Mahindra XUV400 EL battery recycling in Taloja, Maharashtra
Mumbai — Taloja Hazmat Consolidation 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
16,000 TPA
Reverse Logistics Yard
Cities served
0
From Taloja, Maharashtra
Where a Mahindra XUV400 EL pack goes from Taloja, Maharashtra
- 1
Intake at Taloja, Maharashtra
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 475 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 (644 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, 998 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest grading bench | Indore — Pithampur Grading Plant | 475 km |
| Nearest second-life works | Nagpur — Butibori Second-Life Works | 644 km |
| Nearest refinery | Chennai — Sriperumbudur Recovery Campus | 998 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 Taloja, Maharashtra 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
Taloja, Maharashtra site notes
- City pickups use smaller vehicles; tell us about height limits, basement access or restricted loading hours.
- Damaged packs need a separate declaration and travel in steel containment with vermiculite.
- Port-linked consignments need their documents before the booking date is confirmed.
- During the monsoon, collection windows are reconfirmed the day before to account for flooding and road closures.
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 holds Maharashtra Pollution Control Board consent within Taloja MIDC and follows the estate's fire and hazardous-storage conditions. Material is handled within the Battery Waste Management Rules 2022 framework, and any cross-border movement is subject to customs controls and the applicable waste-shipment requirements.
Mahindra XUV400 EL in Taloja, Maharashtra: common questions
Can I drop off a Mahindra XUV400 EL battery at Taloja, Maharashtra?
Yes, by appointment. Mumbai — Taloja Hazmat Consolidation 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 Taloja, Maharashtra?
Intake at Taloja, Maharashtra, then Graded at Pithampur, Madhya Pradesh, 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.
Mahindra XUV400 EL at other sites
Other passenger packs at Taloja, Maharashtra
Retiring Mahindra XUV400 EL packs near Taloja, Maharashtra?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.