The Power of Seconds: Giving Old EV Batteries New Purpose

Rivian and Redwood Materials transform 100 retired EV battery packs into a massive grid storage system at an Illinois factory

22 Apr 2026

Rivian and Redwood Materials have commissioned a 10 megawatt-hour energy storage system at a manufacturing plant in Normal, Illinois. The installation repurposes more than 100 retired battery packs from electric vehicles to provide power to the facility and the local utility grid.

The project marks a transition for Redwood Materials, a company primarily known for battery recycling. Through its energy division, the group is now utilizing its proprietary software to monitor and manage the performance of older battery units. By discharging stored power during periods of high demand, the system reduces electricity costs for the factory and eases pressure on the regional network.

The initiative arrives as American power infrastructure faces increasing strain. Rising consumption from data centres and the electrification of transport have heightened the need for flexible storage. While traditional grid upgrades often face multi-year delays, second-life battery installations can be deployed relatively quickly to provide immediate capacity.

"The existing US battery asset base is a strategic energy resource," said JB Straubel, founder and chief executive of Redwood Materials. He noted that millions of units already in circulation could be redirected into storage roles before eventually being recycled.

Industry analysts suggest the collaboration reflects a shift in how carmakers view the battery lifecycle. Rather than moving directly to material recovery, companies are exploring ways to extend the economic value of battery hardware.

This approach could provide a domestic alternative to imported storage technology. While the Illinois project is currently a pilot, the model offers a blueprint for how industrial firms might integrate renewable energy while maintaining grid stability.

Future adoption will likely depend on the long-term reliability of used cells compared to new systems. For now, the venture highlights a growing focus on industrial resilience as the energy transition accelerates.