Manufacturing & Infrastructure

Two world-class facilities. 1.2 million units monthly capacity. Zero compromise on quality.

Our Facilities

Two Plants. One Standard of Excellence.

Pune Plant (Headquarters)

Area
400,000 sq ft
Capacity
700,000 units/month
Established
1998
Focus
Automotive, Inverter & UPS Batteries

Nashik Plant

Area
320,000 sq ft
Capacity
500,000 units/month
Established
2016
Focus
Solar, EV & Industrial Batteries
Production Capacity

Scale That Powers Industries

0M
Units / Month
0
MWh / Day Output
0
Dispatches / Day
0
Days Avg. Inventory Turn
Animated Process Flow

From Lead Ingot to Finished Battery

Eight precision-controlled stages, each independently quality-checked before moving to the next.

1
Material Sourcing

Virgin lead and certified polypropylene procured from audited global suppliers.

2
Grid Casting

Precision gravity die-casting of lead-calcium alloy grids at controlled temperatures.

3
Paste Mixing

Active material paste mixed to exact density specifications for optimal capacity.

4
Plate Curing

Cured in humidity-controlled chambers for 48-72 hours to develop crystal structure.

5
Cell Assembly

Automated stacking and welding of positive/negative plates with separators.

6
Electrolyte Filling

Precision-dosed sulfuric acid electrolyte filling in cleanroom conditions.

7
Formation Charging

Multi-stage formation charging activates the battery's electrochemical structure.

8
Testing & Dispatch

100% units tested across 18 parameters before packaging and dispatch.

Machinery

Precision German & Japanese Equipment

We invest continuously in best-in-class manufacturing equipment from leading global suppliers to ensure consistency at scale.

Sovema Grid Casting Lines 12 fully-automated lines, 99.2% dimensional accuracy
Wirtz Paste Mixers High-shear mixing for uniform active material density
MAC Engineering COS Lines Cast-on-strap technology for low internal resistance
Digatron Formation Systems Computer-controlled multi-stage charge/discharge cycling
Bitrode Battery Testers 18-parameter automated electrical testing per unit
Robotic Palletizing Cells Automated packaging and warehouse-ready palletizing
Quality Control

NABL-Accredited Testing Laboratory

Every battery undergoes rigorous testing in our in-house laboratory, accredited under ISO/IEC 17025, before it ever leaves the factory.

Cold Cranking Amps (CCA) Testing

-18°C chamber simulating extreme winter starts

Capacity & Reserve Testing

20-hour and high-rate discharge verification

Vibration & Shock Testing

Simulates rough road and transport conditions

Life Cycle Testing

Accelerated charge-discharge cycling to failure

Dimensional & Visual Inspection

Automated vision systems for casing integrity

Acid Leakage & Safety Testing

Pressure and thermal stress validation

18
Testing Parameters per Unit
100%
Units Tested Before Dispatch
Research & Development

Engineering Tomorrow's Energy Today

120 scientists and engineers across two dedicated R&D centres, focused on next-generation battery chemistry.

Solid-State Research

₹800 Cr investment in next-gen solid-state battery chemistry for 2027 launch.

BMS Development

In-house Battery Management System design for all lithium product lines.

Electrolyte Chemistry

Proprietary electrolyte formulations for extended cycle life and faster charging.

Thermal Engineering

Advanced thermal management systems for safe high-rate charge/discharge.

Safety Standards

Zero-Harm Workplace Commitment

ISO 45001 Certified

Occupational health and safety management system across both facilities.

PPE Compliance

100% mandatory PPE zones with continuous monitoring and compliance audits.

Fire Safety

Automated fire suppression systems and quarterly emergency drills.

On-Site Medical

Dedicated occupational health centre with 24/7 medical staff at both plants.

Air Quality Monitoring

Real-time lead exposure and air quality monitoring exceeding OSHA standards.

Safety Training

Mandatory safety induction and quarterly refresher training for all employees.

Certifications

Globally Recognised Standards

Inside VoltCore

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Schedule a Facility Tour

See our manufacturing excellence first-hand. We welcome OEM partners and bulk buyers for guided plant tours.

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