The Power Behind Industrial Equipment- A Guide to Traction and Semi-Traction Batteries

2025 Has Seen Extreme Temperatures. What Does This Mean for Your Battery’s Wear and Tear?

Mon, 19 Jan 2026 06:12:41 GMT

The temperature patterns seen through 2025 have been anything but stable. Prolonged heatwaves, higher average temperatures, and sharper seasonal swings are becoming common across industrial regions. For businesses that rely on industrial batteries, these conditions have a direct and measurable impact on battery wear and tear, performance consistency, and overall lifecycle costs.

In industrial environments, batteries are expected to deliver predictable output across material handling equipment, uninterruptible power supply systems, solar installations, industrial cleaning equipment, golf carts and more. When temperatures move beyond normal operating ranges, even well-maintained batteries experience accelerated aging and reduced reliability.

Understanding how temperature affects battery performance is no longer theoretical. It has become a practical concern for maintenance teams and operations leaders.

How does temperature affect battery wear and tear in industrial use cases?

All batteries operate through chemical reactions, and temperature directly influences the speed and stability of these reactions. When industrial batteries are exposed to high temperatures, chemical activity increases, which accelerates internal degradation. Over time, this results in capacity loss, higher self-discharge, and shortened service life.

Cold conditions create a different challenge. Lower temperatures slow chemical reactions, increase internal resistance, and reduce available capacity. In industrial use cases, this often appears as reduced runtime, delayed charging, or inconsistent performance under load.

Repeated exposure to either extreme gradually increases battery aging , even when daily usage patterns remain unchanged.

What happens to lead-acid batteries in extreme temperatures?

Lead-acid batteries are widely used across industrial environments. While proven and dependable, they are particularly sensitive to temperature variation.

In high-temperature environments, lead-acid battery degradation accelerates due to faster plate corrosion and electrolyte loss. This shortens service life and reduces reliability, especially in applications involving frequent cycling or continuous standby operation.

In colder conditions, lead-acid battery performance declines as internal resistance increases and charge acceptance slows. This can translate into reduced runtime at critical moments.

Without temperature-aware maintenance practices, lead-acid batteries in industrial applications tend to age faster than expected.

How do lithium-ion batteries respond to temperature extremes?

Lithium-ion batteries for material handling equipment and golf carts generally perform more consistently across a wider temperature range. However, prolonged exposure to heat or unmanaged cold still affects long-term health.

High temperatures accelerate internal chemical aging and reduce long-term capacity retention. Cold conditions increase internal resistance and can temporarily limit power delivery, particularly during charging.

What differentiates lithium-ion battery systems is the presence of integrated battery management systems , which actively monitor temperature, voltage, and charging behaviour. These systems help reduce stress during extreme conditions, though sustained exposure will still contribute to wear over time.

What are the early signs of temperature-related battery degradation?

Across industrial battery systems, temperature-related wear often develops gradually. Common indicators include reduced runtime, faster capacity loss, longer charging times, and voltage instability during high-load operations.

These symptoms appear progressively, and are often mistaken for normal ageing. Regular monitoring helps identify battery degradation due to temperature extremes before failures occur.

How can industrial users reduce temperature-related battery wear?

Reducing temperature-related battery wear begins with understanding the operating environment. Adequate ventilation, insulated enclosures, and controlled battery rooms can significantly reduce thermal stress, particularly for uninterruptible power supply systems and solar battery storage.

For lithium-ion batteries used in material handling equipment, correct configuration of the battery management system and charging protocols is essential. For lead-acid systems, maintenance schedules often need adjustment based on ambient conditions rather than fixed intervals.

Routine health checks, capacity testing, and environment-specific maintenance planning remain some of the most effective ways to slow battery wear and tear.

Why 2025’s temperature trends should influence your battery strategy

As extreme temperatures become more frequent, industrial battery selection and maintenance planning must account for environmental exposure alongside duty cycles. Batteries that are well-matched to their application and operating conditions consistently deliver better reliability, longer service life, and lower total cost of ownership.

Ignoring temperature as a design and planning factor increases the risk of premature failure and unexpected downtime.

Final thoughts

Temperature is now one of the most influential factors affecting how industrial batteries age and perform. Whether you rely on lead-acid or lithium-ion batteries, understanding temperature-driven battery wear is essential to protecting your investment.

At UNIK, we work closely with industrial users to design industrial battery solutions aligned with real operating conditions. If recent temperature extremes have raised questions about battery performance or lifecycle expectations, a closer evaluation of chemistry choice and thermal management can often make a meaningful difference. Get in touch with our team today to shield your industry’s batteries against temperature uncertainty.

Everything You Need to Know About Retrofitting MHE Equipment Before Making the Switch to Lithium-Ion Batteries

Tue, 02 Dec 2025 06:27:28 GMT

As India’s logistics and warehousing sectors evolve, many businesses are considering a lithium-ion battery retrofit to enhance performance, efficiency, and sustainability. Retrofitting is emerging as the smarter, cost-effective route to modernising material handling equipment (MHE) without replacing entire fleets.

Whether you operate electric forklifts , pallet trucks , or reach stackers , understanding the process of retrofitting MHE equipment helps ensure a smooth and safe transition from traditional lead-acid batteries to advanced lithium-ion batteries for forklifts .

What is Retrofitting MHE Equipment and Why Does It Matter?

Retrofitting MHE equipment involves modifying existing forklifts and other warehouse vehicles to support lithium-ion battery technology . Instead of purchasing new electric machines, you upgrade the power source and supporting systems — a process known as material handling equipment battery conversion .

This conversion delivers multiple operational benefits, including faster charging, longer battery life, and reduced maintenance costs. It also supports cleaner and more sustainable warehouse operations in line with India’s growing emphasis on green logistics.

What Should You Consider Before Retrofitting MHE Equipment?

Before starting your industrial battery retrofit , it’s important to evaluate several technical and operational factors. These determine the safety, efficiency, and long-term return on investment (ROI) of your lithium-ion battery retrofit .

1. Battery Compartment and Physical Fit

The new lithium-ion batteries for forklifts are typically smaller and lighter than lead-acid units. A retrofit requires adjusting counterweights, brackets, and enclosure designs to maintain the forklift’s balance and stability. Incorrect weight distribution can affect steering and lifting performance.

2. Voltage and Power Compatibility

Ensure that your material handling equipment battery conversion matches the voltage and current requirements of the original system. Lithium-ion batteries have different discharge characteristics, so the motor controllers and chargers must be reconfigured or replaced accordingly.

3. Battery Management System (BMS) Integration

A Battery Management System (BMS) is crucial to monitor temperature, charge cycles, and voltage levels. Integrating a high-quality BMS ensures thermal stability, prevents overcharging, and enhances the safety of your electric pallet truck battery retrofit or forklift conversion.

