Ashok Leyland Boss EV Truck battery recycling in Bhiwadi, Rajasthan
Bhiwadi, Rajasthan is a diagnostics site: Ashok Leyland Boss EV Truck packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
6,405 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
9,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Bhiwadi, Rajasthan
Where a Ashok Leyland Boss EV Truck pack goes from Bhiwadi, Rajasthan
- 1
Collected via Narela, Delhi
Whole packs enter the network at Delhi — Narela Collection Yard, 75 km away, where they are weighed and de-energised.
- 2
Module grading at Bhiwadi, Rajasthan
All 18 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 3
Second life at Mandi Gobindgarh, Punjab
At 80% SOH about 56% of the pack qualifies for reuse and goes to Ludhiana — Mandi Gobindgarh Second-Life Works (315 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, 1,321 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Delhi — Narela Collection Yard | 75 km |
| Nearest second-life works | Ludhiana — Mandi Gobindgarh Second-Life Works | 315 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 1,321 km |
Faster option
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 Bhiwadi, Rajasthan 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
Bhiwadi, Rajasthan site notes
- Bus and heavy truck packs are better routed to an integrated campus with lifting equipment.
- Give module counts and formats when booking so the right fixtures are prepared before arrival.
- Loads from Haryana should carry correct interstate documentation to avoid delays at the gate.
- Declare damaged items in advance; the site has limited quarantine space.
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 station operates under Rajasthan State Pollution Control Board consent in a RIICO industrial area and grades material for producers operating under the Battery Waste Management Rules 2022. Because many consignments cross the state border with Haryana, interstate transport paperwork is checked at intake.
Ashok Leyland Boss EV Truck in Bhiwadi, Rajasthan: common questions
Can I drop off a Ashok Leyland Boss EV Truck battery at Bhiwadi, Rajasthan?
Bhiwadi, Rajasthan is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Narela, Delhi, 75 km away.
What happens to Ashok Leyland Boss EV Truck modules after Bhiwadi, Rajasthan?
Collected via Narela, Delhi, then Module grading at Bhiwadi, Rajasthan, then Second life at Mandi Gobindgarh, Punjab, 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 Bhiwadi, Rajasthan
Retiring Ashok Leyland Boss EV Truck packs near Bhiwadi, Rajasthan?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.