Bhiwadi, Rajasthan cell grading plant
How Jaipur — Bhiwadi Grading Station decides reuse or refining for every module — test sequence, grade bands, outputs and the sites that feed it.
Throughput
9,000 TPA
Process stages
6
Feeder sites nearby
6
Operating since
2023
From intake to grade assignment
- 1
Intake & safety triage
Packs are logged, thermally imaged and screened for swelling, coolant ingress or venting before entering the bench area.
- 2
Controlled de-energising
Residual energy is discharged to a safe state of charge with regenerative load banks and recorded per serial number.
- 3
Module-level capacity test
Full charge-discharge cycling at C/3 establishes usable capacity, internal resistance and cell-to-cell balance.
- 4
EIS fingerprinting
1 mHz–10 kHz impedance sweeps separate SEI growth, lithium plating and contact resistance degradation modes.
- 5
AI optical inspection
Machine-vision inspection of busbars, welds and cell cans flags mechanical defects that block second-life reuse.
- 6
Grade assignment
Grade A (≥85% SOH), B (75–85%), C (65–75%) and D routes are assigned, with D-grade material released to refining.
Acceptance criteria
| Criterion | Requirement |
|---|---|
| Accepted feed | Whole packs and modules from intake yards and fleets |
| State of charge | Below 30% on arrival, recorded per serial |
| Condition | Damaged units declared and routed to quarantine |
| Documentation | Manifest with serials, chemistry and prior history |
Grade bands and routes
| Grade | Route |
|---|---|
| Grade A (85%+) | Grid-tied and commercial storage builds |
| Grade B (75–85%) | Telecom backup and solar buffering |
| Grade C (65–75%) | Low-duty backup, short warranty |
| Grade D (<65%) | Discharge and refining feed |
Why Bhiwadi, Rajasthan
Bhiwadi lies on the Rajasthan–Haryana border, part of the Delhi–Jaipur industrial corridor, with a mix of automotive component, electronics and engineering plants in its RIICO estates. The grading station opened in 2023 to add diagnostics capacity near the NCR while giving Rajasthan's growing electric fleets and suppliers a closer alternative to sending material to Gurugram. Customers south of Delhi often reach it faster than Gurugram.
At 9,000 TPA it is one of the network's smaller grading sites, and its benches are configured for modules and small packs rather than heavy commercial formats. It takes supplier returns and sub-assemblies from the corridor's component makers, two- and three-wheeler packs from Rajasthan, and overflow work from Gurugram when that hub is running at capacity. Grade reports use the same format as every other network grading site.
Permitting
Battery Waste Management Rules 2022 (BWMR)
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.
Technical strengths
Overflow capacity for NCR
Absorbs grading work when Gurugram is busy, keeping turnaround consistent across the region.
Supplier-focused service
Structured grading of module and sub-assembly returns for component makers in the corridor.
Compact bench layout
Fixtures sized for modules and smaller packs, where the site's intake is concentrated.
Sites that feed Bhiwadi, Rajasthan
Packs and modules arrive from these intake sites.
Bhiwadi, Rajasthan plant: technical questions
How long does grading take?
Standard passenger modules are graded within about five working days of intake; large-format bus and truck packs take longer because of disassembly.
What tests are run on each module?
A full capacity cycle, DC internal resistance, impedance spectroscopy and optical inspection of busbars, welds and cans.
Is Bhiwadi suitable for bus batteries?
It is set up mainly for modules and smaller packs. Bus and heavy commercial packs are usually sent to an integrated campus.
Why use Bhiwadi instead of Gurugram?
Bhiwadi can offer shorter queues and is closer for customers in Rajasthan and the southern NCR corridor.
Damaged or defective packs are handled under a separate quarantine protocol — flag them in the form and the team calls you back the same day.
Need modules graded?
Share pack counts, chemistry and condition for a grading slot and indicative value split.