4. Charging Infrastructure and Power Supply

Unlike lead-acid batteries, which require long charging times and cooling periods, lithium-ion batteries enable fast and opportunity charging. You’ll need to assess your existing charging stations and, if necessary, install compatible lithium-ion chargers for warehouse operations.

5. Software and Controller Updates

Many modern forklifts use control software optimised for specific battery chemistries. During a warehouse equipment lithium upgrade , ensure that your firmware and onboard diagnostics are updated to communicate correctly with lithium systems.

6. Safety and Thermal Management

Safety is a critical part of any retrofitting guide for warehouse and logistics equipment . Proper ventilation, thermal sensors, and automatic cut-off systems are essential for mitigating heat buildup and ensuring long-term reliability.

How to Switch Your MHE Fleet to Lithium-Ion Batteries

Transitioning from lead-acid to lithium-ion conversion can be done in stages. Start by retrofitting high-usage forklifts or multi-shift vehicles to maximise early ROI. Partner with certified retrofit specialists who understand both battery chemistries and can customise the solution for your equipment type.

A professional lithium-ion battery retrofit partner will assess your fleet’s duty cycles, design load, and energy needs before recommending a compatible setup.

What is the Cost and ROI of Retrofitting Forklifts with Lithium Batteries?

While the upfront cost of a lithium-ion battery retrofit is higher than a standard lead-acid replacement, the total cost of ownership is significantly lower. Businesses typically recover the investment within 18–24 months through:

Reduced maintenance and downtime

Increased energy efficiency

Longer battery life and fewer replacements

Enhanced operational safety and productivity

This makes retrofitting MHE equipment a strong long-term financial decision for logistics, warehousing, and manufacturing businesses in India.

The move toward lithium-ion batteries for forklifts isn’t just about efficiency — it’s about future readiness. As energy costs rise and sustainability becomes central to industrial operations, industrial battery retrofit solutions offer a practical bridge between existing infrastructure and modern power technology.

A well-planned material handling equipment battery conversion not only enhances fleet performance but also aligns your business with India’s clean energy future.

At UNIK Batteries, our lithium-ion batteries are engineered for seamless integration, higher efficiency, and longer life. Whether you’re planning a forklift battery upgrade or a full-scale warehouse equipment lithium retrofit , our solutions are built to power your fleet safely and sustainably.

What India’s GST Reforms on Batteries Mean for Industrial Batteries in India

Mon, 27 Oct 2025 03:01:05 GMT

Effective 22 September 2025, the Goods and Services Tax Council has established a uniform tax rate of 18 percent on all batteries under the relevant tariff heading. Lead-acid batteries and other non-lithium chemistries that were previously taxed at 28 percent have been moved to 18 percent, while lithium-ion batteries that were already at 18 percent remain at 18 percent. This closes a tax-driven price distortion between chemistries. it.

Why buyers should care: procurement clarity for industrial batteries India

Large institutional buyers — data centre operators, telecommunications providers, manufacturers, warehouses and logistics firms — should now evaluate battery options based on engineering and lifecycle merits rather than tax differentials. It is time to re-run battery total cost of ownership and update any battery procurement checklist items that previously assumed different tax slabs by chemistry. The uniform rate simplifies tender comparisons for stationary batteries , traction batteries, and semi-traction batteries.

The renewable stimulus: why stationary and modular stationary storage get a second push

At the same time, the Council reduced GST on many renewable energy devices and components from 12 percent to 5 percent , effective the same date which points to a structural nudge lowering system-level cost for pairing renewable energy generation with storage. This two-pronged reform of lower taxes on renewable equipment plus uniform battery taxation, materially improves the business case for stationary batteries and modular stationary battery systems used for grid support, commercial building peak management and microgrids. Developers and corporate buyers now see better payback on integrated projects.

What this means for uninterruptible power supply batteries and resilience planning

Operators of mission-critical infrastructure that rely on uninterruptible power supply batteries — hospitals, financial services, and data centres should reprice prospective upgrades and replacement schedules. The savings from tax reductions can be redeployed into extended warranties, redundant modular banks or faster maintenance response, improving uptime without increasing lifecycle cost. These industries should re-run their total cost of ownership for uninterruptible power supply batteries with the new 18 percent assumption for all chemistries.

Tactical playbook for B2B buyers (what to do this quarter)

Re-run total cost models for all active tenders and capital plans using 18 percent on batteries and 5 percent on relevant renewable components. Include procurement, energy use, replacement cadence and end-of-life handling in the battery total cost of ownership model.
Update request for quotations : require vendors to show explicit tax line items, and score bids on lifecycle cost and service rather than upfront price alone.
Pilot modular stationary storage at one high-value site to test flexibility and scaling benefits against monolithic installations. Use the pilot to quantify savings from the renewable-device tax cut.
Negotiate recycling and buy-back clauses to capture residual value and meet battery recycling expectations; convert a portion of tax savings into reverse-logistics guarantees.

Strategic context to keep an eye on

The government’s Production Linked Incentive for the Advanced Chemistry Cell programme remains the bedrock of domestic cell capacity stimulus, with an outlay of roughly Rupee 18,100 crore to scale giga- scale manufacturing and domestic value addition. Buyers should plan three- to five-year sourcing strategies that factor in the likely increase in domestic lithium cell availability and potential price effects as local manufacturing scales up.

Quick priorities to GST Reforms on Batteries into an advantage

Reprice major exposures first: large uninterruptible power supply banks, multi-site stationary backup contracts and material handling fleets.
Use realized tax savings to secure longer warranties and faster replacements.
Launch one modular stationary and one battery-as-a-service pilot in the next six months to measure operating advantage.

The Goods and Services Tax reform of 2025 explicitly brings lead-acid batteries and other non-lithium chemistries into the 18 percent bracket and leaves lithium-ion batteries at 18 percent , while cutting renewable-device taxes to 5 percent . For buyers of industrial batteries India , this returns the decision to technical fit, lifecycle economics and service models. Act now to re-run financials, tighten procurement clauses and pilot modular stationary and uninterruptible power supply battery solutions to turn the policy change into measurable resilience and cost gains.

If you are exploring where to begin after these GST reforms on batteries, let’s connect and evaluate the right approach for your business needs

Understanding Battery Failure Modes: Why Batteries Fail and How to Prevent Them

Tue, 16 Sep 2025 05:44:56 GMT

Battery failure isn't just inconvenient; it’s costly and potentially dangerous. Most failures are predictable if you understand the underlying causes and are proactive about maintenance. Whether you're managing backup systems, renewable storage, or industrial power infrastructure, recognising the common battery failure modes is essential for long-term reliability and safety. In this guide, we break down how and why batteries fail and, more importantly, what you can do to prevent it.

