Ford F-150 Lightning ER battery recycling in Kalamassery, Kerala
Kalamassery, Kerala is a diagnostics site: Ford F-150 Lightning ER packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
6,140 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
7,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Kalamassery, Kerala
Where a Ford F-150 Lightning ER pack goes from Kalamassery, Kerala
- 1
Collected via Zaheerabad, Telangana
Whole packs enter the network at Hyderabad — Zaheerabad Recovery Campus, 860 km away, where they are weighed and de-energised.
- 2
Module grading at Kalamassery, Kerala
All 16 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 3
Second life at Butibori, Maharashtra
At 80% SOH about 47% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (1,242 km). Good — grade-A modules above 80% SOH qualify for commercial-scale BESS strings.
- 4
Refined at Sriperumbudur, Tamil Nadu
Remaining modules are shredded to black mass and refined at Chennai — Sriperumbudur Recovery Campus, 510 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Hyderabad — Zaheerabad Recovery Campus | 860 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 1,242 km |
| Nearest refinery | Chennai — Sriperumbudur Recovery Campus | 510 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 Kalamassery, Kerala 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
Kalamassery, Kerala site notes
- 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.
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 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.
Ford F-150 Lightning ER in Kalamassery, Kerala: common questions
Can I drop off a Ford F-150 Lightning ER battery at Kalamassery, Kerala?
Kalamassery, Kerala is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Zaheerabad, Telangana, 860 km away.
What happens to Ford F-150 Lightning ER modules after Kalamassery, Kerala?
Collected via Zaheerabad, Telangana, then Module grading at Kalamassery, Kerala, then Second life at Butibori, Maharashtra, then Refined at Sriperumbudur, Tamil Nadu. 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 Kalamassery, Kerala
Retiring Ford F-150 Lightning ER packs near Kalamassery, Kerala?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.