (AFM A300, AFM A600, AFM V600) Machine for filling the exact amount of acid or gel into battery cells using specially designed nozzles and a level control system for precise filling volume.
• EVOLINE Production Line Low-cost, high-performance battery assembly line integrating a robotic transfer system for full automation, developed with government grant funding.
• Robotic Transfer System (RTS) Automated system that transfers work across the whole assembly process, making the entire assembly line fully automatic.
• Turnkey Battery Manufacturing Projects Complete battery manufacturing facility design and installation service including all equipment, integration, and commissioning for battery manufacturers.
• Spare Parts and Technical Support Supply of replacement parts and components for Zesar machines plus technical assistance and training for production, maintenance, and engineering teams.

Quantifiable outcome

• Up to 5 batteries/minute production rate on Cast On Strap machines
• +4 more outcomes

Named customers4 records

Segments4 records

Ideal customer profiles3 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature6 records

Partnerships

Three partnerships are on record, tiered minor and core.

• Greek GovernmentminorOthers · 1 January 2009Received government grant to support development and launch of EVOLINE production line in 2009, demonstrating government support for innovation in battery manufacturing technology
• Interbat (Russia)coreGTM or Marketing PartnerRussian battery industry organization with which Zesar has participated in all events including member meetings, exhibitions, and conferences, helping establish their niche in the Russian market
• International Lead AssociationminorGTM or Marketing PartnerGlobal industry association for lead and battery industries. Zesar has participated in association events and conferences including ELBC

Scale indicators7 records

Recent moves8 records

Expansion highlights5 records

Direct peers

• Wirtz Manufacturing: US-based supplier of lead-acid battery manufacturing equipment, including plate processing, assembly, and continuous plate production lines. Closely comparable to Zesar in core product scope, with similar global sales to major battery OEMs.
• Wuxi Lead Intelligent Equipment: Chinese manufacturer specializing in complete lead-acid battery production lines and intelligent manufacturing equipment. A larger-scale Asian competitor with overlapping plate, assembly, and formation equipment offerings, particularly aggressive in emerging markets.
• Hangke Technology: Chinese manufacturer of lithium-ion battery production equipment, including formation, capacity grading, and pack assembly lines. Comparable to Zesar in equipment scope and customer base, though more weighted toward lithium-ion applications.
• Sovema Group: Italian-headquartered manufacturer of complete lead-acid battery production lines, including plate manufacturing, assembly, and formation equipment. Direct head-to-head competitor to Zesar in the global lead-acid battery equipment market with overlapping product portfolios and customer base.
• Yinghe Technology: Shenzhen-listed Chinese supplier of lithium-ion and lead-acid battery manufacturing equipment, including electrode coating, calendering, and assembly lines. Comparable to Zesar as a battery production equipment specialist serving global cell and pack manufacturers.
• Digatron: German-headquartered manufacturer of battery formation, testing, and finishing equipment for automotive and industrial batteries. Overlaps with Zesar's formation solutions and finishing-line product categories for lead-acid and lithium-ion customers.
• Bitrode: US-based designer and manufacturer of battery formation and electrical test equipment, including chargers and cycling equipment. Comparable to Zesar's formation and high-rate discharge testing product lines, serving similar battery OEM customers.

Broad incumbents

• Dürr AG: Large German industrial machinery group with a battery production equipment division covering electrode coating, drying, and cell assembly. A much larger incumbent that competes for the same battery OEM capex pool as Zesar, but as part of a diversified industrial portfolio.

Regional players

• KBP Instruments: India-based supplier of battery manufacturing machinery, including plate-making and assembly equipment for lead-acid batteries. Comparable product offering to Zesar with strong regional presence in South Asia, a key export market for both companies.

Emerging players

• Manz AG: German-listed supplier of integrated production systems for lithium-ion battery cells, modules, and packs. Less direct overlap with Zesar's lead-acid core but highly comparable as a battery production equipment specialist competing for similar customer capex budgets.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

• Xx.com/zesartech

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Zesar