Tesla Model S Plaid battery recycling in Hosur, Tamil Nadu
Hosur, Tamil Nadu is a diagnostics site: Tesla Model S Plaid packs arrive here from intake yards for module-level capacity, resistance and impedance testing, which decides reuse or refining.
Pack value at 80% SOH
4,366 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
14,000 TPA
Cell Grading & Diagnostics
Cities served
9
From Hosur, Tamil Nadu
Where a Tesla Model S Plaid 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 16 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 47% of the pack qualifies for reuse and goes to Nagpur — Butibori Second-Life Works (918 km). Selective — only low-swell pouch stacks above 82% SOH are cleared for 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 Tesla Model S Plaid battery
The Tesla Model S Plaid (2021) carries a 100 kWh NCA Pouch pack with 16 modules at 400 V, weighing roughly 540 kg. Premium nickel-cobalt pouch stacks with the highest recovery credit and the strictest safety handling class.
| Service year | SOH | Grade | Value |
|---|---|---|---|
| Year 2 | 95.3% | A — BESS ready | USD 5,456 |
| Year 4 | 91% | A — BESS ready | USD 5,248 |
| Year 6 | 86.7% | A — BESS ready | USD 5,039 |
| Year 8 | 82.4% | B — Second life | USD 4,580 |
| Year 10 | 78.1% | B — Second life | USD 4,220 |
What the chemistry means here
How it ages
NCA can deliver long life when it is kept in a moderate state-of-charge window, but it is sensitive to high voltage and heat. Swelling from gas generation is a common retirement signal in pouch formats.
Thermal behaviour
NCA shares the oxygen-release behaviour of high-nickel cathodes and is generally considered among the more reactive EV chemistries. Pouch cells have no rigid can, so mechanical damage and swelling translate quickly into safety risk.
Handling NCA Pouch
Collecting a Tesla Model S Plaid pack
100 kWh, 16 modules, about 540 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
5.33 kg
nickel
38.87 kg
cobalt
6.43 kg
manganese
0.63 kg
copper
20.22 kg
aluminium
12.85 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.
Tesla Model S Plaid in Hosur, Tamil Nadu: common questions
Can I drop off a Tesla Model S Plaid 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 Tesla Model S Plaid 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 47% of the pack goes to second life and the rest is refined.
How should a Tesla Model S Plaid 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 Tesla Model S Plaid 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
Tesla Model S Plaid at other sites
Retiring Tesla Model S Plaid 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.