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

Hyderabad-based Cygni Energy has unveiled Phase I of its fully automated Battery Energy Storage System (BESS) gigafactory at E-Mobility Valley in Maheshwaram, Hyderabad, signalling a major leap in India’s electric vehicle (EV) and clean energy manufacturing landscape. The company is investing INR 2.5 billion over two phases to ramp up capacity from 4.8 GWh to 10.8 GWh over the next 12–24 months.

With a sharp focus on electric mobility, energy storage systems, and next-generation battery chemistries, Cygni is positioning itself to meet growing domestic and international demand for sustainable energy solutions. The company is also actively developing sodium-ion and sulphur-based batteries to complement traditional lithium-ion chemistries, alongside investments in thermal safety, recycling and advanced energy management algorithms tailored to Indian conditions.

Venkat Rajaraman, Founder & CEO, Cygni Energy, said, “In the long term, as part of India’s 100 GWh roadmap, we expect to become self-sufficient in cell manufacturing. We are also seeing a convergence of newer chemistries like sodium and sulphur. Sodium-ion batteries, in particular, are expected to play a critical role in India’s EV journey –given their lower cost of USD 6 per kWh versus USD 24 for lithium. While lithium demand currently exceeds sodium by 3x, India’s early-stage advantage allows us to leapfrog.”

“We cater to three markets – BESS, commercial and industrial storage, and electric vehicles. We have been manufacturing EV battery packs for a long time, earlier from a rental facility and now from our own factory. Today, we have a gigawatt-scale order pipeline for two- and three-wheeler EVs and large-scale storage systems. We’re also working with IIT-Madras' Centre of Battery Engineering and Electric Vehicles (C-BEEV) to co-develop future technologies. EVs contributed nearly 50 percent of our revenue till FY2025.”

The new facility spans 160,000 square feet and is engineered with automated Poka-Yoke-enabled lines and end-to-end traceability for high-quality battery module production. Till date, the company has raised USD 6.4 million in 2018 and USD 12.5 million in 2022 to fund its expansion.

The first phase investment of INR 1 billion supports an initial 4.8 GWh capacity. An additional INR 1.5 billion will be invested to reach 10.8 GWh under Phase II. The company expects to generate INR 26 billion revenue from Phase I, which it aims to double post-expansion.

Cygni’s batteries are designed for EV and grid-scale applications. The company has delivered over 500 MWh of batteries and claims to have a confirmed 1 GWh order pipeline, with growing traction in electric two-wheelers, three-wheelers and small commercial vehicles (SCVs). Most of the 80-plus components in its battery systems – such as busbars, cell holders, thermal and mechanical elements – are now locally sourced, reflecting India’s evolving EV ecosystem.

Jayesh Ranjan, Special Chief Secretary to the Government of Telangana and CEO of the Industry & Investment Cell in the CMO, inaugurated the facility alongside Prof. Ashok Jhunjhunwala, Chairman of IIIT-Hyderabad, and Srini Raju, Founder of iLabs Group.

Jayesh Ranjan, said, “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.”

Cygni expects to create over 1,000 direct and indirect jobs and is planning additional 2 GWh cell-to-pack automated lines as part of its future roadmap. With government support and rising EV adoption, the company is well-positioned to be a catalyst in India’s energy transition

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Maruti Suzuki India, the country’s largest passenger vehicle manufacturer, has further expanded its capacity with its new manufacturing facility at IMT Kharkhoda, Haryana, going on stream.

The facility was inaugurated by Prime Minister Narendra Modi and the Prime Minister of Japan, Sanae Takaichi, via video conferencing. The site represents an investment of INR 350 billion and is expected to create 21,000 jobs. Once the facility reaches its capacity of one million units per annum, it will be among the largest vehicle manufacturing sites globally.

Toshihiro Suzuki, Representative Director & President, Suzuki Motor Corporation, said, “It is a great honour for Suzuki group today as its most advanced car manufacturing facility at Kharkhoda, Haryana has been inaugurated by PM Narendra Modi and Sanae Takaichi. From current capacity of half a million units, the plant will be further scaled to one million units, making it one of the largest car plants in the world. It is a testament to the success of India-Japan partnership and ‘Make in India’ initiative. With favourable policy environment under PM Modi’s leadership, Suzuki is accelerating investments, employment, exports and technologies towards Viksit Bharat journey.”

“Over the years, India’s importance has grown significantly within the Suzuki Group. Suzuki’s first Battery Electric Vehicle, the e VITARA, is manufactured exclusively at Maruti Suzuki’s Gujarat plant, for exports to 100 countries globally. Thanks to exports of Made in India cars, Suzuki has become the largest car importer in Japan, one of the most demanding automobile markets. This shift is a strong reflection of how ‘Make in India, Make for the World’ is unfolding in practice, demonstrating growing global trust in India’s quality, capability, and advancement in manufacturing,” added Suzuki.

The Kharkhoda facility operates as a ‘Suzuki Smart Factory,’ utilising digital technologies to monitor operations and Industry 5.0 practices, such as the use of collaborative robots (COBOTS).

