Mahindra XUV400 EL battery recycling in Bhiwadi, Rajasthan
Bhiwadi, Rajasthan 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
9,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Bhiwadi, Rajasthan
Where a Mahindra XUV400 EL pack goes from Bhiwadi, Rajasthan
- 1
Collected via Narela, Delhi
Whole packs enter the network at Delhi — Narela Collection Yard, 75 km away, where they are weighed and de-energised.
- 2
Module grading at Bhiwadi, Rajasthan
All 14 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 56% of the pack qualifies for reuse and goes to Ludhiana — Mandi Gobindgarh Second-Life Works (315 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, 1,321 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Delhi — Narela Collection Yard | 75 km |
| Nearest second-life works | Ludhiana — Mandi Gobindgarh Second-Life Works | 315 km |
| Nearest refinery | Kolkata — Haldia Refining Works | 1,321 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 Bhiwadi, Rajasthan 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
Bhiwadi, Rajasthan site notes
- Bus and heavy truck packs are better routed to an integrated campus with lifting equipment.
- Give module counts and formats when booking so the right fixtures are prepared before arrival.
- Loads from Haryana should carry correct interstate documentation to avoid delays at the gate.
- Declare damaged items in advance; the site has limited quarantine space.
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 station operates under Rajasthan State Pollution Control Board consent in a RIICO industrial area and grades material for producers operating under the Battery Waste Management Rules 2022. Because many consignments cross the state border with Haryana, interstate transport paperwork is checked at intake.
Mahindra XUV400 EL in Bhiwadi, Rajasthan: common questions
Can I drop off a Mahindra XUV400 EL battery at Bhiwadi, Rajasthan?
Bhiwadi, Rajasthan 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, 75 km away.
What happens to Mahindra XUV400 EL modules after Bhiwadi, Rajasthan?
Collected via Narela, Delhi, then Module grading at Bhiwadi, Rajasthan, then Second life at Mandi Gobindgarh, Punjab, 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 Bhiwadi, Rajasthan?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.