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Lead-acid batteries, a process-oriented product, is not as simple to manufacture as it seems.

• Battery manufacturers must know What Not To Do which is as important as What To Do
• This podcast episode is a case study with a twist.
• The battery manufacturer was losing tons of money for a simple fault of his
• The identification of the problem was difficult.
• Listen till the end and enjoy this interesting episode

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The lead-acid battery industry is going through turbulent times.

• Battery manufacturers have to contend with new battery chemistries entering the market.
• Lithium-ion batteries are taking away certain applications that were the preserve of lead-acid batteries.
• The battery manufacturers are competing with each other and getting into a price war - with many manufacturers shutting down shop.
• The customers have become more demanding.
• Manufacturers with deep pockets and good negotiation skills are surviving.

All battery manufacturers must sharpen their negotiation skills to remain in business. How to do it, is the question.

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In today’s episode, I have a dear friend, Mr. Achim Lulsdorf, to discuss an important aspect of battery manufacturing.

Your response to the previous two episodes featuring Mr. Achim has been fantastic, and I’m sure you’ll benefit from listening to him today as well.

In a previous episode, I highlighted the importance of battery charging. That was in April 2023 ‘Secret Revealed – The Key To Long-Lasting Batteries’.

However, we’ve both realized that battery formation still doesn’t receive the attention it deserves from manufacturers. Many high-quality batteries perform poorly in the field or have a shortened lifespan due to neglect during the final stage-battery commissioning charge or initial charging.

Mr. Achim and I believe this critical aspect of battery manufacturing needs more focus and proper resources. We therefore decided to do this episode.

Mr. Achim has served as the CTO of Hammond Industries and the R&D Chief of Exide India. He is a busy international consultant, constantly traveling and often away from his base in the USA.

I love podcasting with him, but securing his time is difficult.

Mr. Achim has over 34 years of extensive experience in the field. I greatly admire his willingness to share his knowledge of lead-acid batteries.

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It gives me great pleasure to inform you that my dear friend Mike - Dr. Michael McDonagh, decided to contribute to my podcast. During our conversation, he generously shared a wealth of his expertise on GEL batteries.

Dr. Michael McDonagh is a battery industry veteran from Wales in the UK. He completed his PhD in Metallurgy and Materials Science in 1977. That same year, he joined Crompton Batteries, marking the beginning of his distinguished career in the battery industry.

Since then, he has played several roles in the battery business, including worldwide consultant, and has made major contributions to the battery industry. He and I first met in 1998.

Dr. Michael McDonagh is currently the technical editor of BEST magazine, an international periodical focused on batteries and associated topics.

This episode includes his thoughts and responses to the following questions, as well as a few others.

• How exactly is a Gel battery different from flooded electrolyte batteries?
• How does the performance of a GEL battery vary with a flooded electrolyte battery?
• Do these batteries need to be operated in a specific environment? I mean AC rooms or in rooms with good ventilation?
• Which is a better battery in terms of life and performance? Flooded Type, AGM, or GEL type?

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Lead-acid batteries, that last long and perform well need good-quality active materials. Active materials have to be made using good-quality Lead Oxide.

• Understand the difference between Ball Mill Oxide and Barton Pot Oxide.
• Listen to Mr. Francesco Marfisi talk about how a good quality ball mill can give you savings in power, good quality adhesion of paste to the grid, better acid absorption, environmental protection, etc.
• Listen to Mr. Francesco Marfisi talk about why tetragonal lead oxide is better than orthorhombic structure oxide.
• Understand from Mr. Francesco Marfisi the benefits of the Lead Shaver System that does away with many uneconomical operations that had to be carried out to cast lead cylinders.
• Most importantly, listen to Mr. Francesco Marfisi talking about the importance of temperature control which is an essential parameter to be adhered to during the manufacturing process of lead oxide.

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Lead-acid batteries, a sustainable product, conforming to a circular economy are made using recycled lead.

• All used batteries are collected as scrap for melting and smelting. These scrap batteries are recycled. They are smelted and refined. The refined lead is combined with other metals to be used again in the future.
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• The recovery of lead from scrap batteries is one of the major advantages that makes lead acid batteries economical and a favorite of the circular economy advocates.
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• All battery manufacturers including established large-scale industries use recycled lead to make alloys for the grid.
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• The lead oxide used as active material in the battery though made from pure lead, is in a majority of the cases obtained from recycled lead.
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• Some distributors & dealers of batteries misinform the battery user that their batteries contain pure lead and the competition uses recycled lead.
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• This podcast episode debunks the myth that battery manufacturers using recycled lead make substandard batteries.

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Dive into the fascinating world of battery technology with our latest podcast episode!

• Learn about the crucial role of paste additives in enhancing battery performance.
• Discover how fiber, barium sulfate, carbon, and other additives improve battery efficiency.
• Explore the intricate details of paste mixture components and their functions.
• Understand why additives are essential for maintaining battery capacity and prolonging battery life.
• Know the importance of each additive and how they work together synergistically.
• Uncover practical tips for optimizing additive usage in battery production processes.

Don't miss out on this informative episode!

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For fifty episodes, I have tried to be your trusted navigator unraveling the mysteries of batteries with my expertise and experience. From the fundamental principles to the latest innovations, each episode has been a captivating journey, offering invaluable knowledge and practical insights to enthusiasts, professionals, and curious minds alike.

Through engaging discussions, expert interviews, and informative deep dives, 'Batteries Demystified' has not only educated but also inspired its audience, fostering a deeper appreciation for the pivotal role lead acid batteries play in our daily lives and the future of technology.

As I commemorate this milestone, let me extend my heartfelt gratitude to your enduring support at all times. Here's to fifty episodes and to many more electrifying adventures ahead with 'Batteries Demystified!'

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