Mahindra XUV400 EL battery recycling in Khordha, Odisha
Bhubaneswar — Khordha Collection Yard takes whole Mahindra XUV400 EL packs straight from fleets, dealers and workshops. Packs are weighed, de-energised and logged here before modules move on for grading or refining.
Pack value at 80% SOH
1,262 USD
Hybrid Split
Second-life share
56%
At 80% SOH
Site capacity
6,500 TPA
Reverse Logistics Yard
Cities served
0
From Khordha, Odisha
Where a Mahindra XUV400 EL pack goes from Khordha, Odisha
- 1
Intake at Khordha, Odisha
One pack per UN-rated pallet box, strapped and restrained, with terminals capped and coolant ports sealed. Each pack is weighed, photographed and discharged below 30% state of charge.
- 2
Graded at Pithampur, Madhya Pradesh
Modules travel 1,064 km to Indore — Pithampur Grading Plant for capacity, resistance and impedance testing across all 14 modules.
- 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 (700 km). Excellent — long calendar life makes LFP the preferred feedstock for stationary BESS repurposing.
- 4
Refined at Haldia, West Bengal
Remaining modules are shredded to black mass and refined at Kolkata — Haldia Refining Works, 331 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Indore — Pithampur Grading Plant | 1,064 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 700 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 331 km |
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 Khordha, Odisha 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
Khordha, Odisha site notes
- Small volumes are grouped into scheduled consolidated runs.
- Declare battery type and quantity when booking.
- Pack batteries so they cannot move during transit.
- Damaged units are isolated immediately on arrival.
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 yard operates under Odisha Pollution Control Board consent within an IDCO industrial estate, and supports producers' obligations under the Battery Waste Management Rules 2022 by keeping unit-level custody records.
Mahindra XUV400 EL in Khordha, Odisha: common questions
Can I drop off a Mahindra XUV400 EL battery at Khordha, Odisha?
Yes, by appointment. Bhubaneswar — Khordha Collection Yard accepts whole Mahindra XUV400 EL packs; book a collection or a drop-off slot so the site can prepare packaging and paperwork.
What happens to Mahindra XUV400 EL modules after Khordha, Odisha?
Intake at Khordha, Odisha, then Graded at Pithampur, Madhya Pradesh, then Second life at Butibori, Maharashtra, then Refined at Haldia, West Bengal. 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.
Mahindra XUV400 EL at other sites
Retiring Mahindra XUV400 EL packs near Khordha, Odisha?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.