Interestingly, 100 percent of the facility’s electricity is sourced through renewable methods, including an installed solar capacity of 20 MWp, which is planned to reach 70 MWp by 2030. The site also includes a biogas plant and a Battery Energy Storage System.

The plant functions as a zero liquid discharge facility, with water requirements met through recycling and rainwater harvesting.

Furthermore, an in-plant railway siding will be established to manage vehicle transportation.

The company is also conducting community development projects in 10 nearby villages and continues to operate Japan-India Institutes for Manufacturing (JIMs) to develop a skilled workforce. Maruti Suzuki currently operates manufacturing plants in Gurugram, Manesar, Hansalpur, and now Kharkhoda, with a target capacity of 2.9 million units by the FY2026-27.

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Hindustan Zinc has expanded its Bureau of Indian Standards (BIS) license to include Hindustan Zinc Die-Casting Alloy 5 (HZDA 5). The company now holds BIS certification for both HZDA 3 and HZDA 5, which are used in sectors including automotive, engineering and infrastructure.

The BIS certification confirms that products meet standards for quality, safety and reliability. This development is intended to provide customers with assurance regarding product consistency and performance.

Arun Misra, CEO & Whole Time Director, Hindustan Zinc, said, “The extension of our BIS license scope to include HZDA 5 is an important step in strengthening customer confidence in our certified product portfolio. For us, certification is not only about meeting standards, but also about assuring customers of dependable quality and long-term value. As industries increasingly look for high-performance and responsibly produced metals, Hindustan Zinc remains committed to delivering products that customers can trust.”

The company manages quality through processes including raw material sourcing, production, and testing. It uses systems such as the Laboratory Information Management System and Agile Quality Circle to monitor production. In addition to BIS, the company maintains certifications such as REACH and LBMA.

Hindustan Zinc produces zinc, lead, silver and alloys, including low-carbon offerings. The company also manages customer engagement through its digital platform, Vedanta Metal Bazaar.

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European auto major Stellantis has installed a blanking press at its Warren Stamping Plant in Michigan to increase in-house production capacity. This development supports the manufacturing of components for Chrysler, Dodge, Jeep and Ram vehicles in North America.

The Warren Stamping Plant and the Sterling Stamping Plant supply components – including hoods, doors and liftgates – to assembly plants in the U.S., Canada and Mexico. These operations contribute to the volume growth targets established in the FaSTLAne 2030 strategy.

Ed Daniels Jr., Vice-President of North America injection and stamping operations, Stellantis, said, “When people think about vehicle manufacturing, they usually picture the assembly line. But stamping is where that work begins. Sterling and Warren give our North America operations the scale, speed and flexibility needed to deliver precision parts on time, support key vehicle programs and help drive sustainable, profitable growth. As Stellantis executes its USD 13 billion U.S. investment plans, these plants and the people behind them are critical to strengthening our manufacturing foundation and keeping assembly operations moving.”

The new press at the Warren facility is expected to produce between 4.5 million and 6 million parts annually for the Ram 1500, Wrangler, Gladiator and Grand Cherokee.

Curtis Booth, Vice-President and Plant Manager, Warren Stamping Plant, Stellantis, added, “The new press has the capacity to produce between 4.5 million and 6 million parts annually for vehicles, including the Ram 1500 and three Jeep models – the Wrangler, Gladiator and Grand Cherokee. Together, the Hellcat line and the new blanking press give WSP the ability to both prepare and form critical vehicle components within a highly integrated manufacturing operation.”

Quality control is maintained using the Automated Body Inspection System, which validates geometry and precision during production.

Greg ‘Butch’ Bauer, Vice-President and plant manager, Sterling Stamping Plant, Stellantis, said, “Our workforce is what makes an operation like this possible. There’s a level of ownership and pride across every shift that ensures we’re delivering the same quality and performance at all times.”

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Chennai-headquartered two-wheeler and three-wheeler major TVS Motor Company has reached a new production milestone with the rollout of the one-millionth TVS iQube electric scooter from its manufacturing facility in Hosur.

This achievement, reached six years after the model's 2020 launch, highlights the adoption of electric two-wheelers in the Indian market.

The company said that the iQube community has achieved significant metrics since the model’s introduction, including covering 14.94 billion kilometres, 522,969 tonnes of CO2 saved, which translates to nearly plantation of 20.9 million trees.

The iQube portfolio has expanded since 2020 to include various battery capacities, range options and connectivity features. TVS Motor Co has supported this growth through a service and sales network consisting of more than 3,300 touchpoints across 3,000 cities.

Sudarshan Venu, Chairman, TVS Motor Company, said, “The rollout of one million TVS iQubes reflects the scale at which electric mobility is becoming part of everyday life in India. The milestone is built on years of investment in engineering, innovation and manufacturing capabilities that have enabled us to build world-class electric mobility solutions designed and manufactured in India for the world.”

The company credits this milestone to its focus on in-house R&D and manufacturing, noting that the iQube serves as a central element of its strategy to support India's transition to sustainable, self-reliant mobility.

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