Windsor’s NextStar Energy Battery Plant Reaches 30% Completion

NextStar Energy Joint Venture Will Provide 40% of Stellantis’ EV Power In North America...

Robert S. Miller December 20, 2023

NextStar Energy marked a significant milestone in the construction of its new electric vehicle (EV) battery plant in Windsor, Ontario, with a celebratory “Topping Out” ceremony. The event commemorated the installation of the last structural steel beam and gathered local trades employees for beam signing, team photos, and appreciative words from NextStar Energy leadership.

The NextStar Energy Plant in Windsor, Ontario as of 12/2023. (Stellantis).

Progress on the colossal 4.23 million square foot NextStar Energy joint venture EV battery plant, in collaboration with Stellantis and LG Energy Solution, is advancing at a rapid pace. At 30% completion, the plant’s construction, handled entirely by a 100% Canadian crew comprising 950 skilled craft workers, remains on schedule. Anticipated to commence operations in the first half of 2024, the initial phase will focus on battery modular production.

The construction journey began in August 2022, witnessing phases like site clearing, mass grading, and foundational activities. The Module Building, the first of two primary structures, has completed its structural steel installation and is now fully enclosed, with equipment installation underway since last week. Meanwhile, the Cell Building, the second major edifice, nears the end of structural steel erection and has achieved approximately 40% enclosure.

Danies Lee, CEO of NextStar Energy, remarked, “The community witnesses this historic structure taking shape as we approach the final stages of construction, gearing up for the installation phase. Our gratitude extends to neighboring businesses and residents for their patience throughout this process.”

The project’s realization involves up to 3,200 tradespeople and equipment installers (1,600 for construction and 1,600 for installations), with 2,300 positions filled by Canadians. Presently, Canadian construction tradespeople have contributed nearly 1,600,000 labor hours, a substantial portion of the estimated 6,800,000 total hours projected for construction—an equivalent of 776 years.

Upon completion, this pioneering facility will stand as Canada’s premier large-scale domestic electric-vehicle battery manufacturing plant. Boasting an annual production capacity of 49.5 gigawatt hours (GWh), up from the initially planned 45 GWh, the plant is expected to generate around 2,500 new employment opportunities in Windsor and surrounding regions.

NextStar’s focus lies in producing cutting-edge lithium-ion battery cells and modules, catering to about 40% of Stellantis’ electric-vehicle production requirements in North America. Aligning with its Dare Forward 2030 strategic plan, the company aims for electric vehicles to constitute more than half of its U.S. and Canadian sales by the decade’s end.

The plant’s footprint spans an impressive 4.23 million square feet, encompassing ancillary structures equivalent to roughly eight Rogers Centre stadiums in Toronto.

Overseen by Alberici-Barton Malow (A-BM) JV, comprised of Alberici and Barton Malow, the construction continues its stride toward the envisioned completion.

7 replies

Join the discussion →

Loading new replies...

bill burke Dec 20, 2023 #1

Him again ! Admittedly I’ve been on a very personal and marginally biased rant on my hope to keep gas powered options on every Stellantis branded vehicle. The free market demands it and will prevail I have argued repeatedly.
This NextStar Energy facility, I admit “energetically”, is clearly a foundation to alternative vehicle power, a smart creation, that assures battery dominance for what will be, without apology or reservation, a key part of everyone’s future.
I see, initially, more relevance in commercial applications like compact and
mid-size vans and fleet markets rather than in large scale general usage. How far this electrification plan goes is anyone’s guess, right now. I’m guessing I’m right and I’m guessing Stellantis will agree for at least a decade. Yes that current all electric plan needs a bit of tweaking.
I guess you readers are guessing right too.....It’s must be HIM again!

Reply 1 Like

click to expand...

patfromigh Dec 20, 2023 #2

For Stellantis to really be in charge of their own destiny, they need to have their own battery plants. The reason for this is they won't be dependent on someone else for production schedules and product mix. Pure ICE power trains will be rare in the future. Most vehicles will have some sort of electrification, mild hybrid, legacy hybrid, plugin hybrid, and pure battery electric. (I lumped in the range extended EVs with plugin hybrids.) All these require batteries of various kinds. In addition to variety, there is also the challenge of continuous improvement versus obsolescence.

I've been to the Villages in Florida. It's not terribly far from the Garlits Drag Racing Museum in Ocala. Residents of these type of retirement communities have the opportunity to operate neighborhood electric vehicles or NEV for short. Many people just use golf carts and many NEVs are based on golf carts. The Citroen Ami would be classified as an NEV in our country. There are strict restrictions about operating them on public highways. NEVs have been around awhile and make a lot of sense for some areas. The next size up would be city cars like the 500e. Such EVs are beneficial pieces to the transportation puzzle. I also agree that fleets and commercial operations will benefit from battery electrics. The key here is having access to a reliable charging network, in other words the business's own private charging stations.

As far as personal vehicles for consumers, I suspect it will become "The bigger they are the harder they will be to sell". High speed charging and massive battery packs are inefficient. They waste a trifecta of resources, time and money. It takes too long to charge a vehicle, the faster charging rates can be disastrous, and no one is running a profit operating high speed charging services. Those who have easy access to level 1 or 2 charging that fits in with there sleep / work schedule can adopt an EV more readily than others. A small battery pack is sufficient for a small EV and takes less time to charge.

Reply 2 Likes

M Moparound Dec 21, 2023 #3

You're not alone Bill. I too am not fond of the current 'electric' strategy. Nor is anyone I have spoken with sold on the idea of a totally battery-powered vehicle. The reasons are too many to mention here and am sure a fair part of the concerns could be addressed and worries eradicated in some instances. However, I do not see anytime soon where the majority of concerns those that are anxious concerns disappearing with the matter based upon stories and information I've read and studied.

But here we are and little did I know that internal combustion engines would be threaten just a few years ago.

In my opinion, there are positives and negatives for BOTH combustion and electric powered vehicles.

Taking emotions and loyalties out of the equation., attempting to apply logic and reasoning:
Am I pleased the Hurricane is coming out? Certainly!
Would I ever consider owning a hybrid vehicle? Certainly!
Would I ever own a pure electric vehicle, not whatsoever, period. Not unless the technology improves where I can travel in any terrain, traffic conditions, etc. and be stuck on the side of the road waiting for a battery charge(assuming charging stations aplenty).
1. Make it possible to change-out battery packs at a 'battery-station'(replacement for gas stations) for ALL vehicles in under fifteen minutes. 2. Make pure battery vehicles safe from various potential fires. 3. Affordable B.E.V.'s , and, affordable 'battery packs' to power them. 4. A 'standard' for battery design and interchangeability between vehicles.

To me, the common-sense thing to do is manufacturer both I.E.C. and B.E.V. now and in the future until/if technology improves to the point of practicality. Allow the public to choose.

The matter and issue at hand seems to stem from elected officials and those who supports these officials. It makes me wonder if the public really knows what is taking place right before their eyes, and, if so, will they care too late? Are we the public being misled and the manufacturers basically strong-armed into adhering to unfair and possibly unsubstantiated rules and regulations? Dunno.

Am probably dreaming. Maybe am totally wrong and way off base? One thing for sure, am not here to condemn anyone. The point is, the freedom to choose is issue is in jeopardy for one reason or another.
We need to stand-up and be heard. We need a voice that speaks directly to the decision makers. We need to be informed and with accurate information. Until this happens, all we have is a forum or two(and very thankful for Mopar Insiders by the way!) to gripe and attempt to be heard. But, don't forget the main 'voting tool' we all have, it's called $

Peace to all!

Reply Like