Exicom Tele-Systems Limited has begun manufacturing advanced liquid-cooled AC and DC power modules at its Hyderabad Smart Manufacturing Facility, marking the first time this class of power electronics has been produced in India for global markets. The move positions Exicom—and India—as a serious player in the high-power EV charging supply chain, with initial output destined for North America and Europe.
Why Liquid Cooling Matters in EV Charging
Heat is the silent killer of power electronics. According to industry data cited by Exicom, heat causes nearly 60% of power electronics failures, and every 10-15°C rise in temperature doubles component failure rates.
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(Related: Battery Health as the New Currency: Omega Seiki and ELECTRA AI Bring AI-Powered Intelligence to India's EV Ecosystem) Traditional air cooling struggles to dissipate heat effectively, especially in high-power charging scenarios where modules operate at elevated loads for extended periods.
Liquid cooling offers a superior thermal management solution. By using liquid coolant—which transfers heat far more efficiently than air—internal temperatures can be kept around 10°C lower. This reduction significantly enhances reliability and extends the lifespan of critical components, addressing a key pain point for charge point operators and fleet managers who depend on uptime.
Technology and Design Advantages
The new modules are built on Tritium's in-house liquid-cooled capability, a proven technology that has been refined in real-world deployments. The design packs more power into a compact footprint, enabling higher power density without compromising thermal performance. This is crucial for ultra-fast chargers that need to deliver maximum power while maintaining safety and durability.
Key advantages of the liquid-cooled design include:
- Continuous high-load operation: The modules can run at full capacity without thermal throttling, ensuring consistent charging speeds.
- Lower lifetime cost: While the initial investment may be higher, the improved reliability and reduced maintenance needs contribute to a lower total cost of ownership.
- Fully sealed design: Protection against dust, moisture, and salt air makes the modules suitable for harsh environments, including coastal areas and industrial sites.
Global Market Strategy and Export Potential
Initial production will primarily serve North America and Europe, supporting Tritium's DC charger portfolio, which includes the TRI-FLEX ultra-fast DC chargers and DC-FLEX charging systems. This strategic focus leverages Exicom's acquisition of Tritium's assets, integrating advanced technology into its manufacturing operations.
Later phases will bring the technology to Exicom's customers in India, including charge point operators, fleets, and OEMs. The modules will eventually be integrated into Exicom's flagship Harmony DC chargers, opening a new line of high-value power electronics exports from India. This dual-track approach—serving global markets first, then domestic—allows Exicom to scale production and refine processes before addressing local demand.
Implications for India's EV Ecosystem
Exicom's entry into liquid-cooled power module manufacturing is a significant step for India's EV ecosystem. It reduces dependence on imported components, which has been a bottleneck for domestic charger manufacturers. By producing advanced power electronics locally, India can strengthen its position in the global EV supply chain and attract further investment in the sector.
The move aligns with the government's push for self-reliance in critical EV components, as outlined in initiatives like the Production Linked Incentive (PLI) scheme for auto and auto components. Local manufacturing of high-tech components also creates skilled jobs and fosters innovation in thermal management and power electronics—a niche but growing field.
Conclusion: A Strategic Leap Forward
Exicom's decision to manufacture liquid-cooled power modules in Hyderabad is more than a corporate milestone; it signals India's readiness to compete in the high-value EV charging technology space. By addressing the fundamental challenge of heat management, Exicom is not only improving charger reliability but also positioning itself—and India—as a key supplier to the global high-power charging market.
As the demand for ultra-fast charging grows worldwide, the ability to produce reliable, high-performance power modules locally will be a competitive advantage. Exicom's move is a strategic leap forward, one that could catalyze further advancements in India's EV manufacturing capabilities.
Frequently Asked Questions
What are liquid-cooled power modules?
Liquid-cooled power modules are electronic components used in EV chargers that use liquid coolant to dissipate heat, rather than relying on air cooling. This allows for higher power density and improved reliability.
Why is liquid cooling important for EV charging?
Heat causes nearly 60% of power electronics failures, and every 10-15°C rise doubles failure rates. Liquid cooling keeps temperatures about 10°C lower, significantly enhancing reliability and lifespan.
Who is Exicom?
Exicom Tele-Systems Limited is an Indian company specializing in EV charging and critical power solutions. It recently acquired Tritium, a global DC fast charger manufacturer, and is now producing liquid-cooled power modules in Hyderabad.
Where will the initial production be used?
The initial production will primarily serve North America and Europe, supporting Tritium's DC charger portfolio, including TRI-FLEX and DC-FLEX systems. Later, it will be available for Indian customers and integrated into Exicom's Harmony DC chargers.
What are the benefits of Exicom's liquid-cooled modules?
The modules offer a compact design, continuous high-load operation, lower lifetime cost, and a fully sealed design that protects against dust, moisture, and salt air.
