By Neha Basudkar Ghate
India’s electric two-wheeler market is evolving rapidly, driven by the need for sustainable mobility solutions. BGauss, a brand under the RR Global umbrella, has emerged as a key player in this transformation by focusing on innovation, reliability, and superior engineering. Established in 2020, BGauss has built a strong foundation in electric mobility, emphasizing safety, performance, and localized manufacturing.
During our visit to the state-of-the-art BGauss manufacturing facility in Chakan, Pune, we gained insights into the company’s meticulous production process, stringent quality control measures, and commitment to ‘Make in India.’ From advanced battery testing to precision-driven assembly lines, every aspect of the plant reflects BGauss’ vision to redefine electric mobility in India.
BGauss, a brand under the RR Global umbrella, is redefining electric mobility with a steadfast focus on safety, comfort, and reliability – key differentiators in an evolving industry. Started in 2020, BGauss is built on a foundation of meticulous manufacturing and advanced engineering, BGauss ensures superior product quality and performance. Its flagship models, the RUV 350Max in two models and BG C12i Max in three models, are available in variants each, catering to diverse consumer needs. With over 80 patent filings, the company continues to drive technological advancements in the Electric two-wheeler (E2W) segment.
BGauss has developed its state-of-the-art manufacturing facility at Chakan, Pune which manufactures around 3,000 vehicles in a month and daily in one shift around 50 vehicles are manufactured. The plant highlights BGauss’ commitment to ‘Make in India’, with a strong focus on localisation, stringent quality control, cutting-edge engineering and precision driven production process to develop world-class EVs. By developing its self-reliant EV ecosystem, BGauss aims to lead India’s electric mobility transformation.
Operating from its Chakan-based facility with an annual production capacity of 1 lakh units, BGauss has built a strong customer base of 50,000 happy riders. With an expanding dealer network of 110 outlets, the company is set to grow to 250 dealerships by next year.
BGauss is strengthening its market position by making electric mobility more accessible. Following a successful ₹161 crore funding round, the company plans to introduce a new product range priced at approximately ₹80,000. Additionally, BGauss is set to launch one new product in June and another in July, with premium vehicle introductions planned for 2026.
The BGauss RUV 350 Max is a cutting-edge electric scooter designed for urban commuters seeking a blend of performance and convenience. Equipped with a powerful 3500W PMSM in-wheel hyper drive motor, the RUV 350 Max delivers a top speed of 75 km/h and an impressive range of 145 km on a single charge. Its 3 kWh CAN-enabled LFP battery ensures reliable performance. The scooter features a 5-inch TFT display with turn-by-turn navigation, call notifications, and ride statistics, making it a smart choice for tech-savvy riders. With cruise control, hill hold control, and regenerative braking, the RUV 350 Max offers a safe and comfortable ride, while its sleek design and robust build make it a standout in the electric scooter market.
BGauss C12i Max 2.0 the BGauss C12i Max 2.0 sets a new standard in electric mobility with its advanced features and exceptional performance. This model is powered by a 2500W PMSM HUB motor, offering a top speed of 60 km/h and an extended range of 135 km. Its 3.2 kWh CAN Enabled battery, featuring Advanced 21700 Lithium Ion Cells, ensures long-lasting power and reliability. The C12i Max 2.0’s CAN Enabled Digital Console keeps riders informed, while regenerative braking, and CBS provide added safety. With a robust build and superior suspension, this scooter is designed to handle various road conditions, making it an excellent choice for both urban and suburban riders.
Both electric scooters are powered by a Hyperdrive Motor, which is directly attached to the wheel rather than functioning as a hub or neutral motor. This design ensures maximum power delivery, giving riders a thrilling, energy-efficient, and dynamic riding experience.
Additionally, BGauss is set to launch a two-wheel cross motor, an innovative new technology developed as part of its patented advancements. With a strong combination of technological expertise, sustainable practices, and a rapidly expanding market presence, BGauss continues to lead the way in shaping India’s electric two-wheeler future.
Behind the Scenes: Building the BGauss RUV 350 Max & C12i Max 2.0
Streamlined Material Handling & Quality Control at BGauss
The manufacturing process for both electric scooter models begins with the incoming materials, sourced from 82 different suppliers. The majority of these suppliers are located near Pune, with 5-10% from Aurangabad, 2-3% from Ahmednagar, and 1% from Bangalore. Pune was strategically chosen as the manufacturing hub due to its strong automotive ecosystem, ensuring easy access to well-established vendors and cutting-edge technology.
Upon arrival, the materials undergo invoice verification, where quantities, part numbers, and names are checked for accuracy. Next, a source person conducts a physical count to confirm all details. If everything is correct, the materials are sent to the Incoming Quality Control (IQC) area for further inspection.
