Mahindra XUV400 EL battery recycling in Hosur, Tamil Nadu
Hosur, Tamil Nadu is a diagnostics site: Mahindra XUV400 EL packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
1,262 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
14,000 TPA
Cell Grading & Diagnostics
Cities served
9
From Hosur, Tamil Nadu
Where a Mahindra XUV400 EL pack goes from Hosur, Tamil Nadu
- 1
Collected via Zaheerabad, Telangana
Whole packs enter the network at Hyderabad — Zaheerabad Recovery Campus, 550 km away, where they are weighed and de-energised.
- 2
Module grading at Hosur, Tamil Nadu
All 14 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 56% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (918 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, 230 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Hyderabad — Zaheerabad Recovery Campus | 550 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 918 km |
| Nearest refinery | Chennai — Sriperumbudur Recovery Campus | 230 km |
Faster option
Inside the Mahindra XUV400 EL battery
The Mahindra XUV400 EL (2023) carries a 39.4 kWh LFP Prismatic (LiFePO4) pack with 14 modules at 350 V, weighing roughly 292 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 | 96.6% | A — BESS ready | USD 2,075 |
| Year 4 | 93.5% | A — BESS ready | USD 2,010 |
| Year 6 | 90.4% | A — BESS ready | USD 1,945 |
| Year 8 | 87.3% | A — BESS ready | USD 1,880 |
| Year 10 | 84.2% | B — Second life | USD 1,635 |
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 Mahindra XUV400 EL pack
39.4 kWh, 14 modules, about 292 kg — this is how the Hosur, Tamil Nadu team plans the job.
Removal
Packs are dropped on a vehicle lift using the OEM procedure and a rated battery table, then isolated at the service disconnect.
Packaging
One pack per UN-rated pallet box, strapped and restrained, with terminals capped and coolant ports sealed.
Consolidation
Dealer and workshop returns are consolidated into full truckloads, typically eight or more packs per run.
Before the truck arrives
- Pull the service disconnect and record pack voltage
- Drain or cap coolant lines before lifting
- Photograph the pack casing and any impact damage
- Keep the VIN and pack serial together on the manifest
Hosur, Tamil Nadu site notes
- Box or crate two-wheeler packs individually; loose-stacked packs are repacked on arrival and slow intake.
- Swap operators can set up recurring weekly collections from Bengaluru depots.
- Send a serial list with each load so bench results map directly back to your asset records.
- Packs with visible swelling must be declared and are tested only in the isolated quarantine room.
What this pack yields
lithium
2.92 kg
nickel
0 kg
cobalt
0 kg
manganese
0 kg
copper
8.84 kg
aluminium
10.55 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 centre operates under Tamil Nadu Pollution Control Board consent and grades material for producers registered under the Battery Waste Management Rules 2022. Because much of its intake crosses the state border from Karnataka, interstate transport documentation and waste descriptions are checked at the gate before unloading.
Mahindra XUV400 EL in Hosur, Tamil Nadu: common questions
Can I drop off a Mahindra XUV400 EL battery at Hosur, Tamil Nadu?
Hosur, Tamil Nadu 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, 550 km away.
What happens to Mahindra XUV400 EL modules after Hosur, Tamil Nadu?
Collected via Zaheerabad, Telangana, then Module grading at Hosur, Tamil Nadu, 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 Mahindra XUV400 EL pack be prepared for pickup?
Pull the service disconnect and record pack voltage. Drain or cap coolant lines before lifting. Photograph the pack casing and any impact damage. Keep the VIN and pack serial together on the manifest.
Which rules apply to Mahindra XUV400 EL 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 Hosur, Tamil Nadu
Mahindra XUV400 EL at other sites
Retiring Mahindra XUV400 EL packs near Hosur, Tamil Nadu?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.