Ford F-150 Lightning ER battery recycling in Mandi Gobindgarh, Punjab
Mandi Gobindgarh, Punjab receives graded Ford F-150 Lightning ER modules that passed as grade A or B and rebuilds them into warrantied stationary storage.
Pack value at 80% SOH
6,140 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
7,500 TPA
Second-Life BESS Works
Cities served
0
From Mandi Gobindgarh, Punjab
Where a Ford F-150 Lightning ER pack goes from Mandi Gobindgarh, Punjab
- 1
Collected via Narela, Delhi
Whole packs enter the network at Delhi — Narela Collection Yard, 257 km away, where they are weighed and de-energised.
- 2
Graded at Gurugram, Haryana
Modules travel 298 km to NCR — Gurugram Collection & Grading Hub for capacity, resistance and impedance testing across all 16 modules.
- 3
Second-life build at Mandi Gobindgarh, Punjab
Grade A and B modules — about 47% of a pack at 80% SOH — are matched and rebuilt into storage systems on site.
- 4
Refined at Haldia, West Bengal
Remaining modules are shredded to black mass and refined at Kolkata — Haldia Refining Works, 1,564 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Delhi — Narela Collection Yard | 257 km |
| Nearest grading bench | NCR — Gurugram Collection & Grading Hub | 298 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 1,564 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 Mandi Gobindgarh, Punjab 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
Mandi Gobindgarh, Punjab site notes
- Only graded modules are accepted.
- Each module must include its grade report.
- Delivery of finished systems is scheduled with the customer.
- Site inspections are available by appointment.
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 works operates under Punjab Pollution Control Board consent and builds systems to applicable Indian electrical and safety requirements, with module traceability maintained from source pack to finished unit.
Ford F-150 Lightning ER in Mandi Gobindgarh, Punjab: common questions
Can I drop off a Ford F-150 Lightning ER battery at Mandi Gobindgarh, Punjab?
Mandi Gobindgarh, Punjab is a second-life bess works and does not accept whole packs from customers. Book a collection and the pack enters the network at Narela, Delhi, 257 km away.
What happens to Ford F-150 Lightning ER modules after Mandi Gobindgarh, Punjab?
Collected via Narela, Delhi, then Graded at Gurugram, Haryana, then Second-life build 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 Mandi Gobindgarh, Punjab
Retiring Ford F-150 Lightning ER packs near Mandi Gobindgarh, Punjab?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.