Ford F-150 Lightning ER battery recycling in Gurugram, Haryana
Gurugram, Haryana 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
18,000 TPA
Cell Grading & Diagnostics
Cities served
21
From Gurugram, Haryana
Where a Ford F-150 Lightning ER pack goes from Gurugram, Haryana
- 1
Collected via Narela, Delhi
Whole packs enter the network at Delhi — Narela Collection Yard, 48 km away, where they are weighed and de-energised.
- 2
Module grading at Gurugram, Haryana
All 16 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 47% of the pack qualifies for reuse and goes to Ludhiana — Mandi Gobindgarh Second-Life Works (298 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, 1,318 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Delhi — Narela Collection Yard | 48 km |
| Nearest second-life works | Ludhiana — Mandi Gobindgarh Second-Life Works | 298 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 1,318 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 Gurugram, Haryana 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
Gurugram, Haryana site notes
- Heavy vehicles are given fixed arrival windows outside NCR peak traffic hours; tell us if your site has its own gate timings.
- Palletise packs with terminals taped and service disconnects removed before the truck arrives, so unloading takes minutes rather than hours.
- Swollen, dented or water-exposed packs must be declared at booking so a quarantine bay is reserved before arrival.
- Fleet batches above 20 packs are graded in a dedicated row and reported as a single batch for settlement.
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 hub operates under consent conditions from the Haryana State Environment Protection Council and HSPCB, and grades material for producers registered on the CPCB EPR portal under the Battery Waste Management Rules 2022. Movement of spent lithium-ion packs within NCR follows national dangerous-goods practice for UN 3480 and UN 3481, and interstate consignments from Delhi or Rajasthan carry e-way bills and a declared waste description.
Ford F-150 Lightning ER in Gurugram, Haryana: common questions
Can I drop off a Ford F-150 Lightning ER battery at Gurugram, Haryana?
Gurugram, Haryana 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, 48 km away.
What happens to Ford F-150 Lightning ER modules after Gurugram, Haryana?
Collected via Narela, Delhi, then Module grading 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.
Cities collected by Gurugram, Haryana
Ford F-150 Lightning ER at other sites
Other commercial fleet packs at Gurugram, Haryana
Retiring Ford F-150 Lightning ER packs near Gurugram, Haryana?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.