Battery-buffered EV charger built from repurposed EV battery packs delivers up to 400 kW of charging power

Battery-buffered EV chargers are all the rage these days—they enable fleets and other charging providers to deploy high-power charging without grid upgrades, and to avoid utility demand charges.

Allye Energy’s new Allye MEV charger features built-in battery storage made from whole repurposed EV packs. MEV can be charged from whatever electrical supply a depot has, and release that energy at up to 400 kW to two vehicles at once, even from a 16 A connection.

Allye offers two complementary battery-equipped products:

• The MAX300 is analogous to a fuel tanker. It’s a portable BESS and EV charger mounted on a trailer that can be towed by a van or pick-up truck. It can be used for portable DC charging at up to 400 kW, or to add battery storage to a stationary charging site.
• The MEV is analogous to a fuel pump with its own tank underneath. It’s a battery-buffered charger that can charge two vehicles at once. It has been launched in two variants, the MEV200 (with 155 kWh of energy storage and up to 200 kW of charging power) and the MEV300 (232 kWh of storage and 300 kW of power). Both can run from 16 A single-phase to 125 A three-phase.

Some fleets may choose to have both. A depot could start with a MEV and add a MAX when more capacity is needed.

“We have built two ranges, not two versions of the same thing,” explains founder and CEO Jonathan Carrier. “If the charger stays put and only ever charges vehicles, MEV does it on the supply you already have, often for less than the connection works it replaces. If the energy needs to move, towed behind a van or feeding a row of chargers, that is the MAX300.”

MEV is engineered and built in the UK with batteries from UK-registered vehicles and 95% British-sourced components. Deliveries are expected to begin Q2 2027, in time for Round 2 of the UK government’s Depot Charging Scheme.

According to Allye, reusing EV battery packs avoids an estimated 15 to 24 tons of CO₂ per MEV compared with new cells. Allye’s PackFlex technology gives each pack independent battery management and power control, so packs of different sizes, ages and chemistries can share a cabinet. An 800 V architecture maximizes efficiency and power, and serves both 400 V and 800 V vehicles.

“MEV is the direct result of our work on the MAX300,” said CTO Robert Carter. “The hard part was never the battery. It was making packs of different sizes and ages behave as one system and deliver up to 400 kW of DC charging through an 800 V architecture and our in-house technology stack. Once we had solved that, MEV was the obvious next step: the same architecture in a cabinet that only ever charges, where one pack can slide out for service while the others keep charging.”

Allye offers charging-as-a-service, handling everything from site survey to commissioning.

More than 20 MAX systems, built from over 100 repurposed batteries, are currently in service with customers including JLR and Roadchef. At Roadchef’s Killington Lake services on the M6, a MAX300 has run for more than two years on a fixed 315 A supply shared by shops, a hotel and EV chargers. On the Lower Thames Crossing, MAX500 units are charging electric excavators for National Highways.

Source: Allye Energy