The Battery Factory has invested into the new continuous casting technology, which in terms of product quality, proved to be superior over other casting systems. It is also in line with the latest developments of the battery industry.

Via continuous casting of the negative calcium grid and continuous plate pasting manufacture of the hybrid starting battery has commenced. The said technology results in lighter, stronger, high-quality batteries and the current capacities installed is 1,500,000 units perannum. The plate design of the continuous-cast full-frame grid adds firmness to the thin carrier, resulting in enhanced vibration- resistance during use. The casting technology enables manufacture of such grid structure, which is exceptionally resistant to corrosion at high temperatures of up to +75C.

Lead powder, a key component in the production of lead-acid batteries, is manufactured with equipment from the Italian mill-maker Sovema.

 

The new assembly line has been chosen to ensure high quality and productivity. 

High quality, thin, micro-porous, polyethylene, pocket separators eliminate all shortcut possibilities during use as well as reducing electric resistance and enhancing starting at low temperatures. TEXMAX machines perform enveloping of plates and stacking battery cells.

TBS cast on strap machine produces an excellent combination of quality, flexibility and speed.

Starting ability as well as resistance of a battery to vibration depends on the quality of the intercellular weld. Therefore, the factory had the renowned American Machine maker, Tiegel's machine installed.

In the final stage of assembly, the battery lid is thermally connected to the container. Contact surfaces are heated and bound by pressing against each other. Another unit of the same machine tests whether cells and the lid-container connection are properly sealed.

Aiming at the highest possible final product quality, every single battery is tested for voltage without load and under extreme load. The unit for final control testing is computer-controlled and every single battery has to meet the values set by the software resulting in standard quality of all the batteries produced.