Almont startup turns used EV batteries into mobile power

ALMONT — In an old industrial space on the edge of town, a quiet revolution in mobile energy rolled out on two wheels this week.

While the automotive industry scrambles to figure out what to do with worn-out electric vehicle batteries, Michigan-based startup BarrelCharge unveiled a solution that bypasses the grid entirely: the M50C, a trailer-mounted energy powerhouse built from second-life EV batteries.

The device offers a glimpse into a zero-emissions future for temporary power. Where diesel generators once chugged out noise and fumes, the M50C delivers silent, exhaust-free electricity capable of storing 50 to 150 kilowatt-hours of power — enough to run a remote job site for days or add more than 500 miles of range to a depleted EV.

“We are providing an alternative where the grid just can’t reach,” said Steve Tarnowsky, BarrelCharge co-founder and chief technology officer, who spent 31 years developing electrified propulsion systems at General Motors.

Tarnowsky, along with co-founders Gary Gariglio, Andrew Dillon, and Bill Marsh, set out to solve one of the energy transition’s trickiest puzzles: giving spent EV batteries a second act before recycling. The result is a system using second-life GM battery packs, assembled locally in Michigan, capable of delivering up to 150 kilowatts of power.

Unlike typical EV infrastructure projects, which often languish for months or years in utility approval queues, BarrelCharge’s mobile design targets commercial operators, municipalities, and emergency responders who need immediate, drop-in power.

During a live demonstration at the Almont launch, the unit seamlessly powered multiple applications simultaneously, delivering Level 2 and DC fast charging alongside standard AC power and heavy-duty 48- to 80-volt industrial DC power. Potential uses span from emergency power at municipal buildings and libraries during outages to remote fleet charging, construction sites, and outdoor event operations.

By focusing on commercial and public sector needs rather than consumer charging networks, BarrelCharge aims to bridge the gap between burgeoning power demands and lagging grid infrastructure — one mobile battery pack at a time.