At IQC, specialized engineers examine the materials based on three key commodity categories:
1. Sheet metal components
2. Fabrication and plastic-rubber parts
3. Electrical and electronic components
A sampling inspection plan is followed for each part, using a predefined checklist that covers aesthetic, dimensional, and functional aspects. If a material meets all quality standards, it is moved to the storage area. However, if defects are found, it is sent to the rejection area with proper identification tags for further review.
This rigorous quality control process ensures that every component used in BGauss electric scooters meets high-performance and reliability standards before moving forward in production.
Panel Checkers: Ensuring Dimensional Accuracy
One of the crucial aspects of manufacturing involves measuring complex vehicle parts. While straight components can be measured with a vernier, convex and concave shapes require specialized tools like panel checkers. These devices simulate the shape of the vehicle and help detect any warpage in the parts, which is a common issue during production.
To certify a part’s accuracy, it is placed on the panel checker and clamped. If the gap between surfaces is within the 2-3 mm tolerance range, the part is deemed acceptable. This step is vital in ensuring proper fitment of body panels and eliminating alignment issues during assembly.
Chassis Inspection: The Skeleton of the Vehicle
The chassis serves as the structural foundation of the vehicle, with various mounting points for components. Any deviations in bracket positioning or hole alignment during welding can cause assembly challenges, leading to misaligned parts. To mitigate such issues, two chassis samples from every lot undergo rigorous quality checks to verify hole placements and structural integrity.
If the chassis meets the required standards and body parts show no signs of warpage, the vehicle’s fit and finish are flawless. This meticulous validation process prevents unnecessary adjustments during assembly, ensuring a precise and reliable build.
Runout Testing: Detecting Wheel and Rim Imperfections
Another essential quality control process is checking for facial, axial, and radial runout. When a vehicle wobbles during movement, it often indicates a defect in the wheel or rim alignment. Engineers inspect these components in a controlled environment to identify and analyze any deviations. Certified components are then approved for use, ensuring smooth and stable rides.
Electrical Component Inspection
Every electric two-wheeler is equipped with essential electrical components such as switches, speedometers, throttles, ignition locks, motors, indicators, and headlights. These components undergo rigorous testing as part of the invoice inspection process. Engineers connect them to a power supply setup and verify that each function operates correctly before final approval. A comprehensive checklist is maintained to ensure that no defects go unnoticed.
Additionally, quality checks are performed at the vehicle level, ensuring that all inspected parts work seamlessly when assembled. Once the parts pass quality inspection, they are handed over to the production team for final assembly.
Training for Quality Assurance
At the plant, ongoing training ensures that new personnel can differentiate between acceptable and defective parts. Deliberate placement of non-conforming components helps trainees understand variations in fitment, reinforcing their ability to maintain high-quality standards.
To document inspections, an incoming inspection check sheet is maintained for every part. This includes details such as part number and name, ensuring traceability and accountability in the manufacturing process
Battery Testing and Validation
The battery is a critical component of an electric vehicle, and BGauss ensures its reliability through a dedicated battery testing lab. The company sources its batteries from Trontek, a supplier based in Delhi, and all batteries are ICAT certified.
To ensure quality, each battery undergoes thorough testing to validate key parameters. Engineers log battery data and verify compliance with testing benchmarks. Given the importance of batteries in EVs—alongside the motor and MCU—BGauss maintains a 100% inspection rate to guarantee safety and performance.
The plant handles multiple battery variants, including a 48 AH battery pack, a smaller 32 AH variant for C1-2 models, and additional options like 45 AH and 68 AH packs. Battery weight varies between 26.5 depending on the model. The company primarily uses lithium-ion and lithium iron phosphate (LFP) batteries, with LFP offering better longevity despite a slight cost variation.
Alongside battery testing, charger inspections are also conducted. Chargers undergo a 100% inspection, similar to the battery and motor, ensuring consistent quality across components.
Electric Scooter Production Process
1. Production Line Overview
The production line is divided into two key areas:
• Sub-assembly Area – Components that cannot be fitted directly on the main line are pre-assembled here.
• Main Line Area – The final vehicle assembly takes place here.
There is also a dedicated Chassis Sub-assembly Area, where chassis components are pre-assembled before integration into the main production line.
2. Initial Process: Vehicle Identification Number (VIN) Assignment
• The production process begins with the Vehicle Identification Number (VIN) being punched onto the chassis.
• The VIN determines the vehicle model and the corresponding components to be assembled.
3. Assembly Process
A. Chassis Sub-assembly Area
• The assembly process starts with the chassis.
• The sub-assembly ensures that all child parts are installed before moving to the main assembly.
• Missing parts at this stage can cause major delays and rework at later stages.
