Montra Electric has unveiled fully automated battery plant in Manesar, advancing large-scale EV battery production for heavy-duty trucks, writes Richa Tyagi.
Montra Electric eM&HCV (IPLTech Electric Private Limited), part of the Murugappa Group, has made another strong stride in advancing clean mobility by unveiling a state-of-the-art, all-women monitored, fully automated battery manufacturing plant at its Manesar, Haryana facility. The launch coincided with the introduction of the Rhino 5538 EV 4×2 TT, a heavy-duty electric truck that integrates advanced battery swap technology, signifying the company’s focus on innovation, localisation, and sustainable freight mobility.
Over the past few years, Montra Electric has built a comprehensive electric mobility portfolio catering to freight, logistics, and rural transportation segments. The Rhino brand encompasses a wide range of electric vehicles, including the 55-ton tractor trailer Rhino, the 3.5-ton small commercial vehicle Eviator, the last-mile passenger vehicle Super Auto, the delivery-focused Super Cargo, and India’s first electric farm tractor, the E-27. The latest addition, the Rhino 5538 EV 4×2 TT, represents the next evolution of Montra’s long-haul electric freight solutions, supported by one of India’s most advanced battery manufacturing ecosystems.
Landmark Battery Manufacturing Facility
The newly inaugurated battery plant at Manesar serves as the cornerstone of Montra Electric’s push toward technological self-reliance and high-efficiency production. With an annual capacity of 1.7 GWh, the plant can produce over 6,000 truck batteries per year, each engineered for reliability, longevity, and performance in India’s demanding commercial vehicle environment.
What sets this facility apart is its all-women monitored operation, an industry first in India’s EV manufacturing landscape. The plant combines cutting-edge automation with inclusivity and empowerment, where women lead operations, quality control, and data-driven process management.
Equipped with fully automated production lines, the facility leverages robotic pick-and-place systems, precision cell stacking, bottom and top case gluing, vacuumised fluid filling, and end-of-line testing. These processes ensure the production of 282 kWh Lithium Iron Phosphate (LFP) batteries, rated at 614 V and 460 Ah, tailored for heavy-duty applications like electric tractor trailers. The plant’s automation significantly reduces human error, enhances consistency, and improves thermal and electrical safety standards. The facility is designed with advanced dust-control measures, including air showers for both personnel and material.
In addition to the battery plant, Montra Electric inaugurated a semi-automatic truck conveyor assembly line, seamlessly integrated with Automated Guided Vehicles (AGVs) and digital Manufacturing Execution Systems (MES) and Warehouse Management Systems (WMS). The line uses GPS-enabled AGV trolleys and electromechanical manipulators to move components efficiently across the assembly floor. This hybrid automation system provides operational flexibility while maintaining the p
recision required for large-scale electric vehicle production. The combined infrastructure allows Montra to produce more than 6,000 electric trucks annually with remarkable efficiency.
Key Highlights:
- Location: Manesar, Haryana
- Annual Capacity: 1.7 GWh, capable of producing 6,000+ truck batteries per annum
- Battery Type: LFP (Lithium Iron Phosphate)
- Battery Specification: 282 kWh capacity, 614 V, 460 Ah
- Robotic pick-and-place systems
- Automated cell stacking and alignment
- Bottom and top case gluing for structural integrity
- Vacuumised fluid filling for thermal management
- End-of-line automated quality and performance testing
- Production Output: Over 6,000 heavy-duty electric trucks per year supported through the integrated line
Rhino 5538 EV 4×2 TT
This electric truck expands Montra Electric’s portfolio following the 6×4 TT, which has recorded over 1.2 crore kilometres in two years, as the company claims. The new 4×2 variant is designed for long-haul freight and incorporates features to enhance performance, reliability, and versatility.
A key addition is the battery swap system, which allows batteries to be exchanged in under six minutes, compared to over an hour with conventional fast charging. The system has a 7+1 automated configuration and can handle more than 160 swaps per day, enabling fleet operators to maintain high uptime. The design allows trucks with trailers to move in and out efficiently, while a controlled charging environment helps extend battery life.
Technical Specifications
The electric truck is designed for durability and operational flexibility, featuring a PMSM Permanent Magnet Synchronous Motor and a 282 kWh LFP battery, with an optional swappable varient configuration. It delivers 280 kW (380 HP) of power and 2,000 Nm of torque, paired with a 6-speed Automated Manual Transmission (AMT) for efficient performance. Safety and control are ensured through full air dual-line S-Cam brakes with ABS and tilt & telescopic power steering. Built for heavy-duty operations, the truck has a Gross Combination Weight (GCW) of 55,000 kg, high gradeability, and a wheelbase of 4,000 mm, with a 16 m turning circle for manoeuvrability. It rides on 295/90 R20 low rolling resistance tyres, supported by a forged “I” beam front axle and a single reduction rear drive axle. The parabolic front suspension and semi-elliptical two-stage hybrid rear suspension provide stability and comfort, while the truck is compatible with various trailer types, including skeleton, flat bed, side wall, tip trailer, and bulker. Additional features such as a D+1 tiltable sleeper cabin, fully suspended chassis, 230 mm ground clearance, and a conventional ladder-type heavy-duty frame ensure durability and driver comfort. The vehicle offers a range of 198* km on a single charge (under standard test conditions, one side loaded, one side empty), and can be fully charged in 60 minutes using a 240 kW CCS 2 dual-gun charger, making it suitable for diverse freight operations over long distances.
Felicitation & Key Handovers
At the launch event, felicitation and key handovers were also carried out. SG Green Logistics Pvt Ltd was felicitated, with Utkarsh Jain, Managing Director, being recognised for operating 100+ Rhino EV trucks, completing over one million trips, and expanding operations across 10+ states while remaining committed to green initiatives and soon introducing solar solutions. GHCL, represented by P. N. Rao, Senior Vice President, was honored as the first company to deploy eHCVs through their existing LSPs. As India’s second-largest soda ash manufacturer, GHCL has already achieved over one million kilometers on e-trucks and has plans to electrify all their operations by 2030. Transvolt was also felicitated for executing the largest single-site deployment of eHCVs with 70 Rhino EV trucks for leasing cement company in India.
Key handovers included several partners. Enviiro Wheels, part of Inland World Logistics, is already operating Montra EV trucks for Hindustan Zinc and Hindalco, and is now deploying 50 additional units. Ampvolts, previously associated with Montra EV for charging infrastructure solutions, has now ventured into logistics services and received their first 10 Rhino 5536 Montra EV trucks. Golden Enterprises, founded by Menshi Bhai Barad after his retirement, is starting its EV journey with 5 trucks. Switch Labs, a new-age LSP and dedicated EV player that began with a single truck in June 2024, is expanding to new routes. SG Green, already operating a fleet of over 100 Montra eHCVs, is now entering the cement sector with 20 units. Awaze, a 30+ year-old leading warehousing company in South India, is beginning its EV journey with 8 units. Finally, Savy Infra and Logistics, active in infrastructure creation and transportation projects, is also starting its EV operations with 12 units.
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