JSW MG Motor India has firmly established itself in India’s electric vehicle landscape. As one of the early pioneers, introducing the ZS EV in 2020, MG has now achieved significant success, boasting the Windsor as one of India’s best-selling electric vehicles by 2025. Recognizing that battery packs are the heart of any EV, the company has heavily invested in precision manufacturing and large-scale production of this crucial component.
Our recent visit to MG’s cutting-edge battery manufacturing facility in Halol, Gujarat, offered an insightful look into how battery packs for both the popular Windsor Pro and the compact Comet EV are meticulously assembled. This impressive assembly line is engineered to produce up to 140 battery units daily.
What truly sets this shop floor apart, beyond its advanced technology, is its exceptional workforce. MG has made a conscious effort to champion diversity within its production teams, a commitment powerfully demonstrated on the battery assembly line. At one point, the entire line was managed exclusively by women, and even today, women constitute nearly 80 percent of the workforce. Their roles extend far beyond routine assembly, with many women leading teams, overseeing rigorous quality checks, and holding significant supervisory and managerial positions. This image shows a group of skilled women engineers and technicians proudly working on the MG production line.
MG Comet, Windsor Pro: Battery Specifications
This image features the sleek design of an MG Comet EV battery pack, emphasizing its compact yet powerful structure.
The Comet’s battery system incorporates 150Ah cells, arranged into 5 modules, and operates at a rated voltage of 116V, delivering a total capacity of 17.3 kWh. It employs an air-cooling system for efficient thermal management, with dimensions of 1129 × 932 × 240 mm. In contrast, the Windsor battery is a powerhouse, utilizing 171Ah cells with a substantially higher rated voltage of 310V, resulting in a robust 52.9 kWh capacity. This larger battery features a sophisticated liquid cooling system for enhanced heat control, ensuring optimal performance and longevity.
Inside the Battery Shop: A Journey of Precision
The production of the Windsor’s larger 52.9 kWh pack exemplifies the meticulous attention to detail at the Halol plant. Each pack comprises 98 individual cells. Before assembly even begins, every single cell undergoes an open-circuit voltage test to ensure it meets stringent quality standards. The process then progresses to the lower box preparation, where insulation pads are carefully placed before the cells are precisely slotted in.
This image captures a close-up of the Windsor Pro battery in its manufacturing phase, showcasing the intricate internal components and advanced assembly techniques.
Following initial assembly, the modules are subjected to an insulation withstand test. This is succeeded by bus-bar assembly and precise laser welding, which expertly fuses the connections. A voltage-sensing harness is then integrated, also using laser welding to ensure accuracy. This is followed by a comprehensive module layer testing. To bolster durability and stability, a foam pasting process is applied to the pack before its final assembly.
This image highlights the striking MG Windsor EV, a testament to the advanced battery technology and skilled craftsmanship that powers its impressive performance.
Even after this rigorous assembly, the battery’s journey isn’t complete. Each fully assembled battery undergoes extensive charging and discharging cycles on the final line, simulating real-world usage to guarantee reliability. Any cell or module that fails to meet expectations at any stage is immediately removed, upholding a zero-compromise approach that MG believes is fundamental to earning customer confidence in its EVs.
This image provides a detailed view of the Windsor Pro battery, emphasizing the advanced engineering and robust construction that ensure its efficiency and safety.
The Remarkable Result
For consumers, this meticulous manufacturing process translates into a battery pack that not only delivers impressive range and performance but also instills a crucial sense of trust—an area where many EV owners still harbor concerns. The Windsor, offering a certified range of up to 449 km with its 52.9 kWh pack, stands as a clear example of how these high-quality batteries lead to strong market acceptance.
The sales figures speak for themselves. Since its launch in September 2024, the Windsor has achieved wholesale sales exceeding 30,000 units, accounting for nearly 60 percent of MG’s passenger vehicle sales in India. Just last month, the company dispatched 4,511 units, consistently ranking it as the country’s bestselling EV.
By manufacturing battery packs in-house, MG reinforces its commitment to quality and gains significant advantages. This approach facilitates quicker adaptation to market demands, strengthens supply chain control, and provides a tighter grip on costs—a critical factor as battery prices continue to represent the largest portion of an EV’s sticker price.