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 commenced production at its second manufacturing plant at Kharkhoda.

With this, the company has expanded its production capacity to 2.65 million units per annum across Gurugram, Manesar and Kharkhoda in Haryana and Hansalpur in Gujarat.

The new facility can manufacture 250,000 units, which takes the total production at Kharkhoda to 500,000 units per annum combined. It will produce the company’s popular Brezza and Victoris SUVs.

The expansion is part of Maruti Suzuki India’s expansion strategy to meet customer needs, and once fully operational the Kharkhoda facility will produce a million units per annum, making it the biggest four-wheeler manufacturing location for Suzuki globally.

For FY2027, Maruti Suzuki India aims to add 500,000 units capacity.

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Tier 1 automotive supplier Uno Minda has announced that its Board of Directors has approved the establishment of a greenfield manufacturing facility in Chhatrapati Sambhajinagar, Maharashtra.

The facility, managed through its subsidiary Uno Minda Auto Innovations (UMAIPL), will focus on high-voltage electric powertrain products for four-wheeler passenger vehicles.

The plant will manufacture and assemble Electric Drive Units (EDU) and Dedicated Hybrid Transmission (DHT) systems. The expansion is supported by orders for these systems from an anchor customer. The project involves an estimated investment of INR 5.5 billion, funded through a combination of debt and equity. Capital expenditure will be phased over the next two years, with commissioning expected by Q2 FY2028.

This represents the second electric vehicle (EV) powertrain facility announced by UMAIPL, following the ongoing construction of its plant in Khed City, Pune, which is scheduled to start operations in H2 FY2027.

The expansion comes as the automotive market increases the adoption of advanced powertrains, including battery electric vehicles, hybrid electric vehicles, plug-in hybrids and range-extended electric vehicles.

Ravi Mehra, Managing Director, Uno Minda, said, "The Indian automotive landscape is undergoing a structural shift toward sustainable mobility, and Uno Minda is at the forefront of this transition. By establishing our second dedicated EV powertrain plant in Maharashtra, we are not only expanding our capacity but also advancing our product offerings with Electric Drive Unit and DHT. Our commitment remains firm: to lead the localization of high-voltage powertrain technologies in India, ensuring that our partners have access to global-standard innovation right at their doorstep."

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Hindustan Zinc, a Vedanta Group company, hosted ‘Zinnovation 2026’ in partnership with V-Spark DeepTech Ventures. The company aims to achieve INR 20 billion in value delivery through AI-driven industrial transformation. The initiative focuses on accelerating the deployment of technology across mining, smelting and manufacturing operations.

The projected value is expected to be derived from several operational areas, including productivity improvement, cost optimisation, asset reliability and energy efficiency. The transformation also targets enhanced safety, improved mineral recoveries and accelerated decision-making across the company's mines and smelters.

V-Spark intends to extend these AI use cases to the broader manufacturing sector, which currently contributes 17 percent to India’s GDP but maintains lower levels of digital integration compared to other sectors.

During the event, Hindustan Zinc and V-Spark signed several agreements to move technologies from proof-of-concept to industrial scale –

• Memoranda of Understanding (MoUs) were signed with XCMG, Sandvik, STL Digital and AVEVA.
• V-Spark entered agreements with emerging firms, including Beta Tanks Robotics, Symboticware AI, Kernely, Uncharted Technologies, Infinite Uptime, Intellisense.io and Flutura.
• Hindustan Zinc is currently working with over 50 deep-tech startups on more than 100 projects through the V-Spark platform.

Priya Agarwal Hebbar, Chairperson, Hindustan Zinc, said, “The future of manufacturing will be defined by our ability to scale with intelligence. At Hindustan Zinc, we are embedding technology directly into the core of our operations to prove that an industry traditionally defined by grit can be led by data”.

Akarsh Hebbar, Chairman, V-Spark DeepTech Ventures, added, “Zinnovation reflects our commitment to moving innovation from pilots to performance, proving that a 3x to 4x return is a highly achievable reality for deep tech AI enterprises. This is how we create globally benchmarked, future-ready operations across industries.”

The forum highlighted specific industrial applications of AI, such as predictive maintenance, digital twins, autonomous systems and computer vision. Hindustan Zinc also demonstrated its existing digital capabilities, including tele-remote operations and a winder simulator for mining. The venture-client approach utilised by the company is designed to rapidly validate and scale technologies with measurable business impact.

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California-headquartered Aptera Motors Corp., the solar mobility company specialising in ultra-efficient electric vehicles, has announced that five validation vehicles have successfully completed assembly on its new low-volume validation line.

The vehicles were manufactured at Aptera's facility in Carlsbad, using a 14-station assembly process designed to bridge the gap between prototype development and high-volume manufacturing. By running multiple units in sequence, the company is validating the assembly system's repeatability and refining technician workflows.

The 14-station line is being used to test cycle times, workstation efficiency and the precision of the manufacturing system. Each build provides real-world data to sharpen production predictability and identify improvements for future high-volume scaling. The five vehicles will now join an expanding validation fleet for a rigorous testing regime, including durability, safety verification, software integration and solar energy harvest performance.

The Aptera EV, with its around 700 watts of integrated solar cells, claims to provide up to 40 miles or 64km of range per day and a 400 miles or 640km range per full charge. It can accommodate 2 passengers plus a pet, and is targeted as a city vehicle.

Chris Anthony, Co-CEO, Aptera Motors, said, "Every vehicle we run through this line teaches us something. With five vehicles now off the line, we have a growing foundation of data, a team that is getting sharper with every build, and a process that is proving itself in real time. That is what gives us confidence as we move toward our goal of customer deliveries."

Steve Fambro, Co-CEO of Aptera Motors, added, "What we are building here is not just vehicles, but the system to build them well. Each cycle through the line improves precision, efficiency and repeatability. This is how we plan to meet our customers' expectations when they finally get their hands on their own Aptera vehicle."

With nearly 50,000 reservations, the transition to a sequenced assembly line is a vital step for Aptera. The ‘low-volume’ approach allows the engineering team to implement firmware and hardware refinements in real-time before finalising the configuration for mass production.

The milestone underscores Aptera's progress in proving that its unique three-wheeled, solar-integrated design can be manufactured consistently at scale, a critical factor for the company as it approaches its first wave of customer handovers.

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