Tesla Model S Plaid battery recycling in Warsaw, Mazovia
Warsaw, Mazovia 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
17,000 TPA
Cell Grading & Diagnostics
Cities served
0
From Warsaw, Mazovia
Where a Tesla Model S Plaid pack goes from Warsaw, Mazovia
- 1
Collected via Dubai, UAE
Whole packs enter the network at Dubai — Jebel Ali Logistics Yard, 4,157 km away, where they are weighed and de-energised.
- 2
Module grading at Warsaw, Mazovia
All 16 modules are tested for capacity, DC resistance and impedance, then assigned grade A to D.
- 3
Second life at Zwickau, Saxony
At 80% SOH about 47% of the pack qualifies for reuse and goes to Zwickau — Saxony Second-Life Works (613 km). Selective — only low-swell pouch stacks above 82% SOH are cleared for repurposing.
- 4
Refined at Rotterdam, South Holland
Remaining modules are shredded to black mass and refined at Rotterdam — Maasvlakte Refining Works, 1,128 km away.
| Stage | Facility | Distance |
|---|---|---|
| Nearest intake yard | Dubai — Jebel Ali Logistics Yard | 4,157 km |
| Nearest second-life works | Zwickau — Saxony Second-Life Works | 613 km |
| Nearest refinery | Rotterdam — Maasvlakte Refining Works | 1,128 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 Warsaw, Mazovia 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
Warsaw, Mazovia site notes
- Cross-border loads need appropriate shipment documents.
- Bus operators should book in advance for large packs.
- Send a serial list with each load.
- Declare damaged packs before collection.
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 Poland
EU Battery Regulation (EU) 2023/1542 and the Polish Act on Batteries and Accumulators
Regulator: Chief Inspectorate of Environmental Protection (GIOS), with the BDO waste database
The centre operates under Polish environmental permits and the EU Battery Regulation (EU) 2023/1542. Transport follows ADR dangerous-goods rules, and cross-border movements follow EU waste shipment requirements.
Tesla Model S Plaid in Warsaw, Mazovia: common questions
Can I drop off a Tesla Model S Plaid battery at Warsaw, Mazovia?
Warsaw, Mazovia is a cell grading & diagnostics and does not accept whole packs from customers. Book a collection and the pack enters the network at Dubai, UAE, 4,157 km away.
What happens to Tesla Model S Plaid modules after Warsaw, Mazovia?
Collected via Dubai, UAE, then Module grading at Warsaw, Mazovia, then Second life at Zwickau, Saxony, then Refined at Rotterdam, South Holland. 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 Poland?
EU Battery Regulation (EU) 2023/1542 and the Polish Act on Batteries and Accumulators, overseen by Chief Inspectorate of Environmental Protection (GIOS), with the BDO waste database. Road transport follows ADR, and cross-border shipments follow the EU Waste Shipment Regulation.
Tesla Model S Plaid at other sites
Retiring Tesla Model S Plaid packs near Warsaw, Mazovia?
Share pack counts and condition. The despatch desk confirms a collection window within one working day and sends the right packaging.