Cygni Energy has commenced operations at its new Battery Energy Storage System (BESS) Gigafactory in Hyderabad, with an initial production capacity of 4.8 GWh. The facility, set up with an investment exceeding INR 1 billion, is located at the Electronics Manufacturing Cluster (EMC) in Maheshwaram and spans 160,000 square feet on a 5-acre campus.
The factory features a fully automated assembly line and includes an Advanced Engineering Lab and a Battery Management System (BMS) Lab. According to the company, the site is equipped to manufacture high-capacity battery packs intended for grid-scale energy storage projects and electric vehicle applications. Cygni has reported an existing order pipeline of 1 GWh from BESS developers and automotive clients.
Founder and CEO Venkat Rajaraman stated that the production line utilizes practices such as Poka-Yoke-enabled stations and end-to-end traceability, and is capable of manufacturing 105 kWh liquid-cooled base modules using 314Ah cells. The company uses a Manufacturing Execution System (MES) to enable real-time production monitoring, analytics, and quality control.
Cygni plans to expand the facility’s capacity to 10.8 GWh by 2027, with Phase II involving an additional investment of INR 1.5 billion. The expansion will include three new automated 2 GWh cell-to-pack manufacturing lines and container integration capabilities. The company anticipates creating over 1,000 direct and indirect jobs over the next two years.
Ongoing research and development at the site will focus on sodium-ion battery technology, thermal management systems, and advanced energy management algorithms. The company is also exploring design architectures such as Cell-to-Pack (CTP) and Cell-to-Chassis (CTC), in collaboration with IIT Madras.
Cygni Energy, established in 2014 and based in Hyderabad, is an energy storage engineering and manufacturing firm. The company is IATF 16949, ISO 9001:2015, and ISO 14001:2015 certified, with AIS 156 compliance for automotive products. It supplies battery solutions to both corporate and government clients across India.