1. Battery Cell Selection & IR Sorting
The foundation of any high-performance lithium pack is cell consistency. We strictly procure Grade-A+ LiFePO4 cells — including cylindrical 32140 15Ah cells and Highstar/EVE 100Ah prismatic cells. Prior to assembly, each cell is tested for internal resistance (IR), open-circuit voltage (OCV), and capacity to ensure minimal drift across series strings.
- Grade-A+ LiFePO4 chemistry with high thermal stability
- Verified internal resistance grading to avoid hotspots
- Capacity-matched batch selection
2. Cell Configuration and Assembly
Cells are positioned into flame-retardant structural interlocking holders. This prevents physical rubbing between cell walls, cushions against road shocks and potholes, and creates cooling micro-channels for heat dissipation. Interconnections are made using thick nickel-plated pure copper busbars for ultra-low resistance.
- Heavy-duty vibration-resistant cell brackets
- Low-resistance spot welded / bolted busbar interconnects
- Flame-retardant insulating sheet barriers between series groups
3. BMS Integration (Smart & Standard)
The Battery Management System (BMS) is the brain of the pack. We wire and integrate genuine Smart BMS units (such as JK-BMS with active cell balancing and Bluetooth app connectivity) or rugged Standard Industrial BMS units. Voltage balance leads are routed neatly with silicone insulation and protective sleeving.
- Active 1A-2A cell balancing prevents series cell drift
- Multi-point NTC temperature sensors monitor cell core heat
- Bluetooth smartphone telemetry for live SOC & cell voltage readout
4. Battery Pack Enclosure Fabrication
The finished battery core is nestled inside a heavy gauge cold-rolled steel enclosure with internal shock cushioning. We install water-resistant gasket seals, high-current Anderson quick plugs or M8 brass terminals, robust handles, and digital LED voltage/capacity displays on the exterior plate.
- Corrosion-resistant powder-coated industrial finish
- Sealed cable entry glands protecting against road splash
- Heavy-duty chrome folding carry handles
5. Quality Inspection & Testing
No battery leaves our facility without verified functional testing. Every pack undergoes full charge and discharge cycle testing to verify rated capacity, insulation resistance testing, and BMS protection verification (testing high-current cutoff, low-voltage cutoff, and temperature limits).
- 100% capacity verification test prior to packaging
- BMS overcharge and over-discharge trip testing
- Terminal torque check and polarity verification
6. Final Product Delivery & Dispatch
Packs are carefully clean-wrapped with protective film, packaged with high-density EPE foam corner protectors, and sealed into reinforced corrugated cartons. We coordinate logistics across Uttar Pradesh and all major transit hubs in India for prompt delivery to dealers and fleet clients.
- Moisture-sealed shrink wrapping
- Heavy-duty carton packaging with hazard labeling
- Prompt freight dispatch from Moradabad facility
Visit or Inspect Our Moradabad Facility
We welcome vehicle manufacturers, fleet operators, and bulk distributors to schedule a technical visit to our facility in Bhojpur Dharampur, Moradabad, Uttar Pradesh.