Gurugram, Haryana cell grading plant
How NCR — Gurugram Collection & Grading Hub decides reuse or refining for every module — test sequence, grade bands, outputs and the sites that feed it.
Throughput
18,000 TPA
Process stages
6
Feeder sites nearby
6
Operating since
2019
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 Gurugram, Haryana
Gurugram sits at the centre of the National Capital Region's automotive belt, a short drive from the Manesar and IMT Bawal manufacturing clusters and from the regional service networks of India's largest passenger-vehicle makers. The hub opened in Sector 34 in 2019 so that NCR fleets, dealers and component suppliers could have packs graded close to where they are removed, rather than trucking them hundreds of kilometres south before anyone knows what they are worth.
As a diagnostics site it receives whole packs and modules, never black mass. Its 18,000 TPA of bench capacity is weighted towards passenger-car and ride-hailing fleet packs, but a growing share of intake is e-rickshaw and two-wheeler batteries consolidated from Delhi and western Uttar Pradesh. Modules that pass grading are released to second-life works in the north; the rest are consolidated and dispatched for black mass production elsewhere in the network.
Permitting
Battery Waste Management Rules 2022 (BWMR)
The hub operates under consent conditions from the Haryana State Environment Protection Council and HSPCB, and grades material for producers registered on the CPCB EPR portal under the Battery Waste Management Rules 2022. Movement of spent lithium-ion packs within NCR follows national dangerous-goods practice for UN 3480 and UN 3481, and interstate consignments from Delhi or Rajasthan carry e-way bills and a declared waste description.
Technical strengths
Fleet-scale bench rows
Parallel capacity-test channels let a complete fleet retirement be graded as one batch, so every pack in the batch is reported and settled together.
EPR hotline desk
The network's NCR compliance hotline is staffed from this site, so producers can resolve certificate questions with the team that graded their material.
Urban-safe routing
No shredding happens here. Modules below reuse threshold are consolidated and sent on, keeping black mass production out of a dense urban catchment.
Sites that feed Gurugram, Haryana
Packs and modules arrive from these intake sites.
Gurugram, Haryana 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 the Gurugram hub accept e-rickshaw batteries?
Yes. Lithium e-rickshaw packs aggregated across Delhi NCR are accepted. They are most economical when an aggregator consolidates them, so a single load justifies a scheduled collection.
Can NCR producers get help with EPR certificates here?
Yes. The EPR hotline team is based at this site and can explain the certificates generated from your consignments and how they relate to your obligations on the CPCB portal.
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.