What the site does
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.
What arrives at the gate
Feedstock at Bhiwadi, Rajasthan reflects its catchment and plant type. Every consignment is weighed, photographed and logged against the originating manifest before it enters the process area.
- Supplier returns and rejects from the Bhiwadi industrial belt
- Two-wheeler and three-wheeler packs from Rajasthan
- Overflow grading work from the NCR hub
- Small commercial fleet packs
The process, step by step
The 3 operating lines — module soh bench, eis diagnostics laboratory, ai optical cell grading — run the sequence below.
| Stage | What happens |
|---|---|
| Intake & safety triage | Packs are logged, thermally imaged and screened for swelling, coolant ingress or venting before entering the bench area. |
| Controlled de-energising | Residual energy is discharged to a safe state of charge with regenerative load banks and recorded per serial number. |
| Module-level capacity test | Full charge-discharge cycling at C/3 establishes usable capacity, internal resistance and cell-to-cell balance. |
| EIS fingerprinting | 1 mHz–10 kHz impedance sweeps separate SEI growth, lithium plating and contact resistance degradation modes. |
| AI optical inspection | Machine-vision inspection of busbars, welds and cell cans flags mechanical defects that block second-life reuse. |
| Grade assignment | Grade A (≥85% SOH), B (75–85%), C (65–75%) and D routes are assigned, with D-grade material released to refining. |
What sets the site apart
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.
Where material goes next
Material that Bhiwadi, Rajasthan does not finish on site moves to the nearest specialist facility in the network, keeping transport distances and dwell times down.
| Facility | Role | Distance |
|---|---|---|
| Ludhiana — Mandi Gobindgarh Second-Life Works | Second-Life BESS Works | 315 km |
| Kolkata — Haldia Refining Works | Hydrometallurgical Refinery | 1,321 km |
Field note