Battery factory & manufacturing

The manufacturing process: ten stages — and what each controls

A buyer who understands these ten stages can audit a factory properly — each stage is a quality checkpoint, and each checkpoint controls a specific output.

1. Grid casting — lead alloy grid; maintenance-free batteries use lead-calcium. Controlled: grid thickness, alloy composition and weight — they set mechanical strength and conductivity.
2. Paste mixing — paste consistency determines capacity. Controlled: paste density and acid-to-oxide ratio — they set capacity and cycle life.
3. Pasting — even paste application on the grid. Controlled: paste weight and distribution — uneven paste is the root of capacity variation.
4. Curing — 2–4 days of crystallisation that determines mechanical strength. Controlled: temperature and humidity over the curing window — they set plate strength and porosity.
5. Assembly — plates and separators into the case. Controlled: plate count, alignment and compression — they set internal resistance and therefore CCA.
6. Welding — lug and terminal welding. Controlled: weld integrity — a poor weld adds resistance and heat under load.
7. Electrolyte filling — acid fill. Controlled: acid density and fill level — they set both capacity and cold-cranking performance.
8. Formation charging — activates the active material. Controlled: charge profile and duration — under-formation leaves capacity on the table.
9. Sealing & finishing — lid sealing. Controlled: seal integrity — the leak-prevention checkpoint.
10. Testing & packaging — 100% electrical performance testing. Controlled: CCA, capacity, voltage and leak — every battery is tested before packing.

Capacity

200,000 m² facility, 18 automated lines, 40,000 batteries per day.

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