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Samsar upcycles EV battery from 1000th Nissan Leaf

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Samsar upcycles EV battery from 1000th Nissan Leaf

EV battery remanufacturing startup Samsar Resources is celebrating a key milestone: it has now repurposed 1000 Nissan Leaf batteries into new energy storage.

According to the US company, it has now returned over 25 MWh of battery capacity ‘to the field’ through its remanufacturing programme. Samsar operates out of a facility in Sugar Land, Texas, where it dismantles Leaf battery packs, tests their individual cells and modules, and refurbishes them for future use. It says it has now reached the 1000-pack milestone after three years of remanufacturing, during which it has experienced an uptick in production; in 2022, it processed just 20 Nissan battery backs, before exceeding 300 in 2025. Samsar now expects to have remanufactured 2000 battery packs in 2027.

Arguing that a battery’s removal from a vehicle is not “the end of its useful life”, the Samsar team assesses the remaining capacity of a battery pack’s individual components before embarking on a process that it claims can capture around 90 per cent of the value of each pack. This is done by reducing the packs to modules then carrying out cell-level quality control. The remanufactured batteries can then be used for a variety of applications including stationary energy storage, marine and worksite power. Samsar has called Nissan Leaf batteries “the perfect fit” for this process thanks to their air-cooled architecture and “well-understood” lifetime performance.

“When I joined the team in 2022 we didn’t know if this was going to work,” said Guillermo Garcia, founder and CEO of Samsar.



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