Cygni Energy Opens 4.8 GWh BESS Gigafactory, To Double Output by 2027

• Features fully-automated line for grid-scale energy storage solutions
• Secures order pipeline of 1 GWh from BESS developers and automotive customers
• Over ₹100 crores invested in Phase One, with ₹ 150 Crores earmarked for Phase Two

Hyderabad-headquartered Cygni Energy, India’s largest independent energy storage solutions company, announced today the commencement of its Phase-I, fully operational and automated Battery Energy Storage System (BESS) Gigafactory. Located in E-Mobility Valley, at the Electronics Manufacturing Clusters (EMC) Maheshwaram, Hyderabad, it is also India’s first “Leadership in Energy and Environmental Design” (LEED) qualified facility equipped with an Advanced Engineering Lab and Battery Management System (BMS) Lab.

Set up with an investment of over ₹100 crores, the 1,60,000 sq. ft Phase-I facility is located on a 5-acre campus and is designed with an initial capacity to produce 4.8 GWh of high-capacity battery packs for electric vehicles and energy storage systems. These advanced BESS systems will cater to large grid-scale stationary storage projects and Independent Power Producers (IPPs).

Shri. Jayesh Ranjan Inagurating cygni energy gigafactory at Maheswaram

Venkat Rajaraman- ​Founder & CEO​, Cygni Energy at the new Gigafactory

Mr. Venkat Rajaram, Cygni Energy, Founder & CEO, along with Vipin and Gautam

Shri. Jayesh Ranjan, Special Chief Secretary to Government of Telangana, and CEO Industry & Investment Cell in CMO, unveiled the first phase in the presence of Prof. Ashok Jhunjhunwala, Chairman, IIIT-Hyderabad, Mr. Srini Raju, Founder, iLabs Group, alongside many industrialists and the leadership team of Cygni on Wednesday.

In his address Shri. Jayesh Ranjan commended Cygni for completing its first milestone and setting up the BESS Gigafactory. “The inauguration of Cygni's battery manufacturing gigafactory in Telangana marks a transformative step toward sustainable energy, manufacturing excellence, and innovation. This facility not only strengthens India’s commitment to clean energy but also creates jobs, fosters local talent, and builds a robust ecosystem for the future of energy storage solutions”.

Venkat Rajaraman, Founder and CEO of Cygni said, “This Gigafactory positions us to lead in the energy storage sector, delivering high-quality, safe battery packs across multiple applications. Cygni's Automated BESS Assembly Line is engineered for advanced, high-quality BESS module manufacturing, leveraging globally recognized best practices such as Poka-Yoke-enabled stations and end-to-end traceability. We plan to grow exponentially in energy storage over the next few years in India and internationally”.

“In Phase II, we are scaling our Gigafactory’s capacity to 10.8 GWh in the existing facility itself. With a total investment of Rs. 250 Cr across 2 phases, this will result in direct and indirect job creation of over 1,000 jobs in the next 24 months. As part of this expansion, we will be adding three additional automated 2 GWh cell-to-pack manufacturing lines and container integration facilities to our existing lines, to meet the rising demand for stationary and e-mobility storage applications.” Rajaraman added.

Going forward, Cygni will provide advanced high-capacity energy storage solutions featuring modular, scalable designs and integrated with Machine Learning for predictive analysis, Digital Twin technology for real-time monitoring, high-performance energy management systems, seamless smart grid-code integration, and precision-engineered manufacturing. It also leverages research on futuristic technologies and battery chemistries through its long-term partnership with IIT-Madras, such as Cell-to-Pack (CTP) and Cell-to-Chassis (CTC) Design Architectures, sodium-ion batteries, and super-capacitors.

Cygni has manufactured and delivered 500 MWh of batteries for the power and energy segment. Currently, it has a pipeline of 1 GWh in orders for BESS projects and EV battery packs, backed by a nationwide service network and an experienced project commissioning team.

This production line is capable of manufacturing 105kWh liquid cooled base modules using advanced 314Ah cells, serving as the fundamental building blocks for nearly all energy storage containers worldwide. The Manufacturing Execution System (MES) Software in this BESS manufacturing line ensures seamless production monitoring, real-time data analytics, quality control, and enhanced traceability, driving operational efficiency and product reliability.

Ongoing R&D at the Gigafactory will include development of innovative energy storage solutions with Sodium-ion chemistry, thermal management strategies to improve safety, and advanced Energy Management System (EMS) algorithms to cater to evolving grid-code and design of India specific energy storage solutions.

