Tesla Model S Plaid battery recycling in Butibori, Maharashtra
Butibori, Maharashtra receives graded Tesla Model S Plaid modules that passed as grade A or B and rebuilds them into warrantied stationary storage.
Pack value at 80% SOH
4,366 USD
Hybrid Split
Second-life share
47%
At 80% SOH
Site capacity
9,500 TPA
Second-Life BESS Works
Cities served
0
From Butibori, Maharashtra
Where a Tesla Model S Plaid pack goes from Butibori, Maharashtra
- 1
Collected via Zaheerabad, Telangana
Whole packs enter the network at Hyderabad — Zaheerabad Recovery Campus, 387 km away, where they are weighed and de-energised.
- 2
Graded at Pithampur, Madhya Pradesh
Modules travel 385 km to Indore — Pithampur Grading Plant for capacity, resistance and impedance testing across all 16 modules.
- 3
Second-life build at Butibori, Maharashtra
Grade A and B modules — about 47% of a pack at 80% SOH — are matched and rebuilt into storage systems on site.
- 4
Refined at Atchutapuram, Andhra Pradesh
Remaining modules are shredded to black mass and refined at Visakhapatnam — Atchutapuram Refinery, 558 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Hyderabad — Zaheerabad Recovery Campus | 387 km |
| Nearest grading bench | Indore — Pithampur Grading Plant | 385 km |
| Nearest refinery | Visakhapatnam — Atchutapuram Refinery | 558 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 Butibori, 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
Butibori, Maharashtra site notes
- Whole packs are not accepted; modules must arrive already graded.
- Each module needs its grade report and serial number.
- Finished units are dispatched on scheduled delivery runs agreed with the buyer.
- Buyers can inspect systems before dispatch by appointment.
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 works operates under Maharashtra Pollution Control Board consent. Repurposed storage systems are built to applicable Indian electrical and safety requirements, and the provenance of every module is recorded so each system can be traced back to its source packs.
Tesla Model S Plaid in Butibori, Maharashtra: common questions
Can I drop off a Tesla Model S Plaid battery at Butibori, Maharashtra?
Butibori, Maharashtra is a second-life bess works and does not accept whole packs from customers. Book a collection and the pack enters the network at Zaheerabad, Telangana, 387 km away.
What happens to Tesla Model S Plaid modules after Butibori, Maharashtra?
Collected via Zaheerabad, Telangana, then Graded at Pithampur, Madhya Pradesh, then Second-life build at Butibori, Maharashtra, then Refined at Atchutapuram, Andhra Pradesh. 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.
Tesla Model S Plaid at other sites
Other passenger packs at Butibori, Maharashtra
Retiring Tesla Model S Plaid packs near Butibori, Maharashtra?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.