Why Do Lead‑Acid Batteries Fail ?

The most common questions about lead-acid batteries are: “Why won’t my battery hold a charge anymore?” or “Why is my backup battery failing early?” The answer often lies in how the battery has been used or, in many cases, neglected.

Sulphation in Batteries — What It Is and How to Fix It

One of the most searched problems is sulphation in batteries . It occurs when a lead‑acid battery remains in a discharged state for too long. Soft lead sulphate crystals form on the plates and, if not reversed early, harden and become permanent. This increases internal resistance and decreases capacity often leading users to think the battery is "dead."

To prevent sulphation, it’s critical to:

Keep batteries at full charge when in standby
Avoid storing batteries when discharged
Use equalisation charging periodically (especially in off-grid setups)
Invest in maintenance or float chargers for systems not regularly cycled

Once hard sulphation sets in, full recovery may not be possible — making prevention key.

Positive Grid Corrosion

Another major cause of lead-acid battery failure is positive grid corrosion. This chemical process occurs over time as the lead grid oxidises, especially in high temperatures or overcharge conditions. This results in deformation of the grid, increased internal resistance, and ultimately, failure to deliver power when it’s most needed.

Prevention includes ensuring chargers are temperature-compensated and preventing float voltage from going too high. Cooler operating environments significantly extend grid life.

VRLA Battery Dry-Out

For Valve-Regulated Lead-Acid (VRLA) batteries, dry-out is a silent killer. These sealed batteries can't be refilled, so when the electrolyte slowly evaporates due to poor ventilation or incorrect charging, the internal resistance rises sharply. Dry-out often leads to total failure even in batteries that appear physically intact.

Key solutions:

Maintain ambient temperature between 20–25°C
Avoid overcharging, which accelerates moisture loss
Monitor float current and temperature trends

Thermal Runaway in Lead‑Acid Battery Systems

Many facility managers ask, “Why did my battery overheat and swell?” This is usually a sign of thermal runaway which happens when excess current causes internal temperatures to rise faster than heat can dissipate, creating a feedback loop. It’s more common in VRLA batteries but can occur in any overcharged or poorly ventilated battery system.

Preventive actions:

Ensure proper airflow in battery enclosures
Set strict charging voltage limits
Use temperature sensors to shut down charging if thresholds are exceeded

Lithium‑Ion Battery Failure Modes and User Solutions

Modern applications rely on lithium‑ion batteries for their high energy density and long life, but these systems bring their own set of risks and failure points.

SEI Layer Build‑Up and Capacity Loss

A gradual but inevitable ageing process in lithium‑ion batteries is the thickening of the Solid Electrolyte Interphase (SEI) layer. Over time, this insulating layer reduces ion flow, increasing impedance and decreasing capacity, which results in a decline in runtime.

Solution:

Use battery systems with smart charging algorithms
Keep operating temperatures within manufacturer limits
Monitor impedance trends over time

Lithium Plating Failure — The Hidden Danger

One of the most serious and widely misunderstood failure modes is lithium plating. This occurs when charging happens too quickly, especially at low temperatures. Metallic lithium deposits on the anode can form sharp dendrites, which may pierce the separator and cause internal short circuits or even thermal events.

How to prevent lithium plating:

Avoid fast charging in sub-zero temperatures
Use smart BMS (Battery Management Systems) to detect unsafe conditions
Ensure consistent thermal management in all seasons

BMS Failures and Cell Imbalance

The Battery Management System is the brain of a lithium battery pack. If it malfunctions due to software bugs, sensor errors, or poor manufacturing, the result can be catastrophic. Overcharging, undercharging, or cell imbalance may go unchecked, increasing the risk of thermal runaway.

To reduce BMS-related risks:

Choose batteries with tested, certified BMS units
Update firmware regularly (if applicable)
Use logging and monitoring systems to catch anomalies early

Understanding common battery failure modes is the first step — choosing the right battery solution is the next. Whether you need reliable replacements for industrial systems, renewable storage, or backup power, selecting high-quality batteries is key to long-term performance and safety.

Explore UNIK’s range of premium lead-acid and lithium-ion batteries — built for durability, tested for performance. Contact us to know more.

Why Integrate BMS & IoT in Lithium-ion Battery Management?

Mon, 15 Sep 2025 10:07:11 GMT

As industries shift to lithium-ion batteries for their higher energy density and fast charging, the question is no longer whether to adopt them, but how to manage them effectively. That’s where Battery Management Systems (BMS) and IoT integration come in.

In this blog, we’ll answer the key search intent questions:

Why integrate BMS and IoT in lithium-ion batteries?
What are the advantages of BMS in lithium-ion battery management?
How do BMS and IoT improve performance in forklifts and golf carts?

What is Battery Management System(BMS) and why does it matter?

A BMS is the “brain” of a lithium-ion battery pack. It:

Tracks State of Charge (SoC) – how much usable energy remains
Monitors State of Health (SoH) – the long-term condition of the pack
Balances cells – preventing overcharging or deep discharging
Controls temperature – avoiding overheating and thermal runaway

Advantage: Without a BMS, lithium batteries in forklifts or golf carts degrade faster, suffer unplanned failures, and can become unsafe.

Why Integrate IoT with a BMS?

While the BMS protects the pack internally, IoT connectivity in batteries unlocks visibility and control externally. When integrated, IoT enables:

Remote monitoring – battery data available in real time
Predictive maintenance – detect faults before they stop operations
Fleet optimisation – compare performance across multiple forklifts or golf carts
Cost efficiency – reduce downtime, avoid unnecessary replacements

Advantage: IoT in lithium-ion battery management turns raw BMS data into actionable insights for operators, fleet managers, and OEMs.

Advantages of BMS & IoT in Material Handling Equipment

Forklifts, pallet trucks, and automated guided vehicles are mission-critical. Here’s how BMS + IoT deliver:

Extended uptime: Real-time SoC monitoring prevents mid-shift breakdowns.
Lower TCO: Predictive insights avoid premature replacements.
Opportunity charging: IoT data helps schedule short, efficient top-ups during breaks.
Fleet-wide visibility: Managers can track usage and State of Health (SoH) across all forklifts.

Advantages of of BMS & IoT in Golf Carts

In golf resorts, residential communities, and airports, smooth operation depends on reliable batteries.

Range confidence: BMS ensures carts never over-discharge; IoT dashboards show live charge levels.
Predictive maintenance: Fault detection prevents cart failures mid-round.
Fleet balancing: Usage analytics ensure even distribution, extending pack lifespans.
Customer experience: Fewer breakdowns = smoother rides for users.