B. Sub-assembly Area
• Components like headlamps, brake levers, and cables are pre-assembled.
• Ensures efficiency by preparing parts before they are mounted on the main line.
C. Main Assembly Line
• The vehicle progresses through multiple stations where different parts are fitted.
• The production follows a mass production line methodology.
• Workstations: 10
• Production capacity: 150 electric scooters in 8 hours.
• Conveyor line design ensures seamless movement of parts and assemblies.
4. Quality Control Measures
• Quality Gates are implemented throughout the assembly process.
• A Maker & Checker system ensures defects are caught early.
• Each workstation has designated quality check sheets to document progress.
• Mid-line Inspection: Conducted at the 6th station for left and right-side operations.
• Final Inspection: Conducted at the 12th station by five analysts.
• Rework Station: Station 13 is dedicated to addressing any defects.
• Error-Free Verification: Station 14 ensures the final product meets all standards before rollout.
5. Handling Defects
• Minor defects: Addressed on the production line.
• Major defects: Handled offline to avoid impacting the production output.
• After all quality checkpoints, the vehicle undergoes final testing before dispatch.
6. Testing and Homologation
• Vehicle Testing:
Aesthetic checks
Dynamometer Testing for performance validation
Road tests for 10-20% of vehicles
Alignment checks for front and rear wheels
Homologation Process (ARAI Certification):
Each part must be marked with a QR code for traceability.
Vehicle parts, such as grab rails, are engraved for identification.
The ARAI team audits manufacturing processes and suppliers to verify compliance with Make in India policies.
Random vehicle testing ensures compliance with declared parameters.
7. Battery and Charging
Battery Charging Times:
500W charger: 5.5 hours
840W charger: 3.5 hours
350W charger: 2 hours
Battery Safety Features:
Lessons from industry best practices have been implemented to enhance safety.
Vehicles are designed to prevent any charging-related incidents.
8. Production Output & Logistics
Production Rate: 18 vehicles rolled out every 5 minutes.
Batch Production Model:
50% of C12i sales are in BG Blue color.
Vehicle Transport:
40-vehicle trucks for out-of-state orders.
24-vehicle trucks for Maharashtra deliveries.
9. Product Range and Export Plans
Color Variants:
C12i Electric Scooter: 7 color options (White, Black, Solid Green, Yellow Techno, Matte Blue, Matte Red, Matte Green)
RUV Model: 5 color options (Blue, Red (Dual Tone), Silver, Green, Anthracite Grey)
Certifications:
ISO 9001:2015 (Quality Management)
ISO 14001:2015 (Environmental Management)
ISO 45000:2018 (Occupational Health & Safety)
Export Plans:
Exports starting in April.
Orders received from France (B2C Market).
Homologation process ongoing for South America.
In Conversation with Hemant Kabra, Founder and Managing Director, BGauss Electric
Investment Plans and Fund Allocation
BGauss has raised a total capital of INR 161 crore, with INR 100 crore infused into the company as planning capital. The primary focus of this investment is twofold:
• Product Development & CAPEX: A significant portion of the funds will be allocated towards product development and capital expenditures (CAPEX) to strengthen BGauss’ electric two-wheeler offerings.
• Marketing & Branding: The company plans to intensify its marketing and branding initiatives to enhance visibility and market penetration.
Upcoming Product Launches
BGauss is set to launch two new electric two-wheelers within the next year:
1. June-July 2025 Launch: A commuter-focused electric scooter positioned at a competitive price point of approximately INR 80,000. This product aims to cater to the mass market and fall within the ‘sweet spot’ for electric vehicles in India.
2. February 2026 Launch: Another new electric scooter, details of which will be shared closer to the launch date. Both upcoming models are nearly ready for market introduction.
Market Strategy & Innovation
• BGauss is actively working on refining its component selection process to ensure reliability, efficiency, and energy optimization.
• The company is focusing on smart and locally integrated architecture, incorporating advanced safety features.
• The target audience spans across diverse consumer segments, with specific models designed to appeal to different demographics, including family-centric users and male riders.
• Future expansion plans include introducing additional models across various price points, ranging from Rs 80,000 to Rs 1,00,000, offering multiple variants tailored to specific market needs.
Production & Cost Optimization
• BGauss is implementing measures to optimize production costs, which is expected to lead to a reduction in electric vehicle (EV) prices.
• The company anticipates that within the next six months, the price difference between EVs and petrol-powered two-wheelers will diminish significantly, making EVs a more attractive option for consumers.
Conclusion
BGauss is committed to expanding its footprint in the electric two-wheeler market through strategic investments in product development and marketing. With upcoming launches, innovative design architecture, and cost reduction strategies, the company aims to position itself as a key player in India’s EV sector.