4.8 GWh and Counting: Cygni's Massive Leap in Battery Production

Cygni Energy, India’s largest independent energy storage solutions provider, has commenced operations at its Phase-I Battery Energy Storage System (BESS) Gigafactory located in E-Mobility Valley at the Electronics Manufacturing Clusters (EMC), Maheshwaram, Hyderabad.

This fully automated, state-of-the-art facility is the first LEED-certified battery manufacturing plant in India. Spread across 1,60,000 sq. ft on a five-acre site and established with an investment of over ₹100 crore, the Phase-I facility has an initial production capacity of 4.8 GWh. It houses an Advanced Engineering Lab and a dedicated Battery Management System (BMS) Lab, and will manufacture high-capacity battery packs for electric vehicles and grid-scale energy storage projects, catering to IPPs and large-scale developers. The plant incorporates globally benchmarked practices, including Poka-Yoke-enabled assembly and full traceability.

In Phase II, Cygni plans to increase production capacity to 10.8 GWh, with a total investment of ₹250 crore across both phases. The expansion will include three fully automated 2 GWh cell-to-pack lines and integrated container assembly units, creating over 1,000 direct and indirect jobs within the next two years.

The facility integrates advanced technologies such as Machine Learning-driven predictive analytics, Digital Twin systems, and EMS-integrated modular solutions. R&D efforts—carried out in partnership with IIT-Madras—are focused on sodium-ion batteries, Cell-to-Pack and Cell-to-Chassis designs, and thermal management strategies optimized for Indian conditions.

News by Rahul Yelligetti.