Kochi — Kalamassery Diagnostics Bench
Kalamassery, Kerala facility: diagnostics centre running module-level SOH, impedance and optical grading to split reuse from refining. Rated at 7,000 tonnes per annum and operating since 2023.
Annual capacity
7,000 TPA
Operating lines
3
Cities collected
0
In operation since
2023
About the Kalamassery, Kerala facility
Kalamassery, on the northern edge of Kochi, hosts KINFRA's industrial park and sits within easy reach of the port city's logistics network. Kerala has an active electric two-wheeler and three-wheeler market and has run state electric bus programmes. The diagnostics bench opened in 2023 so that Kerala's batteries could be graded inside the state instead of being trucked to Tamil Nadu or Karnataka.
At 7,000 TPA it is the network's smallest grading site, focused on two-wheeler, three-wheeler and small commercial packs. Kerala's coastal humidity is a real factor for batteries awaiting testing, so storage is climate-controlled and packs with any sign of water ingress are identified and handled separately before they reach the benches. Reusable modules are sent on to second-life works, and the remainder to processing sites in Tamil Nadu and Karnataka.
What arrives at the gate
What sets this site apart
In-state grading
Grades Kerala's packs locally, cutting transport time and cost for small consignments.
Small-pack focus
Benches configured for two- and three-wheeler formats.
Humidity-controlled storage
Climate-controlled storage limits moisture exposure while packs wait for testing.
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 | 1,242 km |
| Hydrometallurgical Refinery | Chennai — Sriperumbudur Recovery Campus | 510 km |
| Integrated Recovery Campus | Hyderabad — Zaheerabad Recovery Campus | 860 km |
Local rules
Battery Waste Management Rules 2022 (BWMR) · Central Pollution Control Board (CPCB) and State Pollution Control Boards
The bench operates under Kerala State Pollution Control Board consent within a KINFRA park and grades material for producers under the Battery Waste Management Rules 2022, with custody records passed on to the downstream recycler.
Before you book into Kalamassery, Kerala
- Heavy commercial packs are routed to larger sites with lifting equipment.
- Keep packs covered during loading, especially in the monsoon months.
- Send a serial list with every consignment.
- Declare any water ingress or swelling at booking so the pack is isolated on arrival.
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.
Kalamassery, Kerala site: common questions
Does Kochi grade car batteries?
It can handle some passenger packs, but its benches are built mainly for two- and three-wheeler batteries.
Why does water exposure matter?
Water ingress can damage cells and create safety risks, so exposed batteries are declared, isolated and assessed before any testing.
What are the opening hours at Kalamassery, Kerala?
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 Kalamassery, Kerala?
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.