Samsar Resources, a startup based in Sugar Land, Texas, has reached a milestone by repurposing 1,000 Nissan Leaf battery packs. The company focuses on dismantling these packs, testing individual cells and modules, and refurbishing them for secondary use, such as stationary energy storage, marine power, and worksite applications.
The company reports that its remanufacturing program has returned over 25 MWh of battery capacity to the field. Production has scaled significantly over the last three years: while the startup processed only 20 battery packs in 2022, it exceeded 300 units in 2025. Samsar now projects that it will have remanufactured 2,000 battery packs by 2027.
The process involves assessing the remaining capacity of components, which the company claims captures approximately 90 per cent of the value of each pack. Samsar utilizes the air-cooled architecture of Nissan Leaf batteries for its operations. CEO Guillermo Garcia noted that the company developed its own manufacturing processes from scratch since 2022.
