New BESS Gigafactory in India
Cygni Energy, the largest independent energy storage systems manufacturer in India, based in Hyderabad, has announced the launch of the first phase of its fully automated Battery Energy Storage System (BESS) gigafactory. The new facility, located in the prestigious E-Mobility Valley within the Electronics Manufacturing Clusters (EMC) in Maheshwaram near Hyderabad, is the first of its kind in the country to receive LEED (Leadership in Energy and Environmental Design) certification.
Strategic Investment and Advanced Infrastructure
Phase I of the project covers an area of 160,000 square feet (about 14,860 m²) on a 5-acre plot, with an investment exceeding USD 11 million. The factory is designed with an initial production capacity of 4.8 GWh annually, producing high-capacity battery modules dedicated to both electric mobility and stationary energy storage systems.
In the following phases, Phase II plans to more than double the production capacity to 10.8 GWh by 2027, with a total investment of approximately USD 30 million. This development will create over 1,000 direct and indirect jobs in the next two years.
Technology, Automation, and Innovation
Cygni Energy has implemented an automated BESS module production line in the gigafactory, based on global standards such as Poka-Yoke stations (minimizing operational errors) and a full traceability system. The high-end MES (Manufacturing Execution System) allows real-time monitoring of processes, production data analysis, quality control, and operational performance optimization.
The production line enables the manufacturing of battery modules with a capacity of 105 kWh, based on advanced 314 Ah cells, which are key components of energy storage systems worldwide.
Future Development: ML, Digital Twin, Sodium-Ion Batteries
Cygni is not only focusing on current technologies but is also investing in future solutions. The company plans to develop scalable, modular systems integrated with advanced Machine Learning algorithms, Digital Twin technology, and next-generation energy management systems. In collaboration with IIT-Madras, they are working on innovative architectures such as Cell-to-Pack (CTP), Cell-to-Chassis (CTC), sodium-ion batteries, and supercapacitors.
The R&D center located in the gigafactory will focus on developing solutions tailored to the specific needs of the Indian market, considering thermal safety, compliance with evolving energy grid codes, and optimization of energy efficiency.
Government Support
The opening ceremony of the facility was attended by Shri Jayesh Ranjan, Special Secretary of the Telangana Government, Prof. Ashok Jhunjhunwala from IIIT-Hyderabad, and Srini Raju, founder of iLabs. As Ranjan emphasized, “The launch of Cygni’s gigafactory marks a breakthrough in sustainable energy, manufacturing excellence, and innovation, strengthening India’s position as a leader in clean energy, creating jobs, and supporting the development of local talent.”
Source: pv-magazine-india.com