Cygni Energy introduces a BESS gigafactory for EVs and grid storage

By Staff Report May 3, 2025 5:17 pm IST

Cygni Energy has opened the first phase of its Battery Energy Storage System (BESS) gigafactory at the Electronics Manufacturing Cluster in Maheshwaram. The facility, constructed to LEED standards, can produce 4.8 GWh of high-capacity battery packs for grid-scale storage systems and electric vehicles.

At the Electronics Manufacturing Cluster (EMC) in Maheshwaram, Cygni Energy, an energy storage solutions company located in Hyderabad and incubated at IIT Madras, opened the first phase of its Battery Energy Storage System (BESS) gigafactory. This plant, the first BESS production unit in India to be constructed by LEED (Leadership in Energy and Environmental Design) standards, occupies 160,000 square feet on a five-acre plot of land.

The factory, established with an initial expenditure of ₹100 crore, can produce 4.8 GWh of high-capacity battery packs for grid-scale storage systems and electric vehicles. It has state-of-the-art engineering and battery management labs. The batteries will be used by large-scale energy storage projects and independent power producers.

Advanced manufacturing software controls real-time analytics, quality checks, and production monitoring. The facility integrates automated assembly lines with error-proof systems and completes product traceability. It can also use high-performance 314 Ah batteries to construct 105 kWh liquid-cooled modules.

Cygni intends to invest an extra ₹150 crore to increase the facility’s capacity to 10.8 GWh by 2027. Three additional automated production lines and container integration systems will be added in Phase II to meet the increasing demand for stationary and e-mobility applications. In around two years, it is anticipated that the total project would create approximately 1,000 direct and indirect jobs.

Modular energy storage systems with integrated machine learning for performance predictions, digital twin integration, and enhanced grid interoperability are among the plant’s upcoming products. Along with structural innovations like cell-to-pack and cell-to-chassis arrangements, Cygni is also collaborating with IIT Madras on new battery chemistries including sodium-ion and supercapacitors.

Telangana government representatives, including Jayesh Ranjan, Special Chief Secretary for Industries, attended the launch event. He said the manufacturing was a big milestone for the state’s clean energy, job growth, and technological advancement.

Cygni CEO Venkat Rajaraman said, The new plant is equipped with automated systems designed for high-volume, high-precision battery production. This facility gives us a strong position in the growing energy storage market, noting that features like error-proof assembly lines and full product traceability have been integrated into the manufacturing process.”