Ford F-150 Lightning ER battery recycling in Narela, Delhi
The Ford F-150 Lightning ER is not sold in India, so packs reach Narela, Delhi through importers, research and test fleets or cross-border consolidation. They are accepted as whole packs, with extra checks on documentation and transboundary paperwork.
Pack value at 80% SOH
6,140 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
12,000 TPA
Reverse Logistics Yard
Cities served
0
From Narela, Delhi
Where a Ford F-150 Lightning ER pack goes from Narela, Delhi
- 1
Intake at Narela, Delhi
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 Gurugram, Haryana
Modules travel 48 km to NCR — Gurugram Collection & Grading Hub for capacity, resistance and impedance testing across all 16 modules.
- 3
Second life at Mandi Gobindgarh, Punjab
At 80% SOH about 47% of the pack qualifies for reuse and goes to Ludhiana — Mandi Gobindgarh Second-Life Works (257 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Haldia, West Bengal
Remaining modules are shredded to black mass and refined at Kolkata — Haldia Refining Works, 1,337 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | NCR — Gurugram Collection & Grading Hub | 48 km |
| Nearest second-life works | Ludhiana — Mandi Gobindgarh Second-Life Works | 257 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 1,337 km |
Faster option
Inside the Ford F-150 Lightning ER battery
The Ford F-150 Lightning ER (2022) carries a 131 kWh NMC 811 Cylindrical 2170 pack with 16 modules at 400 V, weighing roughly 734 kg. High-nickel cylindrical cells with the strongest hydrometallurgical recovery credit per tonne of black mass.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.6% | A — BESS ready | USD 8,271 |
| Year 4 | 91.3% | A — BESS ready | USD 7,945 |
| Year 6 | 87% | A — BESS ready | USD 7,619 |
| Year 8 | 82.7% | B — Second life | USD 6,687 |
| Year 10 | 78.4% | B — Second life | USD 5,847 |
What the chemistry means here
How it ages
NMC 811 loses capacity through a mix of SEI growth, cathode surface reconstruction and micro-cracking of nickel-rich particles. Resistance climbs faster than in LFP, which matters as much as capacity for second-life duty.
Thermal behaviour
High-nickel NMC cathodes release oxygen as they decompose, so once runaway starts it is fast and energetic. Cylindrical 2170 cells vent through a designed rupture point, which helps, but cell-to-cell propagation inside a tightly packed module is the main hazard.
Handling NMC 811 (2170)
Collecting a Ford F-150 Lightning ER pack
131 kWh, 16 modules, about 734 kg — this is how the Narela, Delhi 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
Narela, Delhi site notes
- Delhi goods-vehicle timing restrictions apply, so pickups are booked into permitted entry windows.
- Aggregators should present each load with unit counts and declared chemistry to speed weighbridge intake.
- E-rickshaw batteries need protected terminals and must be secured so they cannot shift in transit.
- Damaged units go directly to the quarantine area and are logged separately.
What this pack yields
lithium
7.45 kg
nickel
48.13 kg
cobalt
5.96 kg
manganese
5.54 kg
copper
23.85 kg
aluminium
20.02 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 Delhi Pollution Control Committee consent and within the Battery Waste Management Rules 2022. Aggregators delivering to Narela are expected to hold the registrations the rules require of them, and the yard's unit-level records support producers' EPR reporting further down the chain.
Ford F-150 Lightning ER in Narela, Delhi: common questions
Can I drop off a Ford F-150 Lightning ER battery at Narela, Delhi?
Yes, by appointment. Delhi — Narela Collection Yard accepts whole Ford F-150 Lightning ER packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Ford F-150 Lightning ER modules after Narela, Delhi?
Intake at Narela, Delhi, then Graded at Gurugram, Haryana, then Second life at Mandi Gobindgarh, Punjab, then Refined at Haldia, West Bengal. At 80% SOH roughly 47% of the pack goes to second life and the rest is refined.
How should a Ford F-150 Lightning ER 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 Ford F-150 Lightning ER 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.
Ford F-150 Lightning ER at other sites
Other commercial fleet packs at Narela, Delhi
Retiring Ford F-150 Lightning ER packs near Narela, Delhi?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.