What is inside the Ashok Leyland Boss EV Truck battery pack
The Ashok Leyland Boss EV Truck carries a 200 kWh pack built from LFP Prismatic (LiFePO4) cells arranged in 18 serviceable modules at a nominal 600 V. Pack mass lands near 1480 kg including the enclosure, cooling plate, contactors and BMS harness.
Because the cells are LFP Prismatic, the recoverable value profile is dominated by lithium, copper and aluminium rather than nickel and cobalt. That decides whether a retired pack is worth repurposing, refining, or both.
| Parameter | Value |
|---|---|
| Chemistry | LFP Prismatic (LiFePO4) |
| Cell format | Prismatic hard case |
| Energy / voltage | 200 kWh · 600 V |
| Modules | 18 |
| Estimated pack mass | 1480 kg |
| On sale since | 2023 (India) |
Step 1 — Removing and shipping a commercial fleet pack
Large packs are removed at the depot with a forklift-rated battery table and the vehicle isolated under lock-out tag-out. Retired packs are UN 3480 or UN 3481 dangerous goods, so the pack must be below 30% state of charge and any deformation, swelling or thermal history declared before pickup.
Each pack travels in a rated crate or on a restrained pallet, with coolant drained and ports sealed. Depot retirements are batched against the fleet replacement schedule so collections line up with vehicle swaps.
- Share telematics SOH history if it is available
- Confirm forklift access and dock height at the depot
- Isolate high-voltage systems under lock-out tag-out
- Declare any pack involved in a collision
Step 2 — Module-level state of health grading
Each of the 18 modules is tested independently — a whole-pack SOH figure hides the spread that decides second-life eligibility. We run a full capacity cycle, DC internal resistance measurement and impedance spectroscopy.
Our degradation model for the Ashok Leyland Boss EV Truck shows how value falls with age. Measured results replace these estimates once the pack is on the bench.
| Service year | Modelled SOH | Grade | Residual value |
|---|---|---|---|
| Year 2 | 95.9% | A — BESS ready | USD 10,459 |
| Year 4 | 92.8% | A — BESS ready | USD 10,129 |
| Year 6 | 89.7% | A — BESS ready | USD 9,798 |
| Year 8 | 86.6% | A — BESS ready | USD 9,467 |
| Year 10 | 83.5% | B — Second life | USD 7,968 |
Step 3 — What you actually recover
For modules routed to refining, a pack of this size and chemistry typically yields about 33.4 kg lithium, 0.0 kg nickel, 0.0 kg cobalt and 100.9 kg copper.
At 80% SOH our model sends about 56% of the pack to second life, worth USD 5,156, and credits USD 1,250 for the remainder as black mass. Avoided emissions come to roughly 8,946 kg CO2.
Field note
Step 4 — Where to send it and what paperwork you get
Ashok Leyland Boss EV Truck packs are received directly at 8 intake sites in its markets, including Chakan, Maharashtra, Sanand, Gujarat, Taloja, Maharashtra, Narela, Delhi. From there, modules move to the nearest grading bench and refinery.
Every consignment closes with a certificate showing quantity processed, recovery percentages achieved and downstream vendor disclosure, in the form needed for CPCB EPR filings under the Battery Waste Management Rules 2022. Fleets retiring several Ashok Leyland Boss EV Truck units should book one consolidated pickup to cut per-pack cost.