Production Technology

We manufacture every battery component under fully controlled environment. We are not just an assembler that outsources plates & components for assembly. Our Automotive & Home Inverter batteries represent the major use of cutting edge lead-acid technology. We use state-of-the-art factory located in Himachal Pradesh & our sophisticated machineries are from Germany, USA, Denmark, Taiwan and other reputed Indian companies having technological foreign collaboration.

Although quality tests are carried out at every stage of production yet at the final stage of assembly line every battery unit goes through HRD, Polarity, and Short Circuit test to ensure compliance with international battery standards in addition to JIS & DIN Standards. Evidently, our all batteries are free from manufacturing defects and guarantee 100% output, shelve & service life as mentioned in the specifications.

The major steps in manufacturing process, which is shown in the process flow chart, are described below in stages:

We use high quality raw material procured from trusted sources so as to ensure fully backward integrated supply chain to produce high quality automotive, Home Inverter and power storage batteries.

  • Step 1
  • Step 2
  • Step 3
  • Step 4
  • Step 5
  • Step 6
  • Oxide Manufacture:

    We use milling process; solid lead (which may range in size from small balls to complete pigs) is fed into a rotating mill. The tumbling action of the lead generates heat and the surface of the lead oxidizes. As the particles roll around in the drum, the surface layers of oxide are removed to expose more clean lead for oxidation. The air stream carries the powder to a bag filter, where it is collected.

    Grid production

    Our high-quality grids are produced mainly by Automatic Grid Casting Machines and are particularly cast lead alloy for our automotive batteries.

    Pasting

    We use high-grade Pasting Machine from OPTAMAC USA. Battery paste is made by mixing the oxide with water, Sulphuric acid and a range of proprietary additives. The paste is pressed by machine onto the grid network, and the plates are usually flash-dried in a high-temperature oven.

    Curing

    Pasted plates are cured by storing them in ovens under carefully controlled conditions of temperature, humidity and time. Free lead in the paste converts to lead oxide.

    Formation, Plate Cutting and Assembly

    Cured & dried Battery plates undergo an electrical formation process In tank formation. Plates are loaded into large baths of dilute sulphuric acid and a direct current is passed to form the positive and negative plates. After drying, the plates are cut and assembled, with a HIGH-QUALITY SEPARATOR between them, into battery boxes. Plates of like polarity are connected by welding together the plate lugs.

    Quality & Performance Tests

    Before our batteries get packaged into cartons, they undergo following tests for performance, endurance and compliance with laid down standards. Any deficit in the performance results in the scrapping of the battery.

    Oxide Manufacture:

    We use milling process; solid lead (which may range in size from small balls to complete pigs) is fed into a rotating mill. The tumbling action of the lead generates heat and the surface of the lead oxidizes. As the particles roll around in the drum, the surface layers of oxide are removed to expose more clean lead for oxidation. The airstream carries the powder to a bag filter, where it is collected.