Can a startup based out of Sonipat (a suburb of New Delhi) compete with biggies? What’s enabling it to grow multi-fold and expand its production base?
E-Fill Electric was established by Rupak Jha and Mayank Jain in Delhi in 2019. However, soon the founders realised that they needed to shift to a location that provided them with a competitive edge. So, they chose New Delhi’s suburb Sonipat for the expansion of E-Fill Electric.
Mayank explains that ‘E-Fill Electric’ signifies being infused with electricity, inspired by their emphasis on electric charging. The startup manufactures electric vehicle charging stations, offering a diverse range of products from AC chargers with capacities of up to 3.2 kilowatts to DC fast chargers capable of delivering 120 kilowatts of power.
In addition to charging infrastructure, they also design and produce electric three-wheelers, including e-rickshaws classified under the L3 category. Currently, their focus is on the development and validation of their latest innovation, the L5 electric loader Auto, which is nearing the completion of its final validation phase.
E-Fill Electric manages its manufacturing internally but relies on external partners for specialised components like ICs, chipsets, and fabrication materials. This strategic collaboration ensures access to expertise and technologies beyond its scope, particularly for cables, SPDs, power modules, and displays belonging to diverse domains and businesses.
Over the past 3-4 years, the organisation has secured six patents and five are pending approval. That is because 40 out of a team of 220 focus only on R&D!
One of their claims to fame is their charging management system (CMS) that allows for remote charging operation. As a charging point operator (CPO), individuals can integrate the CMS with their chargers for remote monitoring and management. The monthly cost for this service is `499. By opting in, customers can link their chargers to the system, enabling them to initiate charging by scanning a QR code provided on or near the charger and seamlessly pay for the service.
The company has recorded sales exceeding 4500 chargers, encompassing AC and DC variants. Over the past two years, they have been evaluating their three-wheelers, gathering initial market feedback, and have deployed roughly 1000 units. Their three-wheeler production capacity is approximately 500 units per month. They can manufacture approximately 1300 AC chargers monthly and 400 units of DC chargers spanning 30, 60, and 120 kilowatts capacities.
The startup’s corporate and R&D hub in Sonipat is spread over approx. 1850 square metres (20,000 square feet). This headquarter is the focal point for designing, developing, testing, and evaluating products. Both corporate and sales/marketing teams are stationed here. Its production facility, roughly 25 kilometres away, spans a 1-acre manufacturing plant.
“We have invested around 300 million from inception to date, covering design, development, infrastructure, and plant facilities over nearly four years. Our design, development, and testing equipment include 3D printers, prototype testing machines, EB simulators, LCR meters, oscilloscopes, and current probes. Additionally, we utilise software like SolidWorks, Catia, and Altair for PCB and firmware design,” shares Mayank.
While discussing challenges, Mayank shares that acquiring the right resources is challenging, as the market is relatively new, and expertise is scarce. Another hurdle is finding suitable vendor partners due to competition, especially from Chinese OEMs, and vendors’ reluctance to support low volumes. Additionally, financing poses a challenge for chargers and three-wheelers, with limited options available, leading to higher interest rates.
The startup is developing a 360-kilowatt DC fast charger for the US market and seeking vendor partners capable of providing UL-certified products or components. “Our search spans vendors from Germany, China, and Korea as we explore multiple partnerships,” adds Mayank.
The startup has secured nearly six acres of land for a new manufacturing facility. Operations are projected to commence there in approximately one and a half years.
The company’s revenue surged from 135 million to 280 million in the previous fiscal year. In the next two years, the founder expects a fivefold increase!
