Manufacturing & Export

Make in India · Export-ready.
Two plants. One million smart batteries a year.

Halix Bharat Limited designs, manufactures and tests every battery in-house — across two Greenfield plants in Gujarat and Rajasthan.
Integrating proprietary IoT intelligence into every pack, then shipping domestically and to global markets through our export wing.

Battery Manufacturing Plant
In-house
Cell to product
2 Plants
GJ & RJ
1M / yr
Battery packs
ISO 9001
Quality system
Make in India
Manufactured
12+ Countries
Export markets
01

Own plants

Battery packs, BESS and power electronics built on Halix-owned, certified lines across Dist. Baroda and Dist. Jaipur.

02

Quality labs

In-house testing and certification to BIS, IEC 62619, UN 38.3, AIS 156 and ISO 9001. 100% end-of-line tested — every unit.

03

Global export

Our trade wing takes Halix products to 12+ countries across South Asia, Southeast Asia, the Middle East and Africa.

Flagship Product
🔐 Proprietary Patent Registration in Process — Indian Patent Office + PCT International

The Smart Battery that thinks.

India's first EV battery with an IoT module, 4G SIM, and GPS embedded inside the pack — transmitting live telemetry every 30 seconds. This proprietary system, patent registration in process with the Indian Patent Office, transforms every battery from a commodity into a connected infrastructure asset.

Chemistry
Lithium & Super Capacitor
LiFePo4, LTO & Super Capacitor
Capacity
3 kWh - 1 mWh
51.2V - 409.6V
Cycle Life
4,000 - 25,000
Cycles at 80% DoD
IP Rating
IP67
Dust + Water sealed
Connectivity
4G + GPS
SIM7670G · Cat-M1
IoT Module
HIM-1000
Halix IoT Module - Proprietary (Patent Pending)
Telemetry
Every 30s
Live to Halix Central Server
Calendar Life
10–25 Yrs
Operating life
Halix IoT Module — HIM-1000

Intelligence sealed inside every pack.

The proprietary HIM-1000 board — embedded inside each battery — connects to the Halix Central Server via 4G LTE, transmitting live data every 30 seconds. It is the core intellectual property of Halix Bharat Limited, with patent registration currently in process.

  • →Battery health — SoC%, SoH%, all 16 cell voltages, cycle count, remaining range.
  • →Live GPS location — real-time coordinates, speed, geofence breach & theft alerts.
  • →Thermal monitoring — 4 temperature sensors, overtemperature protection & alerts.
  • →Usage events — swap station ID, user binding, charge/discharge logs, OTA firmware.
  • →72-hour local buffer — data stored on-board if cellular lost, auto-synced on reconnect.
📡
4G LTE + GPS
SIM7670G — always connected
🔋
BMS IC TI BQ76952
16S cell monitoring + balancing
🔐
Unique Device Identity
HSM certificate + UUID burned in factory
📍
Digital Twin
Live asset on Halix Cloud from Day 1
⚡
OTA Updates
Firmware upgrades without physical access
🛡️
Anti-Theft Lock
Electromagnetic lock — Patent Pending
Plant Locations

Two Greenfield plants.
One unified quality standard.

Both plants are established simultaneously — identical machinery, identical processes, 500,000 units each — providing national reach and built-in redundancy from Day 1.

📍 Plant A — Phase 1A
Gujarat
Dist. Baroda (Vadodara) · GIDC Industrial Zone
500K
Units / Year
20 Acres
GIDC Land
~1,500
Direct Jobs
  • DMIC corridor — excellent national logistics connectivity
  • Baroda–Mumbai Expressway & Western Railway access
  • GIDC water + 33kV power — immediate allocation
  • Proximity to Ahmedabad, Surat & Mumbai EV market
  • Established auto-component ecosystem for local sourcing
  • Gujarat Govt EV manufacturing incentive package eligible
  • Nearest export port: Hazira, Surat (~100 km)
📍 Plant B — Phase 1B
Rajasthan
Dist. Jaipur · RIICO Industrial Area
500K
Units / Year
20 Acres
RIICO Land
~1,500
Direct Jobs
  • Jaipur–Delhi NH48 highway — North India distribution hub
  • Access to Delhi NCR, UP, MP & Punjab EV markets
  • RIICO 33kV power allocation readily available
  • Highest solar irradiance — 5 MW rooftop at optimal ROI
  • Lower land & operational cost vs. western India
  • Rajasthan Invest Summit state incentives eligible
  • Jaipur railway junction for national battery distribution
⟳
Built-in redundancy

If either plant faces disruption, the second plant ramps to 75–80% of total combined capacity within 48 hours — a resilience guarantee no single-plant competitor can match.

Production Process

One line, fully integrated.

14 precision stages — from cell IQC to Digital Twin creation — with 100% automated end-of-line testing on every single battery before it leaves the plant.

