Energy at full power in Oss

By developing charging infrastructure solutions and battery technology, Staad plays a role in the energy transition. In recent years, the company has grown so significantly in this role that it established a battery production facility to meet the rising demand for battery packs—or "Powerboxes," as Staad calls them. Yet, none of this would be possible without the people behind the scenes; they contribute to shaping the future every day. We spoke with Jos Nuchelmans, the enthusiastic workshop manager at the facility.

Jos joined Staad four years ago as an assembly technician for battery packs. Before that, he had worked as an electrician in the construction industry for 33 years. “I worked on all kinds of projects across the country. That sometimes meant long commute times, and I didn't want to do that anymore. My wife, who was working at Staad at the time, told me about the assembly technician vacancy, and that’s how I ended up at Staad.” In the early days of electric excavators, we built 140 kWh units in a corner of the workshop in Veghel. Production was later moved to Vinkel. “We were there for a year and a half before we outgrew the space, as the demand for batteries kept growing.” The 140 kWh units have limited capacity and are intended for smaller machines. “Staad had the ambition to electrify large excavators as well. To allow these machines to operate for longer periods, Staad developed the Powerbox 400 battery pack.”

Safe working practices

A year and a half ago, a new location with more production space was secured in Oss. Staad was also able to utilize existing permits already in place for the site. Due to the raw materials used in the batteries, Powerbox production falls under the heavy industry category. The battery production facility in Oss comprises two halls and a large shipping container in the outdoor area. One of the two halls is used for storing components, while the assembly of the Powerbox units takes place in the second hall. “We test the Powerboxes inside a shipping container that meets strict regulatory standards. The container—which allows for the simultaneous testing of three Powerboxes—is equipped with all necessary safety features, including a sprinkler system, smoke detectors, and a fire-extinguishing system. The Powerboxes are certified only after this testing phase, ensuring the user has a safe battery pack at their disposal.”

500 Powerbox 400s

Jos takes pride in ‘his’ workshop; this is evident in the passionate way he speaks about his work. “We manufacture Powerbox 400 battery packs here, as well as Fieldmaster fast chargers (DC) and Fieldmaster inverters (AC),” he explains. “Every week, eight fully tested Powerbox 400 battery packs roll off the production line. They are then transported by electric truck to our facilities in Veghel or Harlingen, where they are installed in new machinery.” Jos enthusiastically notes that the 500th Powerbox 400 was delivered in April to the Neder-Betuwe dike reinforcement project, a venture by the Dijkalliantie Neder-Betuwe consortium, comprising GMB, Ploegam, and Dura Vermeer.

The range

While many electric machines from other brands feature built-in batteries that must be charged on-site, the Powerbox 400 is primarily used as a swappable battery for electric earthmoving machinery. In addition to powering the machine, the Powerbox can serve as a stationary battery unit at construction sites or festivals, or act as a charging solution when paired with Fieldmaster fast chargers or inverters. The Powerbox 400 is supported by an ‘Energy as a Service’ concept; as part of this service, battery packs are swapped on-site daily for a fixed fee.

The Fieldmaster DC can be used to charge electric vehicles and electric machinery equipped with battery packs. Meanwhile, the Fieldmaster AC functions like a traditional power distribution unit, supplying electricity to everyday equipment and site cabins. This makes the Powerbox 400 a versatile charging solution for the construction site.

Ramp-up

The pressure to produce the Powerboxes was intense, especially in the early stages. “Many Powerboxes had already been sold before production even began. As with any new product, there were some initial teething troubles. Once these were ironed out and the supply of components was streamlined, things improved. Fortunately, we were able to resolve those start-up issues relatively quickly.”

The components are delivered individually and assembled in Oss. Four cells are installed in each Powerbox, after which they are electrically and mechanically connected. Electronic systems handle the control functions. Thanks to Active Climate Control, the Powerbox never gets too cold or too hot, allowing it to operate consistently at the optimal temperature of 20 degrees Celsius.

Our home base

“Operating in an energy-neutral and zero-emission way is the future—both for the current generation and for our children’s,” says Jos. “The planet is in increasingly poor shape. But perhaps we can still repair some of the damage. At Staad, we can contribute to that recovery with our machines and battery packs. Our ambition is to build eight hundred excavators a year. If we reach that goal, we’ll have to move to a larger facility.” According to Jos, the Oss location plays a key role in making the Dutch civil engineering and infrastructure sector more sustainable. He concludes: “The product we make here is fantastic and clean. I feel proud when I see a machine running on a Powerbox battery we’ve built. My colleagues feel the same way. We have a great team here, and it’s a fun place to work. Staad Oss really is our home base.”