About Cygni Energy

Cygni, headquartered in Hyderabad, India, is a New Age, chemistry agnostic, Energy Storage engineering and manufacturing company. Established in 2014, it has the distinction of becoming the first company recognized under the “Make in India” (Start-up India) initiative. Cygni’s Founder is also a Recognized Mentor under the Atal Innovation Mission (AIM).

Cygni is IATF 16949 certified (one of the highest levels of quality certification in the automotive sector). It also has ISO 9001:2015 and ISO 14001:2015 certifications and AIS 156 certifications for its automotive products.

The company boasts a robust portfolio of corporate and government customers. To know more about its offerings visit – https://cygni.com/

Tesla Receives Approval of 'Gigafactory Berlin', Its Only Production Facility in Europe

Tesla has received approval for the expansion of its Gigafactory Berlin, which is its only production facility in Europe. The approval came after a meeting between community members and local officials held in the Hangelsberg district of Grünheid, Germany. Despite some opposition and ongoing protests concerning environmental concerns and the use of local resources, the expansion plans were approved with a majority vote by the local council. The expansion aims to increase the factory's production and logistical capacity, including the construction of a train station. This development is part of Tesla's strategy to enhance its manufacturing capabilities in Europe.

There were a number of environmental concerns regarding Tesla's Gigafactory Berlin. The factory's demand for 1.4 million cubic meters of water per year, which is equivalent to the consumption of a town of 30,000 people. This has raised concerns about the potential strain on the area's water supplies, especially since about two-thirds of the site is located on a water reserve.

Demonstrators walk past the Tesla factory in Gruenheide, Germany, May 11, 2024, at the end of their protest. A local council in Germany on Friday May 17, 2024, approved a plan by electric carmaker Tesla to expand the grounds of its first plant in Europe, which has drawn persistent protests this year. ( Image source|Patrick Pleul/dpa via AP, File)

There have been Deforestation and Wildlife concerns. Local authorities made objections to the clearing of trees from the site, which involved relocating protected anthills, and lawsuits over the presence of snakes and lizards.

Moreover, there are allegations of "suspected water pollution and a possible environmental crime" related to the factory. Building on vast areas of open land might disrupt groundwater formation, affecting the regional water association.

These concerns have led to a series of complaints and legal actions by environmental groups, as well as protests and attempts to disrupt the factory's operations. Despite these challenges, the factory has continued to move forward with its expansion plans.

Steps Tesla is taking to address Environmental concerns

Tesla has taken several measures to address the environmental concerns related to its Gigafactory Berlin:

• Tesla plans to install around 400 nesting boxes for birds breeding in the area.
• The company will search the forest for hibernating bats, forest lizards, and other creatures that need to be moved to safer locations.
• Tesla is implementing water-saving and wastewater-reducing measures to mitigate the impact on the local water supply.
• There are specific requirements for groundwater protection included in the factory's environmental approval.
• Measures for species protection have been incorporated to ensure the safety of local wildlife.
• Tesla has set limit values for air pollutants and regulations on their measurement to minimize air pollution.

These steps are part of more than 400 ancillary provisions included in the final environmental approval to address the various concerns raised by environmentalists and local residents. Tesla's efforts reflect a commitment to balancing its expansion with environmental stewardship.

Energy integration at the Gigafactory

Tesla has contracted with E.ON, Germany's largest electric utility company, to design energy solutions for the factory. This collaboration is focused on utilizing sustainable energy products and aligns with Tesla's mission to build sustainable energy vehicles using sustainable energy.

The Gigafactory is designed to be a net-zero energy factory upon completion, meaning it will be entirely powered by renewable energy sources.

Noida-based GoodEnough Energy Plans to Establish A 7 GWh Gigafactory in Jammu and Kashmir

GoodEnough Energy, a company based in Noida, has announced plans to set up a Battery Energy Storage Systems (BESS) gigafactory in Jammu and Kashmir (J&K). This BESS gigafactory will be India's largest, and will help reduce over 5 million tonnes of CO2 annually, claims the company as per Media reports. 

The initial capacity of the gigafactory will be 7 GWh, with an investment of over ₹450 crore. The operations are scheduled to start by October 2024. The investment will cover the cost of the manufacturing plant, machinery, and infrastructure, and is expected to be completed by 2026.