Business Benefits of Integrating BMS & IoT

For both MHE and golf carts, the integration delivers clear ROI:

Safety – reduced risk of overheating and failures
Performance – consistent battery availability and reliability
Sustainability – longer pack life means less waste and fewer replacements
Cost savings – optimised energy usage and reduced downtime

If you’re searching for the advantages of BMS in lithium-ion battery management, the answer is clear: on its own, a BMS protects your battery. But when integrated with IoT, it transforms your forklift or golf cart fleet into a smarter, safer, and more cost-effective operation.

For operators, OEMs, and facility managers, investing in BMS + IoT isn’t just a technical upgrade—it’s a competitive advantage.

At UNIK, we believe reliable energy should also be intelligent. That’s why all our lithium-ion batteries are equipped with IoT, BMS, and smart charging technology as standard. Together, these features extend battery life, reduce downtime, and give you greater control over your operations. To explore how our solutions can benefit your business, get in touch with us today.

Sulfation: The Silent Killer of Lead‑Acid Batteries & How You Can Prevent It

anjali@unikautomation.com (Unik Techno) — Fri, 01 Aug 2025 13:05:49 GMT

Sulfation is a widespread yet often overlooked issue in the world of lead-acid batteries. Frequently dubbed the “ silent killer” , it operates without obvious warning signs, quietly reducing both battery performance and service life. Whether used in industrial machinery, UPS systems, or off-grid energy storage, sulfation poses a serious risk to any application reliant on reliable battery power.

What is Sulfation in Lead Acid Batteries?

At its core, sulfation refers to the accumulation of lead sulphate crystals on the battery’s internal plates. This occurs naturally during discharge as the active material on the plates reacts with sulphuric acid. In a properly maintained battery, these crystals dissolve again during the charging process. However, when a battery is left undercharged, stored in a discharged state, or routinely subjected to deep discharge cycles, these sulphate crystals begin to harden. Over time, they become dense and irreversible, severely inhibiting the battery’s ability to hold and deliver electrical charge.

What Causes Sulfation in Lead Acid Batteries?

Understanding the root causes of battery sulfation is the first step to avoiding it. One of the most common contributors is infrequent or incomplete charging. A battery that is not brought back to a full state of charge after use may retain a residue of sulphate on the plates. This residue becomes the starting point for permanent sulfation, especially if the battery is neglected over repeated cycles. It is not just charging habits either—environmental conditions also play a significant role. High ambient temperatures accelerate the electrochemical reactions inside a battery, increasing the likelihood of crystal formation and growth. In warmer climates, or in confined battery enclosures without proper ventilation, this risk is amplified.

Prevention of Sulfation in Lead Acid Batteries

Prevention begins with proper charging practices. Always use a smart charger that can automatically adjust the charging voltage and current based on the battery’s state-of-charge. These chargers typically include bulk, absorption, and float stages that ensure a complete and balanced charge. Some models even include pulse or maintenance modes that help dissolve early-stage sulphate deposits, reducing the onset of crystallisation.

Routine maintenance is another critical factor. For flooded lead-acid batteries, it’s important to regularly check electrolyte levels and top up with demineralised water when necessary. Low electrolyte levels expose the upper portions of the battery plates to air, causing oxidation and increasing the likelihood of sulphate build-up. In addition to fluid checks, make sure to clean terminal posts, check for corrosion, and tighten connections to ensure efficient current flow.

Equalisation charging is a powerful tool in the prevention arsenal. This is a controlled overcharge applied periodically—usually once every 30 to 90 days that helps equalise the voltage between cells and reverses mild sulfation. Equalisation charges are particularly effective in larger battery banks where cell imbalance is common. However, they should only be performed according to the manufacturer’s guidelines, as excessive overcharging can damage the battery.

Storage practices also matter. If a battery is left unused for extended periods, it must be stored fully charged and kept in a cool, dry environment. Batteries in storage should be recharged every 60 to 90 days to prevent the slow self-discharge that can lead to sulphate crystallisation. Even sealed lead-acid batteries are vulnerable if stored improperly.

While some specialised de-sulfation chargers claim to reverse sulfation through high-frequency pulse technology, their effectiveness is generally limited to early-stage sulphate deposits. Once the crystals become hard and dense, recovery is unlikely, and battery capacity is permanently reduced. Prevention remains far more effective than any attempted cure.

The consequences of ignoring sulfation can be expensive. Reduced runtime, increased charging times, and eventual failure can disrupt operations and require premature battery replacement. For businesses, this translates to higher operational costs, increased downtime, and reduced energy efficiency.

At UNIK Batteries, we believe that prevention is the smartest investment. By manufacturing high-quality lead-acid batteries and state-of-the-art charging components, we help customers protect their power infrastructure from day one. Whether you operate forklifts , golf carts , maintain a solar backup system , or manage a unit of UPS batteries , we have the right solution to keep you powered and protected from sulfation.

Contact us to explore our range of batteries and charging components today!

How to Build a Battery Room for Lithium-ion, Traction, Stationary & Modular Stationary Batteries

anjali@unikautomation.com (Unik Techno) — Tue, 24 Jun 2025 08:57:44 GMT

Designing a battery room is not just about storing batteries—it’s about ensuring long-term safety, performance, and compliance. Whether you're powering forklifts with lead-acid traction batteries , running backup systems on stationary lead-acid banks , maintaining golf carts with EV or semi-traction batteries , or using lithium-ion batteries for modern applications, your battery room needs to be purpose-built and future-ready.

In this guide, we explore the core considerations for building a multi-purpose battery room that accommodates multiple battery chemistries, improves operational safety, and simplifies ongoing maintenance.

Plan the Layout with Functionality in Mind

A well-designed layout is the backbone of a safe battery room . Begin by allocating sufficient space for each battery system , allowing for clear access during installation, charging, or maintenance. Traction and semi-traction batteries , which are handled frequently, should be positioned near entry points or charging stations for convenience.

Racks or trolleys can be used to allow movement of batteries, while walkways between battery stands should remain unobstructed. If your room will house both lead-acid and lithium-ion batteries , it's good practice to physically separate these systems, especially considering their different safety and environmental requirements.

Flooring and Structural Integrity

The floor of a battery room must be robust and resistant to chemical corrosion. For lead-acid systems , spills and leaks can occur over time, especially during maintenance. Use acid-resistant flooring materials such as epoxy coatings or ceramic tiles and ensure the floor slopes slightly towards a sump or drain to contain any accidental electrolyte discharge.

Additionally, consider the structural load. Large stationary batteries or battery racks can be extremely heavy. Reinforcing the floor where heavy banks will sit is not only good practice but may be a compliance requirement depending on the scale of installation.

