Kalamassery, Kerala cell grading plant
How Kochi — Kalamassery Diagnostics Bench decides reuse or refining for every module — test sequence, grade bands, outputs and the sites that feed it.
Throughput
7,000 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 Kalamassery, Kerala
Kalamassery, on the northern edge of Kochi, hosts KINFRA's industrial park and sits within easy reach of the port city's logistics network. Kerala has an active electric two-wheeler and three-wheeler market and has run state electric bus programmes. The diagnostics bench opened in 2023 so that Kerala's batteries could be graded inside the state instead of being trucked to Tamil Nadu or Karnataka.
At 7,000 TPA it is the network's smallest grading site, focused on two-wheeler, three-wheeler and small commercial packs. Kerala's coastal humidity is a real factor for batteries awaiting testing, so storage is climate-controlled and packs with any sign of water ingress are identified and handled separately before they reach the benches. Reusable modules are sent on to second-life works, and the remainder to processing sites in Tamil Nadu and Karnataka.
Permitting
Battery Waste Management Rules 2022 (BWMR)
The bench operates under Kerala State Pollution Control Board consent within a KINFRA park and grades material for producers under the Battery Waste Management Rules 2022, with custody records passed on to the downstream recycler.
Technical strengths
In-state grading
Grades Kerala's packs locally, cutting transport time and cost for small consignments.
Small-pack focus
Benches configured for two- and three-wheeler formats.
Humidity-controlled storage
Climate-controlled storage limits moisture exposure while packs wait for testing.
Sites that feed Kalamassery, Kerala
Packs and modules arrive from these intake sites.
Kalamassery, Kerala 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.
Does Kochi grade car batteries?
It can handle some passenger packs, but its benches are built mainly for two- and three-wheeler batteries.
Why does water exposure matter?
Water ingress can damage cells and create safety risks, so exposed batteries are declared, isolated and assessed before any testing.
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.