Ashok Leyland Boss EV Truck battery recycling in Khordha, Odisha
Bhubaneswar — Khordha Collection Yard takes whole Ashok Leyland Boss EV Truck packs straight from fleets, dealers and workshops. Packs are weighed, de-energised and logged here before modules move on for grading or refining.
Pack value at 80% SOH
6,405 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
6,500 TPA
Reverse Logistics Yard
Cities served
0
From Khordha, Odisha
Where a Ashok Leyland Boss EV Truck pack goes from Khordha, Odisha
- 1
Intake at Khordha, Odisha
Each pack travels in a rated crate or on a restrained pallet, with coolant drained and ports sealed. Each pack is weighed, photographed and discharged below 30% state of charge.
- 2
Graded at Pithampur, Madhya Pradesh
Modules travel 1,064 km to Indore — Pithampur Grading Plant for capacity, resistance and impedance testing across all 18 modules.
- 3
Second life at Butibori, Maharashtra
At 80% SOH about 56% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (700 km). Excellent — long calendar life makes LFP the preferred feedstock for stationary BESS repurposing.
- 4
Refined at Haldia, West Bengal
Remaining modules are shredded to black mass and refined at Kolkata — Haldia Refining Works, 331 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Indore — Pithampur Grading Plant | 1,064 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 700 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 331 km |
Inside the Ashok Leyland Boss EV Truck battery
The Ashok Leyland Boss EV Truck (2023) carries a 200 kWh LFP Prismatic (LiFePO4) pack with 18 modules at 600 V, weighing roughly 1480 kg. Cobalt-free prismatic chemistry dominant in Indian passenger EVs and commercial fleets. Low black mass value, exceptional second-life economics.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.9% | A — BESS ready | USD 10,459 |
| Year 4 | 92.8% | A — BESS ready | USD 10,129 |
| Year 6 | 89.7% | A — BESS ready | USD 9,798 |
| Year 8 | 86.6% | A — BESS ready | USD 9,467 |
| Year 10 | 83.5% | B — Second life | USD 7,968 |
What the chemistry means here
How it ages
LFP fades slowly and fairly linearly for most of its life. Capacity loss is driven mainly by lithium inventory being locked up in the SEI layer on the graphite anode, while the cathode structure stays largely intact.
Thermal behaviour
LFP's olivine cathode holds its oxygen tightly, so thermal runaway typically starts at higher temperatures than nickel-rich cells and releases noticeably less heat. It is not inert: a failing LFP cell still vents flammable electrolyte vapour and hydrogen, and large prismatic cans store a lot of energy in one place.
Handling LFP Prismatic
Collecting a Ashok Leyland Boss EV Truck pack
200 kWh, 18 modules, about 1480 kg — this is how the Khordha, Odisha team plans the job.
Removal
Large packs are removed at the depot with a forklift-rated battery table and the vehicle isolated under lock-out tag-out.
Packaging
Each pack travels in a rated crate or on a restrained pallet, with coolant drained and ports sealed.
Consolidation
Depot retirements are batched against the fleet replacement schedule so collections line up with vehicle swaps.
Before the truck arrives
- Share telematics SOH history if it is available
- Confirm forklift access and dock height at the depot
- Isolate high-voltage systems under lock-out tag-out
- Declare any pack involved in a collision
Khordha, Odisha site notes
- Small volumes are grouped into scheduled consolidated runs.
- Declare battery type and quantity when booking.
- Pack batteries so they cannot move during transit.
- Damaged units are isolated immediately on arrival.
What this pack yields
lithium
14.83 kg
nickel
0 kg
cobalt
0 kg
manganese
0 kg
copper
44.86 kg
aluminium
53.54 kg
Refining-route estimate at 80% SOH. Measured module health on the bench sets the final split.
Rules in India
Battery Waste Management Rules 2022 (BWMR)
Regulator: Central Pollution Control Board (CPCB) and State Pollution Control Boards
The yard operates under Odisha Pollution Control Board consent within an IDCO industrial estate, and supports producers' obligations under the Battery Waste Management Rules 2022 by keeping unit-level custody records.
Ashok Leyland Boss EV Truck in Khordha, Odisha: common questions
Can I drop off a Ashok Leyland Boss EV Truck battery at Khordha, Odisha?
Yes, by appointment. Bhubaneswar — Khordha Collection Yard accepts whole Ashok Leyland Boss EV Truck packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Ashok Leyland Boss EV Truck modules after Khordha, Odisha?
Intake at Khordha, Odisha, then Graded at Pithampur, Madhya Pradesh, then Second life at Butibori, Maharashtra, then Refined at Haldia, West Bengal. At 80% SOH roughly 56% of the pack goes to second life and the rest is refined.
How should a Ashok Leyland Boss EV Truck pack be prepared for pickup?
Share telematics SOH history if it is available. Confirm forklift access and dock height at the depot. Isolate high-voltage systems under lock-out tag-out. Declare any pack involved in a collision.
Which rules apply to Ashok Leyland Boss EV Truck recycling in India?
Battery Waste Management Rules 2022 (BWMR), overseen by Central Pollution Control Board (CPCB) and State Pollution Control Boards. Retired packs move as hazardous goods by road under central motor vehicle rules, and export needs Basel-compliant permissions.
Ashok Leyland Boss EV Truck at other sites
Other commercial fleet packs at Khordha, Odisha
Retiring Ashok Leyland Boss EV Truck packs near Khordha, Odisha?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.