German luxury carmaker Mercedes-Benz has opened Europe's first battery recycling plant with an integrated mechanical-hydrometallurgical process making it the first car manufacturer worldwide to close the battery recycling loop with its own in-house facility.

The recycling plant in Kuppenheim, southern Germany, creates a genuine circular economy. Unlike existing established processes, the expected recovery rate of the mechanical-hydrometallurgical recycling plant is more than 96 percent. Valuable and scarce raw materials such as lithium, nickel and cobalt can be recovered – in a way which is suitable for use in new batteries for future all-electric Mercedes-Benz vehicles. The company has invested tens of millions of euros in the construction of the new battery recycling plant and thus in the value creation in Germany. Federal Chancellor Olaf Scholz and Baden-Württemberg's Environment Minister Thekla Walker visited the plant for the opening ceremony in Kuppenheim, Baden.

Ola Kaellenius, Chairman of the Board of Management, Mercedes-Benz Group said, “Mercedes-Benz has set itself the goal of building the most desirable cars in a sustainable way. As a pioneer in automotive engineering, Europe's first integrated mechanical-hydrometallurgical battery recycling factory marks a key milestone towards enhancing raw-materials sustainability. Together with our partners from industry and science, we are sending a strong signal of innovative strength for sustainable electric mobility and value creation in Germany and Europe.”

Ola Scholz said, “The future of the automobile is electric, and batteries are an essential component of this. To produce batteries in a resource-conserving and sustainable way, recycling is also key. The circular economy is a growth engine and, at the same time, an essential building block for achieving our climate targets! I congratulate Mercedes-Benz for its courage and foresight shown by this investment in Kuppenheim. Germany remains a cutting-edge market for new and innovative technologies.”

The luxury carmaker has joined hands with Primobius, a joint venture between German plant and mechanical engineering company SMS Group and Asutralian process technology developer Neometals, which is its technology partner for the battery recycling factory.

The plant is receiving funding from the German Federal Ministry for Economic Affairs and Climate Action as part of a scientific research project with three German universities. The project looks at the entire process chain for recycling, including logistics and reintegration concepts. The partners are thus making an important contribution to future scaling of the battery recycling industry in Germany.

Integrated mechanical-hydrometallurgical

For the first time in Europe, the Mercedes-Benz battery recycling plant covers all steps from shredding battery modules to drying and processing active battery materials. The mechanical process sorts and separates plastics, copper, aluminium and iron in a complex, multi-stage process. The downstream hydrometallurgical process is dedicated to the so-called black mass. These are the active materials that make up the electrodes of the battery cells. The valuable metals cobalt, nickel and lithium are extracted individually in a multi-stage chemical process. These recyclates are of battery quality and therefore suitable for use in the production of new battery cells.

Unlike the pyrometallurgy established in Europe at present, the hydrometallurgical process is less-intensive in terms of energy consumption and material waste. Its low process temperatures of up to 80deg Celsius mean it consumes less energy. In addition, like all Mercedes-Benz production plants, the recycling plant operates in a net carbon-neutral manner. It is supplied with 100 percent green electricity. The roof area of the 6800 square-metre building is equipped with a photovoltaic system with a peak output of more than 350 kilowatts.

The Mercedes-Benz battery recycling plant in Kuppenheim has an annual capacity of 2,500 tonnes. The recovered materials feed into the production of more than 50,000 battery modules for new all-electric Mercedes-Benz models. The knowledge gained could help scale up production volumes in the medium to long term.

Holistic approach

Mercedes-Benz takes a holistic approach to the circularity of battery systems and considers three core topics: circular design, value retention and closing the material loop.

With its Design for Circularity approach, the OEM is taking the entire battery technology value chain into account from the outset. At the Mercedes-Benz eCampus in Stuttgart-Unterturkheim, which opened in 2024, circular thinking flows into the development of new battery cells. Battery production for electric Mercedes-Benz vehicles is net carbon-neutral in battery factories on three continents. Local battery production is a key factor for the success of the Mercedes-Benz sustainable business strategy.

In line with circular thinking and to conserve resources, the company offers reconditioned batteries as spare parts for all its electric vehicles. In addition, its Mercedes-Benz Energy subsidiary has established a successful business model with large-scale stationary storage applications. Batteries that are no longer suitable for vehicle use can enjoy a second life as part of an energy storage system.