Ventilation and Temperature Control

Ventilation is essential, particularly for lead-acid batteries emit hydrogen gas during the charging process. Hydrogen is both odourless and explosive at relatively low concentrations, so a proper ventilation system should exchange the air in the room several times per hour. Intake vents should be located near the floor, while exhaust fans should be installed near the ceiling to remove lighter-than-air hydrogen effectively.

For lithium-ion battery systems , thermal management is more important than gas removal. These batteries perform best in ambient temperatures between 15°C and 25°C. If your room is located in a region with high seasonal variation or inside a warehouse without climate control, consider installing dedicated air conditioning or cooling systems to maintain consistent and optimal temperature levels.

Charging Infrastructure

With different battery types come different charging demands. Traction and semi-traction batteries often require high-current chargers, while stationary systems may need float chargers with constant voltage regulation. Ensure each charging station is matched to the battery type, voltage, and chemistry.

Wiring should be properly insulated, labelled, and protected against overcurrent faults. Emergency disconnects and surge protectors should be installed as standard. For lithium-ion charging stations, take extra precautions by placing them in areas with enhanced thermal detection and separation from other battery chemistries.

Safety First Equipment and Precautions

No battery room is complete without a full suite of safety equipment. Fire protection is paramount—install Class C fire extinguishers throughout the space and consider clean-agent fire suppression systems if lithium-ion batteries are present. Emergency lighting, signage, and eye wash stations should be placed near exits or high-risk areas.

Operators working with lead-acid batteries must be provided with PPE, including acid-resistant gloves, aprons, and safety goggles. It’s also essential to train personnel in battery handling, charging safety, and emergency procedures. Even the best-designed battery room can be compromised by human error if safety practices are not enforced.

Battery Segregation and Labelling

Wherever possible, house batteries of similar chemistry and use case together. For instance, group all stationary lead-acid banks in one section and lithium-ion systems in another. This simplifies maintenance and reduces the risk of cross-contamination or operator error. Use durable, legible labels to mark each battery rack with key information: voltage, capacity, date of installation, and battery type.

Routine Maintenance and Monitoring

Battery rooms must be easy to inspect and maintain. Lighting should be bright and resistant to corrosion or acid vapours. Install pull-out trays or sliding racks for traction batteries, and provide room to safely top up lead-acid cells. Include cable management systems to prevent tripping hazards or strain on terminals.

For large or mission-critical systems, consider integrating battery monitoring systems that offer real-time data on temperature, charge levels, and potential faults. This can prevent unexpected failures and allow for predictive maintenance, which significantly extends the life of your battery assets.

Whether you're managing a fleet of forklifts, maintaining a UPS system battery room , or operating a material handling facility , a well-planned battery room is central to operational reliability. By designing a room that accommodates multiple battery types—including traction and semi-traction lead-acid , stationary and modular setups , and lithium-ion —you protect your investment and your people.

From layout and ventilation to charging systems and fire protection, every detail matters. Prioritise safety, plan for scalability, and ensure ease of maintenance—your battery room will reward you with years of dependable performance.

Battery rooms are only as effective as the batteries they house. Speak to our team to find the right solution for powering your operations.

Why Depth of Discharge (DoD) Matters for Industrial Battery Lifespan

anjali@unikautomation.com (Unik Techno) — Thu, 08 May 2025 07:14:58 GMT

In the world of industrial batteries, performance is not just about capacity—it’s about how long that energy lasts. One of the most crucial, yet often overlooked, factors affecting the longevity of batteries is Depth of Discharge (DoD). Whether you're powering forklifts , backup systems, or other heavy-duty equipment , managing DoD can have a significant impact on both operational efficiency and overall costs.

What is Depth of Discharge (DoD)?

Depth of Discharge (DoD) refers to the percentage of a battery's total capacity that has been used during a discharge cycle. For example:

A 100% DoD means the battery has been completely discharged.
A 40% DoD means 40% of the battery's capacity has been used, leaving 60% of the charge remaining.

Example:

If a 100Ah battery is discharged by 40Ah, it reaches a 40% DoD .

DoD is a key factor in determining the lifespan of a battery. Different battery chemistries—whether lead-acid, lithium-ion, or others—perform optimally at different DoD ranges. Exceeding these recommended limits too frequently can degrade the battery's performance over time.

How DoD Affects Battery Lifespan

The relationship between Depth of Discharge and battery lifespan is inverse: the deeper the discharge, the fewer charge-discharge cycles the battery will be able to endure. A cycle refers to the full discharge and recharge of the battery.

For instance, a lead-acid battery fully discharged to 100% DoD may last about 200 cycles.
On the other hand, discharging it only to 30% DoD can extend its life to over 1,200 cycles.

This difference in cycle life highlights the importance of managing DoD carefully to extend battery longevity.

Lithium-Ion vs. Lead-Acid: Tolerances for DoD

Lead-acid batteries typically operate best when discharged to a maximum 50% DoD. Exceeding this can lead to quicker degradation of the battery, reducing its operational life.
Lithium-ion batteries , in contrast, are often designed to handle deeper discharges, with 80–90% DoD being manageable in many cases. This gives them a longer life span in applications requiring frequent discharges. For example, lithium-ion batteries can often withstand thousands of cycles at moderate discharges, making them ideal for high-demand applications.

Each type of battery chemistry has its strengths and is suited to different operational needs, making it important to choose the right one for the specific use case.

Economic Impact of DoD on Industrial Battery Costs

While deeper discharges may provide more energy per use, they shorten the overall lifespan of the battery, which can result in more frequent replacements and higher operational costs.
Lead-acid batteries , despite their lower upfront cost, may require more frequent replacements when discharged deeply, increasing long-term costs.
Lithium-ion batteries , although initially more expensive, often have a longer lifespan due to their ability to tolerate deeper discharges without as much degradation, making them more cost-effective in the long run for certain high-demand applications.

Both technologies have their place, depending on the specific needs and budget constraints of the business.

Best Practices for Managing Depth of Discharge (DoD)

To maximise the lifespan of your batteries and reduce replacement costs, it’s essential to follow these best practices:

Understand your battery’s specifications : Always consult the manufacturer’s guidelines to understand the maximum recommended DoD for your specific battery.
Avoid deep discharges : Regularly recharge your battery before it reaches 20–30% of its capacity. For lead-acid batteries , it’s best to recharge when DoD reaches 50–60% .
Implement Battery Management Systems (BMS) : A BMS tracks DoD in real-time and provides alerts to ensure the battery doesn’t reach critical discharge levels, helping to protect the battery from unnecessary damage.
Properly size your battery system : Ensure your battery system is large enough to operate without frequently discharging more than 30–50% of the total capacity.
Train your operators : Proper training is essential to ensure that all operators understand how to monitor DoD and avoid deep discharges.

