Replus Engitech, a subsidiary of Bhilwara Energy, has commissioned a 1 GWh battery manufacturing plant in Pune, Maharashtra.

Spread across 31,130 square feet, the plant houses a dedicated assembly and integration zone tailored for battery rack assembly, system integration, and advanced module and pack production.

The complex is equipped with fully automated production lines capable of 500 MWh of cylindrical and 500 MWh of prismatic cell output, ensuring scalability and adaptability across multiple cell chemistries.

Designed to be cell chemistry-agnostic, the unit can handle diverse cell types and formats for both the stationary and mobile segments. It incorporates automation technologies such as cell sorting, plasma cleaning, thermal adhesive applications, and precision laser welding, all compliant with European and American standards.

The company said the Industry 4.0-ready hub maintains quality assurance through advanced systems, including air leak testing, IP compliance, and electrostatic discharge-safe operations, while maintaining an ISO Class 7 clean manufacturing environment at 25°C.

Replus has also set up a testing infrastructure on the site. This includes multiple high-capacity cell, module, and pack testers ranging from 5 A to 400 A, along with battery management system testers and climate chambers for performance validation under extreme conditions.

Replus has plans to scale the capacity of the plant to 6 GWh.

In March, Bhilwara Energy bagged an investment of ₹5 billion (~$57.2 million) from growth equity firm Singularity AMC. The two companies have signed definitive agreements to support the creation of an integrated energy transition platform, HEG Greentech.

The platform will focus on power assets, battery-grade anode materials, food-grade bottle-to-bottle recycling, graphene, and advanced battery systems manufacturing for energy storage and electric vehicles.

Bhilwara Energy was one of the winners in Urja Vikas Nigam’s Phase IV standalone battery energy storage systems auction. Bhilwara Energy secured 100 MW each at a tariff of ₹225,993 (~$2,566)/ MW/month.