This gigafactory is expected to play a significant role in reducing carbon emissions by over 5 million tons annually and will support India's burgeoning electric vehicle (EV) ecosystem. It will also create job opportunities for over 100 small and medium-sized enterprises (SMEs) as vendors and suppliers.

Furthermore, GoodEnough Energy aims to expand the Gigafactory's capacity to 20 GWh by 2026, which could potentially reduce CO2 emissions by a projected 15 million tonnes. This initiative is part of India's goal to reach 500 GW of renewable energy capacity and to support industries with high CO2 emissions in achieving their sustainability Targets.

Earlier in January 2019, LIBCOIN Consortium in collaboration with Magnis Energy Technologies Limited and BHEL, have finalized a deal to build India's first Lithium-ion Battery Gigafactory. The starting capacity will be 1 GWh, with an eventual increase to 30 GWh.

In July last year, Elon Musk promoted Tesla resumed talks with the Indian government to build a gigafactory with an annual capacity of 500,000 electric cars.

These developments are part of India's push towards clean energy and electric vehicle adoption. India plans to set up 12 giga factories by 2030 to manufacture lithium-ion batteries to support electric vehicle (EVs) as well as renewable energy generation.

A gigafactory is a large-scale manufacturing facility that specializes in producing batteries and other components for electric vehicles (EVs) and renewable energy applications. The term "giga" refers to "billion," indicating the massive production capacity of these factories, often in terms of gigawatt-hours (GWh) of battery storage. Gigafactories aim to achieve economies of scale, reduce costs, and increase production efficiency, which is crucial for the transition to clean energy technologies.

The concept of 'Gigafactory' was popularized by Tesla, Inc., which built its first Gigafactory in Nevada to produce battery cells in collaboration with Panasonic. This approach allows for the integration of battery production with vehicle assembly, streamlining the supply chain and reducing exposure to supply chain disruptions. Other companies have since adopted the term for their own large-scale battery production facilities.

Tata Group to Set Up a £4 Bn Battery Gigafactory in the UK

• Tata Sons will build a 40GW battery cell gigafactory in the United Kingdom (UK)
• The investment, of over £4 billion, will deliver electric mobility and renewable energy storage solutions for customers in UK and Europe
• JLR and Tata Motors will be anchor customers, with supplies commencing from 2026

Tata Sons today announced plans to establish a global battery cell gigafactory in the UK with a capacity to produce 40GW of cells annually.

This investment of over £4 billion is an integral part of Tata Group’s commitment to electric mobility and renewable energy storage solutions and establishes a competitive green tech ecosystem in the UK at scale.

N Chandrasekaran, Chairman, Tata Sons, said: “The Tata Group is deeply committed to a sustainable future across all of our business. Today, I am delighted to announce the Tata Group will be setting up one of Europe's largest battery cell manufacturing facilities in the UK. Our multi-billion pound investment will bring state-of-the-art technology to the country, helping to power the automotive sector’s transition to electric mobility, anchored by our own business, Jaguar Land Rover. With this strategic investment, the Tata Group further strengthens its commitment to the UK, alongside our many companies operating here across technology, consumer, hospitality, steel, chemicals, and automotive. I also want to thank His Majesty's Government, which has worked so closely with us to enable this investment."

Commenting about the announcement of the UK gigafactory, UK Prime Minister, Rishi Sunak, said: “Tata Group’s decision to build their new gigafactory here in the UK – their first outside of India – is a huge vote of confidence in Britain. This will be one of the largest ever investments in the UK automotive sector. It will not only create thousands of skilled jobs for Britons around the country, but it will also strengthen our lead in the global transition to electric vehicles, helping to grow our economy in clean industries of the future.”

The battery gigafactory will produce high-quality, high-performance, sustainable battery cells and packs for a variety of applications within the mobility and energy sectors. The company’s strategic growth plans for its flexible manufacturing capacity will begin with a rapid ramp-up phase and the start of production in 2026.The gigafactory intends to maximise its renewable energy mix, with an ambition for 100% clean power. The plant will employ innovative technologies and resource efficient processes like battery recycling to recover and reuse all the original raw materials to deliver a truly circular economy ecosystem.

Tesla Built Its 1st Cybertruck at the EV Maker's Gigafactory After 2 Yrs of Delay

In November 2019, Elon Musk Introduced Cybertruck - a futuristic electric pickup-truck to the world. Now, after 3-odd years the first Cybertruck electric Pickup has been built at Gigafactory Texas, the company said in a tweet on Saturday, after two years of delays in the earlier planned schedule.Tesla has been pushing back production timing citing that shortages in sourcing components is the reason for going behind the scheduled launch of Cybertruck.