Jorg Burzer, Member of the Board of Management of Mercedes-Benz Group, responsible for Production, Quality & Supply Chain Management stated “We are systematically deepening our expertise in the battery value chain. Following the opening of the Mercedes-Benz eCampus for development of new battery cell chemistries in Stuttgart-Unterturkheim, we are now sustainably closing the raw materials loop in Kuppenheim. The innovative technology enables us to recover valuable raw materials from the battery with the highest possible degree of purity. This turns today's batteries into tomorrow's sustainable mine for raw materials. The new battery recycling plant strengthens the role of the Mercedes-Benz production network with vehicle and drivetrain plants in Europe.”

Thekla Walker MdL, Minister for the Environment, Climate and Energy Baden-Wurttemberg said, “Battery recycling is of great importance to Baden-Wurttemberg as a state with such a strong automotive sector. Closing the loop on the value chain reduces dependencies, increases resilience in times of crisis and can smooth peaks and troughs in the availability of raw materials. Mercedes-Benz is a pioneer in this respect: With the integrated battery recycling plant, Mercedes-Benz has developed a sustainable approach for dealing with limited resources and is therefore making a valuable contribution to a truly circular economy. We are proud that in this federal state of innovators, we are also at the forefront in this field.”
 

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Jakson Group, a leading diesel genset manufacturer, has announced an expansion of its energy solutions range following a financial year where revenue exceeded INR 90 billion (GBP 850 million).

The Group has expanded its presence across five new categories – Genset Xtra, Battery Energy Storage Systems (BESS), Solar Kits, Mobile Light Towers and electric three-wheelers. This move is intended to broaden the company's presence across power generation, storage and sustainable transport.

The entry into electric mobility follows a partnership with a Bengaluru-based firm to develop research-backed three-wheelers. This adds a transport component to Jakson’s existing operations in solar power, green molecules and infrastructure engineering, procurement and construction (EPC).

Established in 1947, the group operates six manufacturing facilities and maintains a workforce of 3,500 employees serving approximately 100,000 customers.

Jakson Group is positioning itself as an integrated provider for the energy transition, moving from its origins in diesel generator manufacturing toward a diversified portfolio that includes alternative fuels and civil EPC services. With 12 international offices, the group is looking to align its domestic manufacturing scale with global energy requirements.

Sameer Gupta, Chairman, Jakson, said, “At Jakson, our mission has always been to power progress through innovation. With FY26 revenue of over INR 90 billion, Jakson today has both the scale and the responsibility to shape future-ready energy solutions. This portfolio expansion reflects our commitment to building an integrated energy ecosystem that is reliable, responsible and aligned with the evolving needs of customers in India and global markets.”

Sundeep Gupta, Vice-Chairman, Jakson, added, “The market today is looking for energy solutions that are efficient, dependable and future-ready. With this expanded portfolio, Jakson is strengthening its position as a diversified player serving evolving customer needs across sectors.”

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Lloyds Metals and Energy (LMEL) has completed the diesel-to-electric conversion of a Liebherr R996 excavator, marking the first time a mining machine in this category has been retrofitted for fully electric operations.

The project was executed by the company's internal engineering and technology teams and involved a redesign of the vehicle's power architecture and control systems. The shift to electric power is intended to eliminate carbon dioxide emissions associated with the machine's operation while reducing reliance on diesel fuel.

The engineering process included the development of proprietary digital monitoring and safety solutions to manage the high-power requirements of the heavy-duty excavator. By sourcing and engineering major subsystems within India, the project serves as a demonstration of domestic capability in advanced heavy engineering and sustainable industrial innovation.

LMEL expects the conversion to improve operational performance through the use of real-time diagnostics and predictive maintenance.

Established in 1977, LMEL operates iron ore mines in Maharashtra and is expanding its integrated steel operations. The company currently produces 0.7 MTPA of direct reduced iron (DRI) and has commissioned a 4 MTPA pellet plant, with long-term plans to increase iron ore dispatch capacity to 26 MTPA. Its sustainability strategy includes the deployment of electric vehicle fleets and the construction of slurry pipelines to lower transport-related emissions.

B Prabhakaran, Managing Director, Lloyds Metals and Energy, said, “This landmark achievement, is not just about electrifying a machine – it is about reimagining the future of mining. At LMEL, we believe that responsible mining and sustainability must go hand in hand. This achievement demonstrates India’s capability to deliver world-class, zero-emission solutions in even the most complex and heavy-duty environments. We are proud to contribute to a future where mining is both productive and environmentally responsible.”

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Tata Motors, one of the leading commercial vehicle manufacturers, has begun delivering the first batch of Prima E.55S electric prime movers to BillionE Mobility, as part of an order for 250 units of the EV.