Managing Depth of Discharge (DoD) is a crucial element of battery management for businesses relying on industrial batteries. Whether using lead-acid, lithium-ion, or any other chemistry, keeping DoD within recommended limits will significantly extend the life of your batteries, reduce operational downtime, and improve cost efficiency.

Investing in intelligent monitoring systems, training operators, and adhering to DoD guidelines will not only extend battery lifespan but also contribute to more sustainable operations.

Contact us to know more about how our batteries can meet your DoD requirements and optimise your industrial operations today!

Understanding Heat-Sealed Batteries: Enhancing Safety, Reliability, and Battery Longevity

anjali@unikautomation.com (Unik Techno) — Fri, 28 Mar 2025 06:13:26 GMT

Battery safety is critical in industries relying heavily on robust, dependable power sources such as electric forklifts, golf carts, and industrial machinery. One technology significantly advancing battery safety is heat-sealed battery construction . At UNIK Batteries, we utilise advanced heat-sealing techniques to provide superior safety, reliability, and longer battery life for demanding industrial applications.

What Are Heat-Sealed Lead-Acid Batteries?

Heat-sealed lead-acid batteries are constructed using a specialised sealing process where battery casings are permanently bonded through heat application. Unlike traditional battery sealing methods using adhesives or mechanical seals, heat sealing creates a highly durable, airtight enclosure, ideal for demanding industrial environments.

Key Benefits of UNIK's Heat-Sealed Battery Technology

Electrolyte Leakage Prevention

Higher resistance levels, which may impact power output.
Reduced charging efficiency, resulting in longer charge times.
Increased operational strain, potentially leading to faster wear and tear.

Here is why winter battery maintenance is essential:

Proper care reduces the risk of cell damage due to freezing temperatures.
Batteries that are well-maintained offer operational efficiency.
Regular maintenance extends the life of your batteries, saving on replacement costs.

Taking these steps will keep your i ndustrial forklift battery in peak condition, even when temperatures plummet.

Lead Acid & Lithium-ion Battery Care in Cold Weather

Maintenance of Lead Acid Batteries

Lead acid batteries are more sensitive to cold temperatures because their electrolyte solution can freeze, particularly when the battery is in a low-charge state. For efficient battery care in cold weather, follow these tips:

Charge fully after each use as a fully charged lead-acid battery is less likely to freeze.
Store batteries in a temperature-controlled environment indoors or in a heated area to protect them from the elements.
Inspect the battery for cracks or leaks, as these can worsen in the cold.
Lead-acid batteries need adequate water to function correctly, so check and refill water levels routinely.
Clean terminals regularly to prevent corrosion and improve conductivity.

Lithium-ion Battery Maintenance

While lithium-ion batteries fare better than lead acid batteries in colder weather, they still require care to avoid performance drops. Follow these tips for top-notch lithium-ion battery maintenance:

When starting your material handling equipment, give your battery some time to warm up just as you would allow your car battery to reach an optimum temperature before driving.
Lithium-ion batteries should not be charged at sub-zero temperatures, as this can lead to permanent damage.
Lithium-ion batteries are more efficient when they maintain a moderate charge level in winter between 30-80%, to reduce strain on the cells.

Following these steps can help ensure that both l ead acid and lithium-ion battery maintenance routines are winter-ready.

Winter can be challenging for industrial forklift batteries , but with consistent battery care in cold weather , you can protect your investment and keep your operations running smoothly. By paying attention to winter battery maintenance and adjusting your care strategies for different battery types, you can enhance battery performance and extend its life, no matter how cold it gets.

Protect your operations all season long! For more tailored solutions, explore our lithium-ion battery and lead acid battery sections to find the best fit for your material handling operations.

Caring for Your Forklift Battery in the Winter

anjali@unikautomation.com (Unik Techno) — Fri, 31 Jan 2025 11:57:20 GMT

When it comes to powering industrial equipment, the choice of battery plays a crucial role in ensuring efficiency and reliability. Traction and semi-traction batteries are key players in this arena, each designed to meet specific operational needs. This blog delves into what these batteries are and their applications in industrial settings.

What are Traction Batteries?

Traction batteries are specialised rechargeable batteries used to power heavy-duty industrial equipment. Unlike traditional starter batteries, they are engineered to provide reliable and consistent power over extended periods, making them suitable for applications that require deep discharges and frequent recharging.

These batteries are typically made up of several cells connected in series, with the most common types being lead-acid traction batteries and lithium-ion .

Lead-acid traction batteries are favored for their cost-effectiveness and durability, whereas lithium-ion traction batteries are sought after for their high energy density and lower maintenance requirements.

What are the Applications of Traction Batteries?

Traction batteries are widely used for rigorous applications in sectors, such as golf carts, renewable energy systems, medical equipment, and power backup systems.

Material handling and industrial applications benefit significantly from these batteries. Traction batteries for material handling equipment are used for powering forklifts, pallet jacks, and other material-handling equipment. The high capacity and durability of lead-acid traction batteries and lithium-ion traction batteries make them perfect for these tasks. They ensure reliable performance and longevity in demanding environments, including warehouses and factories that rely on robust power supply.

What are Semi-traction Batteries?

Semi-traction batteries, also known as monobloc batteries, are engineered for exceptional performance in industrial settings where consistent power is required over extended periods. These batteries are specifically designed to handle repetitive and intense cycle use. A semi-traction battery is constructed with multiple electrically connected cell compartments containing electrodes, electrolytes, terminals, and separators. These cells can be arranged in series or parallel configurations to tailor the battery's performance to specific applications. Semi-traction batteries are engineered to endure harsh conditions, including wide temperature fluctuations (-30°C to 60°C) and exposure to shocks and vibrations.

What are the Applications of Semi-traction Batteries?

Semi-traction batteries are versatile and provide dependable power for various applications where the energy demand is moderate and consistent, but not as intensive as in heavy industrial use. These batteries are particularly effective in settings where a reliable energy source is needed over an extended period.

They may be used for less intensive off-grid solar power systems and energy storage applications. Semi-traction batteries are particularly advantageous in golf carts and industrial cleaning equipment . Golf carts benefit from the battery’s ability to endure frequent discharge cycles, vibrations, and temperature variations, providing reliable power in varied conditions. Similarly, semi-traction batteries excel in industrial cleaning equipment, such as floor scrubbers, where they provide the necessary power to operate efficiently over long periods, withstanding the rough conditions typical in industrial environments.