Tesla is likely to produce about 2,50,000 Cybertrucks a year, depending on demand.

The stated goal of Tesla in developing the Cybertruck is to provide a sustainable energy substitute for the roughly 6,500 fossil-fuel-powered trucks sold per day in the United States.

According to CarDekho.com, the Tesla Cybertruck is expected to launch in India in December 2023. The Tesla Cybertruck will rival XF, XC60 and X1. The expected prices to start from ₹ 50.70 Lakh, said the Indian auto website.

Recently, after PM Modi's visit to the United States, Tesla has ramped up its plan to setup its factory in India.

Cyberquad

Besides, Tesla is also introducing an electric quad bike in China, drawing inspiration from its Cybertruck model, and will specifically target children aged 8 to 12 years old. The Tesla CyberQuad is a four-wheel, self-balancing electric ride-on car developed by Tesla Motors. It was initially revealed as a concept in 2019 and has already been available for purchase in various other countries including Canada and Europe.

India Plans Its Own 'Giga Factories' for Making Lithium-ion Batteries

Ggovernment of India's policy maker, NITI Aayog, has proposed the establishment of giga factories in India for the manufacture of lithium-ion batteries, which are required for running electric Vehicles, in the next couple of years.

Natably, 'GigaFactory' is a name given to lithium-ion battery and electric vehicle sub-assembly factory of Elon Musk-promoted Tesla, Inc.

Part of NITI Aayog’s earlier proposal, the recommendation has proposed that giga factories be established for making lithium-ion batteries in India and at least three-four factories to come up in the next two-three years.
Earlier proposal by NITI Aayog, which is being facing industry backlash, has suggested that post March 31, 2023 only electric (lithium-ion or other advanced battery chemistry only) two and three -wheelers would be sold in the country after and all new sales of two-wheelers below 150cc would be electric post March 31, 2025.

Rajiv Kumar, Vice Chairman of NITI Aayog, tweeted "We have proposed in this mission that giga factories be established for making lithium-ion batteries in India. We want at least three-four factories to come up in the next two-three years."

We have proposed in this mission that giga factories be established for making lithium-ion batteries in India. We want at least three-four factories to come up in the next two-three years.#FAME-II #electricvehicles #futuremobility #EVs https://t.co/NR8tpUDn8m

— Rajiv Kumar 🇮🇳 (@RajivKumar1) July 3, 2019

"When the policy (moving to electric two and three-wheelers) comes into effect, you will have domestically produced lithium-ion batteries or other advanced technology batteries,” said Rajiv Kumar in a statement to The Hindu.

According to Kumar, Electric Vehicle batteries was a sunrise industry and India needed to start building capabilities to become a globally competitive player in this area. "The lack of domestic capability will result in massive imports as is the case in electronics," he said.

Mr Rajiv Kumar also said that working towards finding lithium-ion and with the advancement of technology, it was likely that it may be replaced with other advanced batteries.

To recall, in September last year, in a warning to India Chairman of Japan's Suzuki Motor had said that Indian dream of all-electric vehicles on road by 2032 can seriously hamper if India do not start manufacturing batteries used by electric vehicles (EVs) locally in the country.

Fe weeks later after that the Prime Minister Office (PMO) had asked department of heavy industry to redraft its proposal to offer incentives of as much as $759 million (₹5,500 crore), which will mostly be use to encourage local manufacturing of lithium-ion (Li-ion) batteries used in EVs.

To push the adoption of electric mobility in the country, Indian government has taken numerous steps of late. Last month, it was reported that government of India is planning to mandate cab aggregators such Uber and Ola to convert 40% of their fleet of cars to electric by April 2026.

In March, The Union cabinet chaired by the Prime Minister Narendra Modi has approved the proposal for implementation of Phase-2 of Electric Vehicle Scheme 'Faster Adoption and Manufacturing of Electric Vehicles in India' (FAME) that include approval of a $1.4 Billion package, which will offer car buyers in the country upfront incentives on purchase of electric vehicles. The package announced will also be used for setting up charging infrastructure and focussing on electrification of public transport.

Early last month, Lucknow-based Sahara India Pariwar announced its entry in to the automobile sector with its new electric vehicle (EV) brand called Sahara Evols.