The fleet is scheduled for phased deployment across freight corridors in Gujarat, Rajasthan, Tamil Nadu, Karnataka, Maharashtra, Haryana and the Delhi NCR region to transport industrial goods including steel and cement.

The Prima E.55S is constructed on the i-MoEV architecture and utilises a 450 kWh battery pack, which is claimed to be the largest in its category. The e-truck comes with a claimed range of up to 350 km on a single charge and features an integrated e-axle, a three-speed automatic transmission and dual-gun fast-charging capabilities.

In terms of safety it get a driver monitoring system, lane departure warning and an electronic braking system.

BillionE Mobility intends to scale its heavy-duty logistics operations to 1,500 units over the next 18 months through this strategic partnership. Tata Motors supports its alternative fuel portfolio through the Sampoorna Seva 2.0 initiative and a service network comprising 3,200 touchpoints across India.

Kartikey Hariyani, Founder of BillionE & ChargeZone, and Sanjeev Kulkarni, CEO of BillionE Mobility, said, “Our focus at Billion Electric Mobility is on building electric commercial vehicle solutions that can be deployed reliably, and at scale across real freight operations for inter-city routes. We are entering into a strategic partnership with Tata Motors as we aim to accelerate our commitment for systematic large-scale acquisition and month on month planned pipeline for deployment 6 to 18 months targeting 1,500 units of heavy‑duty logistics in India. The Tata Prima E.55S delivers the performance, reliability and operational efficiency required for intensive logistics solutions across various applications. We are pleased to induct Prima E.55S 450kWh, India’s largest in-class battery capacity of 450 kWh to enhance our long-haul logistics capabilities.”

Rajesh Kaul, Vice-President and Business Head – Trucks, Tata Motors, said, “Electric trucking scales when vehicles are built for real operating conditions – duty cycles, uptime, energy efficiency and total cost of ownership. Developed with this application‑led approach, the Prima E.55S brings together India’s first high‑performance e‑axle, an advanced battery management system and dual charging ports, supported by a segment‑leading 450 kWh battery pack designed for extended range and demanding duty cycles. These technologies translate into strong performance, higher uptime and lower operating costs, enabling customers to achieve faster payback. Our close collaboration with BillionE Mobility has ensured alignment across the vehicle and the supporting ecosystem, enabling dependable electric operations across key freight corridors.”

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Switch Mobility, the electric vehicle division of the Hinduja Group, has delivered the first 10 units of its EiV12mt intercity electric coaches to Prasanna Purple Mobility Solutions.

The e-buses were inaugurated in Pune and will operate on the Mumbai–Pune corridor. This deployment represents the manufacturer's first supply of intercity coaches to a private sector operator and facilitates the entry of Prasanna Purple Mobility Solutions into the electric intercity segment.

The delivery is part of a larger order for 25 electric buses being deployed in partnership with Vertelo. The remaining units are scheduled for delivery throughout the year. The EiV12mt coach is designed for long-distance operations, featuring 45 pushback seats and a range exceeding 300 km per charge. The vehicle incorporates fast-charging technology and the Switch iON connected system for real-time fleet monitoring and data analysis.

Till date, Switch Mobility has deployed over 2,500 electric buses in India to date and has previously supplied intercity vehicles to state transport undertakings such as UPSRTC. The company intends to scale its presence in the intercity segment as operators transition from internal combustion engines to electric propulsion for high-frequency travel corridors.

Ganesh Mani, CEO, Switch Mobility, said, “The flag-off marks another important step in expanding electric mobility beyond cities and strengthening our presence in the intercity segment. This partnership reflects the growing confidence in electric buses for high-frequency routes like Mumbai–Pune, where performance, reliability, and efficiency are critical. As we commence deliveries, with the first set of buses now deployed, we look forward to progressively scaling this engagement with Prasanna Purple Mobility Solutions in the period ahead. At Switch Mobility, we are focused on delivering solutions through the EiV12 platform that are not only sustainable but also commercially viable for operators, while ensuring a superior passenger experience. With intercity mobility continuing to evolve, we are building on our experience in the segment and remain committed to accelerating the adoption of reliable, efficient, and future-ready electric mobility solutions.”

Prasanna Patwardhan, CMD, Prasanna Purple Mobility Solutions, added, “Entering the intercity segment with electric mobility is a significant milestone for us. Through this collaboration, we are introducing a cleaner and more efficient travel option on the Mumbai–Pune route. We remain focused on enhancing the overall journey experience while moving towards more sustainable operations. With Switch Mobility we value our partnership for long term E Mobility Solutions.”

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