Bengaluru — Hosur Diagnostics Centre
Hosur, Tamil Nadu facility: diagnostics centre running module-level SOH, impedance and optical grading to split reuse from refining. Rated at 14,000 tonnes per annum and operating since 2021.
Annual capacity
14,000 TPA
Operating lines
3
Cities collected
9
In operation since
2021
About the Hosur, Tamil Nadu facility
Hosur, just across the Tamil Nadu border from Bengaluru, is one of India's largest two-wheeler manufacturing centres and has become a focal point for electric two-wheeler production. The diagnostics centre opened in SIPCOT Industrial Complex Phase III in 2021 to grade the small-format packs this belt produces in very large numbers, as well as retirements from Bengaluru's delivery and ride-hailing fleets.
Its 14,000 TPA of bench capacity is laid out for two-wheeler and three-wheeler packs and modules, alongside a smaller share of passenger-car packs. Because units are small and numerous, the centre measures throughput in thousands of units a week. Battery-swap operators are a growing source of intake, bringing packs with detailed usage histories that make grading faster and more accurate.
What arrives at the gate
What sets this site apart
Small-format bench layout
Fixtures and cyclers sized for 2–5 kWh packs allow hundreds of units to be tested in parallel each day.
Swap-network data intake
Serial-level usage histories from swap operators are loaded before testing, cutting grading time and improving routing decisions.
Repair-or-retire diagnostics
Impedance fingerprinting separates packs worth repairing at cell or BMS level from those that should be retired.
What happens to material here
- 1
Intake & safety triage
Packs are logged, thermally imaged and screened for swelling, coolant ingress or venting before entering the bench area.
- 2
Controlled de-energising
Residual energy is discharged to a safe state of charge with regenerative load banks and recorded per serial number.
- 3
Module-level capacity test
Full charge-discharge cycling at C/3 establishes usable capacity, internal resistance and cell-to-cell balance.
- 4
EIS fingerprinting
1 mHz–10 kHz impedance sweeps separate SEI growth, lithium plating and contact resistance degradation modes.
- 5
AI optical inspection
Machine-vision inspection of busbars, welds and cell cans flags mechanical defects that block second-life reuse.
- 6
Grade assignment
Grade A (≥85% SOH), B (75–85%), C (65–75%) and D routes are assigned, with D-grade material released to refining.
Where material goes next
| Role | Facility | Distance |
|---|---|---|
| Second-Life BESS Works | Nagpur — Butibori Second-Life Works | 918 km |
| Hydrometallurgical Refinery | Chennai — Sriperumbudur Recovery Campus | 230 km |
| Integrated Recovery Campus | Hyderabad — Zaheerabad Recovery Campus | 550 km |
Local rules
Battery Waste Management Rules 2022 (BWMR) · Central Pollution Control Board (CPCB) and State Pollution Control Boards
The centre operates under Tamil Nadu Pollution Control Board consent and grades material for producers registered under the Battery Waste Management Rules 2022. Because much of its intake crosses the state border from Karnataka, interstate transport documentation and waste descriptions are checked at the gate before unloading.
Before you book into Hosur, Tamil Nadu
- Box or crate two-wheeler packs individually; loose-stacked packs are repacked on arrival and slow intake.
- Swap operators can set up recurring weekly collections from Bengaluru depots.
- Send a serial list with each load so bench results map directly back to your asset records.
- Packs with visible swelling must be declared and are tested only in the isolated quarantine room.
Damaged or defective packs are handled under a separate quarantine protocol — flag them in the form and the team calls you back the same day.
Hosur, Tamil Nadu site: common questions
Is Hosur set up for two-wheeler batteries?
Yes. Small-format packs make up most of the centre's intake, and its benches and fixtures are designed around them.
Can swap-network batteries be graded here?
Yes. Swap operators can share usage histories in advance, which shortens grading and helps decide between repair, reuse and recycling.
What are the opening hours at Hosur, Tamil Nadu?
Monday to Friday 08:00 – 20:00, Saturday 08:00 – 16:00. Sunday: emergency and damaged-pack intake only, by prior booking.
How do I book a collection into Hosur, Tamil Nadu?
Use the booking button on this page with pack counts, chemistry and condition. The despatch desk confirms a window within one working day and ships UN-approved packaging before collection.