The rise of Lithium Battery Manufacturers is closely tied to the accelerating electrification of modern industry. Batteries are moving beyond their traditional role as energy sources to become critical engineering components in products ranging from medical devices and industrial equipment to robotics, smart electronics and drones.
As OEMs seek lighter, safer, longer-lasting and application-specific power systems, the ability to engineer the right battery architecture is becoming as important as the ability to manufacture it. This shift is also creating space for Indian manufacturers to move beyond assembly and develop deeper capabilities in battery design, BMS integration, testing and customized OEM production.
This is the space Leolus Energy Pvt. Ltd. has steadily built itself to serve. The company's roots go back to 2016, when Founder and Managing Director Manigandan Ganapathy established Carbon Compass Enterprises at a time when India's lithium battery ecosystem was still taking shape.
With more than two decades of experience across industrial electronics, automation and engineering solutions, Manigandan brought a practical understanding of power systems and machinery into the emerging battery business.
Over nine years, the company developed expertise in cell selection, battery pack engineering, battery management systems (BMS), manufacturing, testing and customization, while working with OEMs across multiple applications.
In 2025, the company entered its next phase as Leolus Energy Pvt. Ltd., with a clear focus on strengthening its position as a technology-led OEM battery manufacturer for Indian and global markets. The transition also gave shape to two specialized brands: ZERA, serving consumer electronics and industrial applications, and NEXFLY, dedicated to drone and aerospace battery solutions.
Rather than relying on standardized battery offerings, Leolus Energy works closely with OEMs to understand the specific requirements of each application and develop packs accordingly. This approach has enabled the company to cater to varied applications, including robot vacuums, medical devices, IoT products, industrial handhelds and POS terminals, while also developing lightweight, high-discharge solutions for the rapidly evolving drone sector.
Engineering the Battery Around the Application
The evolution of lithium battery technology is making customization increasingly important. Different products demand different combinations of voltage, capacity, discharge rates, dimensions, weight, thermal behavior and operating cycles. A battery that performs effectively in a medical device may be fundamentally unsuitable for a drone, even when both rely on lithium-based chemistry.
For OEMs, therefore, the battery has become an engineering consideration that must be integrated into the product development process rather than treated as an off-the-shelf component.
Leolus Energy's strength lies in this application-led approach. Through ZERA, the company develops customized battery solutions for consumer and industrial products, tailoring pack configurations to the physical and operational requirements of each application. This range of applications has deepened the company's understanding of how battery design intersects with the wider product architecture.
NEXFLY represents a more specialized extension of this capability. Launched in 2025, the brand focuses on lightweight, high-discharge battery packs for drones and UAV applications, where energy density, weight and power delivery can directly influence flight performance.
The company's introduction of semi-solid-state chemistry for this segment reflects its intention to participate in emerging battery technologies instead of remaining confined to conventional pack manufacturing.
For Leolus Energy, innovation is consequently not about introducing technology for its own sake.
It is about translating a customer's product requirement into a reliable energy solution. This philosophy has allowed the company to operate as an engineering partner, supporting customers from initial requirements and prototyping through manufacturing.
Building Reliability into Every Pack
In a battery industry where safety and reliability are non-negotiable, manufacturing discipline remains as important as product innovation. Leolus Energy has built its quality approach around control at each stage of the production process, beginning with cell sourcing from established global manufacturers such as Samsung, Panasonic, LG Energy Solution, Molicel, EVE and DMEGC.
Cell matching is a particularly important part of this process. Consistency between cells can influence the performance, life and safety of a battery pack, making appropriate selection and matching essential for customized applications. At Leolus Energy, this is complemented by BMS testing, spot welding controls, charge-discharge testing, raw-material inspection and final quality checks.
“The company takes a similarly tailored approach to battery management systems (BMS), configuring them around the specific operating conditions and performance requirements of each pack. This enables the BMS to support the intended application rather than function as a standardized component across products.
While ZERA solutions are designed around compact form factors and extended cycle life, NEXFLY packs are engineered to balance low weight with the high-discharge performance demanded by drone applications”, says Manigandan Ganapathy, Founder and Managing Director.
This production discipline is backed by nine years of manufacturing experience. The company currently produces approximately 30,000 customized packs per month and has built long-term relationships with Indian manufacturers across different industries. Several of these partnerships date back multiple years, illustrating the enduring customer relationships that have emerged from this model.
By working closely with customers from prototype to production, the company aims to reduce the distance between product development and battery engineering
Strengthening India's Battery Manufacturing Capability
India's accelerating shift toward electrification is creating a larger need for domestic battery engineering and manufacturing capabilities. While global cell manufacturers remain an important part of the supply chain, OEMs increasingly require local partners capable of translating those cells into application-specific packs, managing customization and providing responsive technical support.
“Leolus Energy is contributing to this transition by manufacturing customized lithium battery packs in India. Its proposition is particularly relevant for OEMs that may otherwise rely on imported battery solutions with limited flexibility in dimensions, specifications or technical support.
By working closely with customers from prototype to production, the company aims to reduce the distance between product development and battery engineering”, notes Manigandan Ganapathy.
The sustainability opportunity extends beyond manufacturing localization. Longer-lasting rechargeable battery systems can support more energy-efficient products, while applications such as electric drones are opening new possibilities in agriculture, inspection and industrial operations.
ZERA and NEXFLY therefore represent two different but complementary routes into the broader clean-energy transition: one through the electrification of consumer and industrial products, and the other through emerging aerial mobility and automation.
Leolus Energy's approach also reflects the wider shift in India's battery sector from simple assembly toward engineering-led manufacturing. The ability to customize packs, integrate intelligent BMS architecture, maintain quality consistency and respond to specialized applications can become a meaningful differentiator as OEM requirements grow more sophisticated.
Building Globally Trusted Indian Battery Brands
The next phase of Leolus Energy's journey is focused on taking this engineering capability to a larger market. Over the next five years, the company intends to strengthen ZERA across consumer and industrial applications while expanding NEXFLY as a specialized brand for drone and UAV batteries.
The broader objective is to establish Leolus Energy as a trusted global OEM lithium battery manufacturer with the manufacturing capability and technical depth to serve increasingly demanding applications.
This roadmap will involve expanding manufacturing capabilities, developing long-term partnerships and reaching more customers across Indian and international markets. At the same time, the company intends to continue supporting OEMs seeking to reduce dependence on imported battery packs through customized solutions manufactured in India.
“Our participation at DEFTECH Bharat 2026 in May further reflects this outward-looking direction and its interest in emerging technology-led applications. For a company that began in 2016 with a focus on solving battery requirements for emerging industries, the transformation into Leolus Energy represents a natural progression rather than a departure from its roots”, shares Manigandan Ganapathy.
The recognition as one of the leading 'Lithium Battery Manufacturers' comes at an important stage in that evolution. More than a marker of past performance, it places attention on the opportunity ahead: building Indian battery brands capable of competing through engineering, reliability and application-specific innovation.
With ZERA and NEXFLY providing focused platforms for different market segments, Leolus Energy is now working toward a larger ambition, to make customized, intelligent energy solutions an increasingly credible part of India's contribution to the global battery ecosystem.
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