"Many Companies Avoid Pack Testing And Validation Because It Is Time-Consuming"

Battery pack reliability goes beyond cell quality—it relies on precise engineering, thorough testing, and tailored thermal management. In a conversation with EFY’s Nitisha Dubey, Akshay Kashyap of Greenfuel Energy discusses whether the industry will prioritise safety and innovation or compromise quality for cost.

- Nitisha Dubey

How does proper engineering impact battery pack performance and cycle life compared to cell ratings?

A battery pack’s performance heavily depends on its engineering, even if the cell is rated for 1000 cycles. Poorly designed packs fail to deliver the promised cycle life. Despite this, 90% of Indian manufacturers report cycle life based solely on cell data, avoiding time-intensive pack testing and validation, which can take five to six months and incur high costs. As a result, reported figures often neglect the reduction in cycle life during the cell-to-pack transition. Depending on design and integration, cycle life varies widely, from 800 to 4000 cycles, with lifespans ranging between two and seven years.

How does an engineering-driven approach differ from basic assembly in battery pack manufacturing?