In the world of industrial equipment, the choice between traction and semi-traction batteries can significantly impact operational efficiency and longevity. Traction batteries provide robust, reliable power for heavy-duty applications, such as material handling equipment, while semi-traction batteries offer a dependable solution for moderate energy needs, like those found in golf carts and cleaning machines. By selecting the right type of battery for each specific application, businesses can ensure uninterrupted operations, reduce downtime, and maintain consistent performance in all conditions.

UNIK recognises the diverse battery needs of different industries and is here to help you find the perfect fit.

The Power Behind Industrial Equipment- A Guide to Traction and Semi-Traction Batteries

anjali@unikautomation.com (Unik Techno) — Thu, 26 Dec 2024 06:48:41 GMT

What are Traction Batteries?

These batteries are typically made up of several cells connected in series, with the most common types being lead-acid traction batteries and lithium-ion .

What are the Applications of Traction Batteries?

Traction batteries are widely used for rigorous applications in sectors, such as golf carts, renewable energy systems, medical equipment, and power backup systems.

What are Semi-traction Batteries?

What are the Applications of Semi-traction Batteries?

UNIK recognises the diverse battery needs of different industries and is here to help you find the perfect fit.

The Role of Batteries in Sustainable Energy Solutions

anjali@unikautomation.com (Unik Techno) — Thu, 29 Aug 2024 11:32:58 GMT

As the world moves towards a future powered by renewable energy sources, the importance of energy storage systems, particularly batteries, has become increasingly apparent. Batteries play a crucial role in sustainable energy solutions by enhancing energy efficiency, stabilising the grid, and enabling the widespread adoption of renewable energy. This article explores the integral role of batteries in sustainable energy systems and how advancements in battery technology are driving the transition to a greener future.

The Need for Energy Storage in Renewable Energy Systems

Renewable energy sources like solar and wind power are inherently variable. Solar power is only generated during daylight hours, and wind energy depends on weather conditions. This variability poses a significant challenge to maintaining a consistent and reliable energy supply. Traditional energy grids, designed for steady power generation from fossil fuels, need help integrating these intermittent renewable energy sources.

Energy storage systems, particularly batteries, are essential for overcoming this challenge. By storing excess energy generated during peak production periods, batteries ensure that energy is available when renewable energy sources are not generating power. This capability stabilizes the grid and maximizes the use of renewable energy, reducing reliance on fossil fuels.

Battery Storage: A Cornerstone of Sustainable Energy Solutions

Battery storage systems are a cornerstone of sustainable energy solutions. They provide several key benefits that support the transition to a more sustainable energy landscape:

Grid Stability and Energy Efficiency:

Batteries stabilize the grid by balancing supply and demand, preventing blackouts, and improving energy efficiency by storing excess energy for later use.

Integration of Renewables

Batteries enable the smooth integration of renewable energy sources into the grid, allowing for higher renewable penetration without compromising reliability.

Decentralized Energy Solutions:

Batteries support decentralized energy systems like microgrids, offering flexibility and reliability, especially in remote or underserved areas.

Advancements in Battery Technology

The effectiveness of battery storage systems in sustainable energy solutions largely hinges on the underlying technology. Lead-acid batteries have long been the tried and tested technology, but lithium-ion batteries are increasingly becoming the most widely used type in energy storage systems.

Recent advancements in lithium-ion technology have significantly improved their energy density, lifespan, and safety, making them more suitable for large-scale applications. They offer a high energy density, allowing for more energy storage in a smaller space, which benefits both residential and commercial energy systems. Ongoing research enhances their performance and sustainability, including developing recycling processes to mitigate environmental impact.

Beyond lithium-ion, researchers are exploring next-generation battery technologies, such as solid-state and flow batteries. These promising innovations offer even greater storage capacity, faster charging times, and longer lifespans, which could further boost the adoption of renewable energy.

The Future of Sustainable Energy with Battery Storage

The future of sustainable energy is inextricably linked to the development and deployment of advanced battery storage systems. As renewable energy sources grow, the demand for efficient, reliable, and scalable energy storage solutions will increase. Batteries will be pivotal in this transition, enabling a more resilient and sustainable energy grid.

Governments and businesses worldwide recognize battery storage's importance in achieving their sustainability goals. Investments in battery technology are growing, and innovative projects are being launched to demonstrate the potential of batteries in real-world applications.

Conclusion

Batteries are more than just a component of sustainable energy systems—they are the linchpin that holds them together. By providing the necessary storage and flexibility, batteries enable the effective integration of renewable energy sources, enhance energy efficiency, and contribute to grid stability. As technology advances, batteries' role in sustainable energy solutions will become even more critical, paving the way for a cleaner, more sustainable future.

By embracing battery storage as a key element of the energy transition, we can unlock renewable energy's full potential and move closer to a world powered by sustainable energy solutions.

The Advantages of Lithium-Ion Batteries in Industrial Applications

anjali@unikautomation.com (Unik Techno) — Mon, 22 Jul 2024 11:36:35 GMT

In the fast-paced world of industrial applications, efficient and reliable power solutions are crucial. Lithium-ion batteries have emerged as a game-changer as industries strive for more sustainable and high-performance energy sources. This blog explores lithium-ion technology’s remarkable advantages and growing applications in the industrial sector.

The Rise of Lithium-ion Batteries in Industrial Power Applications

Lithium-ion cell technology has revolutionised the energy storage landscape with superior technology and performance. Unlike traditional batteries, they offer several benefits that make them ideal for industrial settings.

Key Advantages of Lithium-ion Batteries

High Efficiency

One of the standout features of lithium-ion batteries is their high energy density. This means they can store more energy in a smaller space, making them incredibly efficient. For industries, this translates to longer operating times and fewer interruptions, enhancing productivity and reducing downtime.

Longer Lifespan.

Lithium batteries are known for their longevity. They can withstand much higher charge and discharge cycles in comparison to lead acid batteries, significantly reducing the need for frequent replacements. This durability is especially advantageous for industrial applications where equipment uptime is critical.

Fast Charging Capabilities

Time is money in industrial operations. Lithium-ion batteries can be charged at a much faster rate compared to other battery types. This rapid charging capability ensures that industrial equipment can be quickly returned to service, maximizing operational efficiency.

Low Maintenance

Lithium-ion technology requires minimal maintenance when compared to lead acid batteries. They do not suffer from memory effects, and their self-discharge rate is low. This means it can retain their charge for extended periods when not in use, providing reliable backup power solutions.

Lightweight and Compact

Lithium-ion batteries are compact and lightweight, making them ideal for use in various industrial equipment. This simplifies the design and integration process and contributes to the equipment's efficiency and portability.

Applications of Lithium-Ion Batteries

The versatility of lithium-ion technology has led to their adoption in numerous industrial applications:

Material Handling Equipment

Forklifts, pallet trucks, and other material handling equipment benefit greatly from the efficiency and reliability of lithium batteries. These batteries provide consistent power output, essential for demanding tasks in warehouses and manufacturing plants.