01
Cell IQC
100% of incoming cells tested for capacity, voltage & internal resistance. Sub-spec cells returned.
02
Cell Matching
AI-based sort — ±5mV OCV, ±2mΩ IR tolerance — for optimal 16S2P pack balance & cycle life.
03
Module Assembly
1 kW fiber laser busbar welding in Class 10,000 cleanroom. Inline vision + X-ray weld inspection.
04
BMS Assembly
BMS board assembled, firmware flashed, 4-hour burn-in at 40°C, all sensors auto-calibrated.
05
IoT Provisioning
UUID, device certificate, M2M SIM activation, MQTT credentials & signal test — proprietary process.
06
Integration
BMS + IoT + cell module assembled. Proprietary CAN bus link verified with live server data test.
07
Thermal Layer
PCM pads + 800°C-rated aerogel/Kapton fireproof barriers installed. Thermal interface material applied.
08
IP67 Sealing
Al 6061 enclosure, silicone gasket, proprietary electromagnetic lock. Every unit water-immersed 1m/30min.
09
Formation Charge
8–10 hr C/10 formation cycle. Discharge at 1C confirms ≥97% of rated 60Ah capacity.
10
18-Point EOL Test
12-minute automated test: pack voltage, 16 cell voltages, BMS protection, 4G, GPS, MQTT, OTA & more.
11
Digital Twin
Battery registered on Halix Cloud. UUID, plant origin (GJ/RJ), lot, firmware, SOH baseline all stored.
12
Label & Pack
Laser-engraved serial, tamper-proof QR, certification marks. Zero-waste reusable crates.
⚗️
Cell & R&D

Chemistry selection, cell testing & pack design.

🤖
Automated Assembly

Robot-assisted module & pack assembly with smart BMS + IoT.

🔬
Test & QC

Cycling, thermal, vibration & 18-point safety validation.

🚚
Dispatch

Domestic & export logistics, GPS-tracked, fully traceable.

Quality System

Quality, non-negotiable.

Every unit earns its way out the door. 100% end-of-line testing, full batch traceability and abuse testing to international safety standards — because energy products only count if they're safe for decades.

  • →100% EOL tested — every single battery, no sampling.
  • →Full batch & cell traceability — lot number, cell serial, plant, date.
  • →Thermal & abuse testing — overcharge, overdischarge, short circuit, crush, vibration.
  • →In-house calibration lab — traceable to NABL standards.
  • →Export-ready documentation — CE, UN 38.3, IEC compliance pathways.
100%
Units EOL-tested
18
Point EOL test in 12 min
4K - 25K+
Cycle life validated
ISO 9001
Quality management
Product Range

What we manufacture & export.

🔋

Smart Battery Packs

IoT-enabled swappable packs for 2W, 3W and LCV EVs. HAL-IoT series. Patent Pending.

🏭

Energy Storage (BESS)

Containerised C&I and utility-scale BESS systems for captive and grid-tied storage applications.

⚡

Power Electronics

Inverters, UPS, DC-DC converters, EV chargers and smart battery management controllers.

🌏

Trade & Global Supply

International distribution across 13+ countries through the Halix export wing — full documentation & compliance handled.

Standards & Certifications

The standards we build to.

Every Halix product is designed and tested to the strictest applicable standards for the Indian market and international export markets.

BIS Certified
Bureau of Indian Standards
IS 16046 — mandatory certification for Li-ion batteries sold in India
AIS-156
EV Battery Safety (India)
Phase II — thermal runaway propagation & abuse tests. Mandatory for all Indian EV batteries
IEC 62619
Industrial Li-ion Safety
Safety requirements for secondary lithium cells in industrial applications
UN 38.3
Transport Safety
Required for air & sea freight of lithium batteries — mandatory for all export markets
ISO 9001
Quality Management
End-to-end quality system across both manufacturing plants
CE Marked
European Conformity
IEC 62619 / IEC 62133-2 — enables sale across 32 European countries
WPC / DoT
M2M Device Approval
Wireless type approval for the 4G LTE radio inside each HAL-BAT battery pack
ISO 14001
Environmental Management
Zero liquid discharge, EPR compliance & green manufacturing at both plants
Export Wing

India-made energy, delivered worldwide.

Our trade wing takes Halix products to markets across South & Southeast Asia, the Middle East and Africa — with documentation, compliance and after-sales handled end-to-end.

  • →Bangladesh, Sri Lanka, Nepal, Myanmar, Vietnam, Indonesia
  • →UAE, Saudi Arabia, Africa — CE & IEC-certified for compliance
  • →End-to-end logistics, warranty support & after-sales managed
Talk to the export team →
Halix global export — logistics and shipping network
13+
Export countries
CE · IEC
Export compliance
Support
End2End Logistics