At Replus, Safety, Reliability, and Performance Aren’t Afterthoughts – They’re Engineered In – Hiren Pravin Shah – Founder & CEO, Replus Engitech Private Limited

Q. REPLUS Engitech is a DPIIT-recognized technology-led startup. How has this recognition helped shape your journey and credibility in the energy storage space?

Recognition by the Department for Promotion of Industry and Internal Trade (DPIIT) has been a transformative milestone in Replus’ journey, lending vital credibility in the highly competitive energy storage sector. This government endorsement has not only enhanced trust among investors, partners, and customers but also provided access to key policy benefits and start-up ecosystems. It has accelerated our ability to scale, attract top-tier talent, and collaborate with stakeholders across the clean energy value chain.

For Replus, DPIIT recognition has validated our mission and positioned us as a leading innovator driving India’s transition toward a more sustainable energy future.

Q. Your mission speaks of enabling the global transition to clean energy. How does REPLUS align its product roadmap with this larger mission?

At Replus, our mission to enable the global transition to clean energy is the compass that guides every decision from R&D to commercialization.

Our product roadmap is strategically aligned with this vision, focusing on scalable, modular, and sustainable energy storage solutions that support the shift toward decentralized, renewable power systems. Whether it’s second-life battery applications, hybrid energy storage, or grid-level solutions, each product is designed to address real-world challenges in energy reliability, affordability, and carbon reduction.

By staying at the intersection of innovation and impact, Replus ensures that every step in our product journey contributes meaningfully to building a cleaner, more resilient energy future both for India and the world.

Q. REPLUS offers solutions based on Lithium-ion technology, advanced cell chemistry, and in house BMS & EMS designs. Could you share more about the uniqueness of your in-house technology capabilities?

What sets REPLUS apart in the energy storage landscape is our deep vertical integration particularly our in-house development of Battery Management Systems (BMS) and Energy Management Systems (EMS), paired with cutting-edge work in advanced cell chemistries. While many players rely on off-the-shelf components, we design and engineer our systems from the ground up to ensure precise performance, safety, and adaptability across diverse use cases from residential and commercial setups to grid-scale storage. Our proprietary BMS ensures real-time health diagnostics, optimal lifecycle performance, and enhanced thermal management, while our EMS architecture enables smart energy orchestration, predictive analytics, and seamless integration with renewable sources.

Combined with our expertise in Lithium-ion and next-gen chemistries, Replus offers a technology stack that’s not just advanced but tailor-made for a cleaner, smarter energy future.

Replus Team has established a fully automated lithium-ion battery manufacturing facility in Pune with an initial capacity of 1 GWh, scalable up to 6 GWh.

This cutting-edge plant reflects our commitment to the Make in India vision, positioning us as a key contributor to the nation’s growing energy storage and electric mobility ecosystem.

Q. How do you ensure safety, reliability, and performance in your battery packs, especially under Indian climatic and grid conditions?

At Replus, safety, reliability, and performance aren’t afterthoughts they’re engineered into the core of every battery pack we build.

Understanding the unique challenges of Indian climatic and grid conditions from extreme temperatures to voltage fluctuations we’ve designed our systems to be both robust and adaptive. Our in-house Battery Management System (BMS) provides real-time monitoring, thermal control, and fault isolation, ensuring operational safety even in harsh environments. Each pack undergoes rigorous testing for thermal runaway prevention, vibration resistance, and lifecycle durability. Moreover, our Energy Management System (EMS) enables intelligent load balancing and predictive maintenance, which is crucial for navigating India’s variable grid infrastructure. Through localized engineering and continuous field feedback, Replus delivers solutions that are not only high performing but also built to thrive in the real-world conditions where they matter most.

Q. Could you highlight some landmark BESS projects Replus has executed, and the challenges overcome during implementation?

Replus has successfully executed several landmark Battery Energy Storage System (BESS) projects that demonstrate both our technical capability and adaptability in complex environments in desert conditions like Saudi Arabia & remote locations like Lupoto in D.R. Congo. One notable project involved deploying a hybrid BESS solution for a remote industrial facility where grid reliability was inconsistent. We integrated Lithium-ion storage with a smart EMS platform to ensure seamless power continuity and optimized renewable energy utilization. Another milestone was a grid-connected storage deployment supporting a solar microgrid for a Green Hydrogen plant in a high-temperature region in India where our energy management systems, thermal management systems and ruggedized BMS proved critical. Across these projects, challenges ranged from unpredictable load profiles and infrastructure constraints to climatic stress and regulatory compliance. By customizing each solution end-to-end—from system design to commissioning, we’ve consistently turned difficult conditions into proof points of Replus’ resilience and innovation in the field.

Q. Replus has announced a six fold scale-up of its Pune facility from 1 GWh to 6 GWh by 2027. What are the strategic drivers behind this expansion, and how will it position you in India’s battery manufacturing ecosystem?

The decision to scale up our Pune facility from 1 GWh to 6 GWh by 2027 is a strategic leap aligned with India’s accelerating clean energy ambitions and the surging demand for localized battery solutions. This expansion is driven by the growing need for high-performance, domestically manufactured energy storage systems across sectors ranging from renewables and e-mobility to industrial backup and grid support.

By enhancing our production capacity, we aim to reduce dependence on imports, drive down costs through economies of scale, and deliver faster, more customized solutions to our customers.

The upgraded facility will also house advanced R&D labs, automated pack assembly lines, and expanded testing infrastructure, positioning Replus as a key player in India’s emerging battery manufacturing ecosystem.

More than just growth in volume, this scale-up is about deepening our technological leadership and supporting India’s vision of energy self-reliance.

Q. What’s your perspective on government incentives and policies (such as PLI schemes or energy storage mandates) and how can they further support companies like Replus?

Government incentives and forward-looking policies such as the Production Linked Incentive (PLI) schemes, energy storage mandates, and the recently announced Viability Gap Funding (VGF) for BESS are critical enablers for companies like Replus. These initiatives not only accelerate domestic manufacturing but also create a predictable demand landscape, which is essential for long-term investments in capacity, R&D, and supply chain development. The PLI scheme helps bridge the cost gap between imported and locally produced components, making India more competitive globally. However, to fully unlock the sector’s potential, consistent policy implementation, streamlined regulatory approvals, and greater support for innovation especially in advanced chemistries and second-life applications are vital.

With the right mix of incentives and execution, the government can foster a robust energy storage ecosystem where Replus thrive and drive India’s clean energy transition from the front lines.

Q. Do you see India emerging as a global hub for advanced battery manufacturing, and what role do you envision for Replus in that journey?

India is uniquely positioned to emerge as a global hub for advanced battery manufacturing, thanks to a combination of strong policy push, a vast domestic market, rising clean energy adoption, and a growing focus on supply chain localization.

As the world looks to diversify beyond traditional battery manufacturing geographies, India can lead with innovation, scale, and sustainability.

At Replus, we see ourselves playing a catalytic role in this transformation – not just as a manufacturer, but as a technology leader. By developing next-gen energy storage solutions, investing in R&D, and scaling our smart manufacturing capabilities, we aim to contribute meaningfully to India’s global competitiveness in this space.

Our vision is to help build not just battery capacity, but battery intelligence creating solutions that are resilient, resource-efficient, and ready for the future of energy worldwide.