Introduction
MG Motor India is seeing a surge in popularity for its electric vehicles, and leading the pack is the MG Windsor EV. This model has been setting new sales records in the country. But beyond the headlines lies a fascinating process that powers this EV - the battery pack, which is completely built at MG’s manufacturing plant in Halol, Gujarat.
Made in India: Batteries Built from Scratch
MG’s Halol plant is not just another car assembly line. It is one of the few facilities in India where battery packs are built entirely in-house. Everything from testing individual cells, wiring, and welding, to charging and final assembly is carried out under one roof. Two main battery types are manufactured here: one for the MG Comet EV, which uses a 17.3kWh battery with 36 cells, and another for the Windsor Pro, which gets a 52.9kWh battery with 98 cells.
Every Minute Counts in Battery Assembly
Each battery pack takes about 7 to 8 minutes to build. That may sound quick, but several highly technical processes are packed into those few minutes. It all starts with imported LFP (Lithium Iron Phosphate) cells, which are tested one by one for voltage and insulation resistance. Only those that pass the quality checks move forward in the line.
Once tested, each cell is wrapped in insulating foam. This ensures the battery stays at a safe operating temperature and prevents overheating. For the Windsor Pro, all 98 cells are then placed in a metal tray in six carefully arranged rows. Cooling pipes are also inserted at this stage, allowing fluid to circulate through the battery and maintain its temperature during use.
Robotic Welding Meets Human Precision
After the cells are set, aluminium busbars are placed on the terminals to connect them electrically. A robotic laser welding arm then welds all the connections - a total of 196 points within minutes. However, it’s not all machine work. Technicians follow up with manual testing by gently prying each busbar to check the weld strength. If anything is even slightly loose, it is rewelded.
Next, a wiring harness is fitted over the battery pack, and then the battery’s control unit, known as the Battery Management System (BMS), is installed. This module acts as the brain of the battery, managing safety, performance, and temperature control.
Charge and Discharge: The Real Test
Once fully assembled, the battery goes into a climate-controlled room for a full charge-discharge cycle. This is the most time-consuming step. The battery is charged to 100 per cent and then completely discharged to test its performance under load. After passing this test, it is charged back to around 50 to 55 per cent.
MG does not store batteries at 100 per cent charge for safety reasons. Charging to full capacity increases voltage levels, which can pose a risk during handling or while the batteries are in storage within the plant.
Final Assembly Before Installation
Once all tests are passed, the battery is sealed with an IP67-rated waterproof gasket. Its weight is recorded, and it is moved to the general assembly line. Here, the battery is installed underneath the vehicle. For the Windsor Pro, this step requires the help of hydraulic machines and robotic arms, since the battery weighs close to 300kg.
Women at the Core of the EV Build Process
One of the most remarkable things about MG’s battery facility is its workforce. While women make up around 40 per cent of the total employees at the Halol plant, the battery assembly area is dominated by women, forming nearly 80 to 90 per cent of the team. These women are leading the way in one of the most high-tech sections of EV production, proving that the future of mobility is not just electric, but inclusive too.
Built in India, Powered by Skill and Technology
Every MG Windsor Pro or Comet EV that leaves the factory is powered by a battery built right here in India - one that’s made with precision, tested for reliability, and assembled by a skilled, mostly female workforce. MG’s Halol plant is a shining example of how local manufacturing is shaping the country’s electric vehicle future, one battery at a time.
