Ashok Leyland Boss EV Truck battery recycling in Taloja, Maharashtra
Mumbai — Taloja Hazmat Consolidation 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
16,000 TPA
Reverse Logistics Yard
Cities served
0
From Taloja, Maharashtra
Where a Ashok Leyland Boss EV Truck pack goes from Taloja, Maharashtra
- 1
Intake at Taloja, Maharashtra
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 475 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 (644 km). Excellent — long calendar life makes LFP the preferred feedstock for stationary BESS repurposing.
- 4
Refined at Sriperumbudur, Tamil Nadu
Remaining modules are shredded to black mass and refined at Chennai — Sriperumbudur Recovery Campus, 998 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Indore — Pithampur Grading Plant | 475 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 644 km |
| Nearest refinery | Chennai — Sriperumbudur Recovery Campus | 998 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 Taloja, Maharashtra 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
Taloja, Maharashtra site notes
- City pickups use smaller vehicles; tell us about height limits, basement access or restricted loading hours.
- Damaged packs need a separate declaration and travel in steel containment with vermiculite.
- Port-linked consignments need their documents before the booking date is confirmed.
- During the monsoon, collection windows are reconfirmed the day before to account for flooding and road closures.
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 holds Maharashtra Pollution Control Board consent within Taloja MIDC and follows the estate's fire and hazardous-storage conditions. Material is handled within the Battery Waste Management Rules 2022 framework, and any cross-border movement is subject to customs controls and the applicable waste-shipment requirements.
Ashok Leyland Boss EV Truck in Taloja, Maharashtra: common questions
Can I drop off a Ashok Leyland Boss EV Truck battery at Taloja, Maharashtra?
Yes, by appointment. Mumbai — Taloja Hazmat Consolidation 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 Taloja, Maharashtra?
Intake at Taloja, Maharashtra, then Graded at Pithampur, Madhya Pradesh, then Second life at Butibori, Maharashtra, then Refined at Sriperumbudur, Tamil Nadu. 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 Taloja, Maharashtra
Retiring Ashok Leyland Boss EV Truck packs near Taloja, Maharashtra?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.