Custom Alkaline Battery Packs

At Epec, we have been providing custom battery solutions for more than a decade. Our expertise in battery design, engineering, and manufacturing has made us a leader in the industry, particularly when it comes to complex alkaline battery packs.

Custom Alkaline Battery Pack

Why Choose Alkaline Batteries for Your Application?

Alkaline batteries are a popular choice for custom battery packs for several reasons:

High Energy Density

Alkaline batteries have a high energy density, which means they can store a lot of energy in a relatively small package. This makes them ideal for applications that require a lot of power in a small space, such as portable electronic devices.

Long Shelf Life

They have a long shelf life and can last for several years before they need to be replaced. This makes them a good choice for applications that require a long service life, such as remote monitoring systems or emergency equipment.

Low Cost

Alkaline batteries are relatively inexpensive compared to other battery chemistries. This makes them a cost-effective choice for applications that require large quantities of batteries.

Wide Temperature Range

They can operate over a wide temperature range, from -20°C to 55°C, which makes them suitable for use in a variety of environments.


Non-toxic and able to be disposed of safely in most municipal waste streams, this makes alkaline batteries an environmentally-friendly choice compared to other chemistries, such as lithium-ion batteries.

Alkaline Battery Pack Design

Designing a custom alkaline battery pack can be a complex process. While things like voltage, capacity, and temperature range are critical for any battery pack, there are several specific aspects to consider, ensuring that an alkaline battery pack meets the specific needs of the application. Alkaline batteries are known for their high energy density, low cost, and long shelf life which makes them an attractive option for many applications. However, alkaline batteries are primary batteries, which means they are designed to be used once and then disposed of.

Primary batteries cannot be recharged, and once their energy is depleted, they must be replaced as they are designed to provide a stable and reliable source of power for a wide range of low-to-medium power applications.

Safety Features

Safety fuses are not typically required in alkaline battery packs, as they are designed with safety features to prevent overcharging or short-circuiting. Alkaline batteries are generally safe and stable, and their chemistry does not pose a significant risk of explosion or fire. However, it is important to ensure that the battery pack is designed and manufactured to meet the specific safety requirements of the application.

If the alkaline battery pack is designed to operate in a high-risk environment or to power critical systems, additional safety measures may be necessary, such as fuses, circuit breakers, or redundant safety features.


Alkaline battery packs are many times potted, which means they can be encapsulated in a protective resin or polymer material to provide additional durability, protection, and insulation. Potting is commonly used in battery pack design to protect the batteries from physical damage, moisture, vibration, and other environmental factors that can affect their performance and reliability.

Potting can also help to improve the thermal management of the battery pack by providing a heat sink for dissipating heat generated by the batteries. This is especially important in high-power or high-drain applications where the batteries may generate a significant amount of heat during operation.

The potting material used for battery packs must be carefully selected to ensure compatibility with the battery chemistry and the specific application requirements. The material must be electrically insulating, thermally conductive, chemically inert, and resistant to the operating temperature range of the battery pack. Common potting materials used for battery packs include epoxy, silicone, and urethane.


Enclosures for alkaline battery packs can be made of a variety of materials, depending on the specific application requirements and design considerations. The selection of enclosure material will depend on a number of factors, including the specific application requirements, environmental conditions, and design considerations such as weight, cost, and manufacturing processes. The enclosure material should be chosen to provide adequate protection for the battery pack, while also meeting the desired performance, safety, and reliability requirements.

Experience In Design and Manufacturing

At Epec Engineered Technologies, our team of engineers has years of experience designing and manufacturing custom alkaline battery packs for a wide range of applications. We have worked with customers in the military, aerospace, medical, and industrial fields, among others. We are well-versed in the unique challenges of each industry and can design a battery pack that meets your specific needs. Our battery packs are tested rigorously to ensure they meet the most stringent performance standards as we have ISO 9001:2015 certification, which means that our processes are regularly audited to ensure they meet the highest quality standards.

We understand that every customer’s needs are unique, which is why we offer custom solutions for every project. We can design battery packs in a wide range of sizes, shapes, and configurations to meet your specific needs. Because we have all of the design, engineering, and manufacturing resources in-house, we can quickly move from prototype to production on alkaline battery packs. Epec is able to handle both small and large production runs as we work closely with our customers throughout the entire process, from initial design to final delivery.

Need Help with a Custom Alkaline Battery Pack?

From design to production, our team of experienced engineers at Epec is here to help you design a custom alkaline battery pack that exceeds your needs.

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America's Oldest. A History of Innovation.

Over the past 70 years, the electronics manufacturing industry has changed dramatically as the industry continues to adapt to evolving demands and technology. Epec is at the forefront of innovation, with the expertise and agility to move at the speed of today’s businesses. At Epec, the customer comes first, and everything we do must be put through that filter. Whether it is developing e-commerce platforms to make it easier to work with us or creating a new product introduction (NPI) process that helps our customers get to market faster, we must focus on building the new. By doing that every day, and by always making the customer our top priority, we plan on being here for another 70 years and then some.

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