Uninterruptible Power Supplies (UPS)

In critical industrial environments, maintaining a continuous power supply is vital. These batteries are increasingly used in UPS systems to ensure that essential operations remain unaffected by power outages.

Automated Guided Vehicles

AGVs are becoming more prevalent in the logistics and manufacturing industries. Lithium-ion batteries provide these vehicles with a reliable and long-lasting power source, enabling them to operate efficiently over extended periods.

Renewable Energy Storage

As industries move towards sustainable energy solutions, lithium-ion technology is crucial in storing energy from renewable sources like solar and wind. This stored energy can power industrial operations, reducing reliance on conventional power sources.

Conclusion

The adoption of lithium-ion batteries in industrial settings is expected to grow exponentially. Their advantages of high energy density, longer lifespan, fast charging, low maintenance, and lightweight design make them ideal choices for various applications. As technology advances, lithium-ion solutions will likely become even more integral to industrial power solutions. Their superior performance characteristics and versatile applications make them essential to modern industrial operations. As industries grow Lithium-ion technology will undoubtedly play a pivotal role in shaping the future of industrial energy storage as industries continue to seek efficient and sustainable power solutions.

By understanding and leveraging the benefits of these batteries, industries can achieve greater efficiency, sustainability, and reliability in their operations. Enhance your industrial power solutions with UNIK’s state-of-the-art lithium-ion batteries.

Mastering UPS Battery Capacity Planning for Industrial Systems

anjali@unikautomation.com (Unik Techno) — Thu, 20 Jun 2024 05:58:54 GMT

In industrial settings, power supply dependability is critical. Activities' maintenance in the event of a power outage greatly depends on Uninterrupted Power Systems . This blog explores how to efficiently plan battery capacity for industrial UPS systems , providing guidance for maximum dependability and performance.

Determining the Necessary Load Conditions

Start by determining how much power the essential equipment needs. For this, a list of all the devices linked to the UPS system must be created, and their power consumption in watts and volt-amperes (VA) must be determined. Accurately estimating the active and apparent power will ensure that your UPS energy storage system is the right size, eliminating inefficiencies and guaranteeing dependable power protection. Underestimating the power needs can result in an underpowered backup system or needless spending on an overpowered system.

Accommodating Future Expansion

Planning for battery capacity with forward-thinking entails projecting future growth. Industrial settings are dynamic and may grow or require modifications to their operational requirements. Plan your UPS battery system for growth in the future so that it can continue to function correctly without constant upgrades. To select a system that can grow with your needs, consider the possibility of scaling operations, seasonal fluctuations and the anticipated lifespan of the UPS batteries.

Understanding Power Consumption Patterns

Devices vary in how they use power, particularly in the initial stages. When equipment starts up, it needs more power than it needs to run continuously, referred to as inrush current. A thorough comprehension of these dynamics aids in selecting a large UPS battery capacity that can efficiently handle transient loads. To guarantee that the UPS batteries can continuously handle all power demands, one must consider both the typical operational and peak loads during startup.

Redundancy and Efficiency

High-efficiency systems can save money since they consume less energy and cool down more quickly. Since they are made to reduce energy losses during power conversion, they are more cost-effective over time. Calculate the required redundancy level to improve system dependability and guarantee a steady power supply. One can achieve redundancy by having backup UPS batteries that can take over and offer additional protection if the primary unit fails.

Evaluating Runtime Requirements

Determine the necessary runtime during blackouts to help choose the suitable UPS battery capacity. This crucial information helps you determine how long vital systems will continue functioning until backup generators are turned on or the systems are securely shut down. Consider the worst-case scenario for power outages and ensure your UPS can continue operating for as long as it takes to shut down vital equipment or restore electricity securely.

Assessment of the Environment

Temperature is a single environmental concern that might affect the lifespan and effectiveness of UPS batteries . Extreme weather could affect the life of batteries because they are susceptible to temperature. To enhance longevity and efficiency, select a solution that will operate well in the specific environmental conditions that you find yourself in. Maintaining ideal circumstances for your UPS can be facilitated by installing suitable ecological controls, such as climate-controlled rooms.

Choosing the Correct UPS Topology

UPS systems offer varying topologies of power protection. The best protection is provided by online systems, which isolate the load from power outages by continuously converting incoming power to DC and back to AC. For less critical applications, Line-Interactive systems offer good protection and efficiency. Because of its affordability and basic safety, offline UPS is suitable for non-critical applications. Select the topology best suited to your needs and budget to ensure efficient power management.

Battery capacity planning requires carefully considering many aspects of industrial UPS systems. By following these best practices, organisations can guarantee operational dependability and a continuous power supply.

Contact UNIK for more information on optimising battery capacity and selecting the best high-capacity UPS for your industrial needs. Our stationary battery solutions for industrial UPS systems offer scalability, efficiency, and reliability tailored to your requirements. Our experts are here to assist you in ensuring uninterrupted power supply and operational efficiency.

Everything You Need to Know About Golf Cart Batteries

anjali@unikautomation.com (Unik Techno) — Thu, 23 May 2024 11:13:44 GMT

Golf cart batteries are the heart of your golf cart, providing the necessary power to drive smoothly across the greens. Understanding the different types of batteries, their maintenance and the factors affecting their lifespan can help you make an informed decision and ensure your cart runs efficiently.

Types of Golf Cart Batteries

There are three main types of golf cart batteries:

Lead Acid Batteries : The most common and economical option, lead acid batteries have been used in golf carts for decades. They require regular maintenance, including checking water levels and cleaning terminals.

AGM Batteries : Absorbent Glass Mat (AGM) batteries are a type of valve-regulated lead acid battery (VRLA). They are sealed, require less maintenance, and are less prone to leakage. AGM batteries are a bit more expensive but offer longer life and better performance.

Lithium-Ion Batteries : The newest and most advanced option, lithium-ion batteries are durable, lightweight and require minimal maintenance. They are also more expensive but provide the best performance and efficiency.

Maintenance Tips for Golf Cart Batteries

Proper maintenance is crucial to extend the life of your golf cart batteries. Here are some essential tips:

Regular Charging : Always keep your batteries fully charged. Avoid deep discharges as they can shorten the battery’s lifespan. Charge the batteries after every use, and if the cart is not in use, recharge them every few weeks.

Water Levels : For lead acid batteries, check the water levels regularly and top them off with distilled water. Never overfill, as it can lead to spillage and corrosion.

Clean Terminals : Keep the battery terminals clean and free of corrosion. Use a mixture of baking soda and water to clean them, and apply a terminal protector spray to prevent future corrosion.

Proper Storage : If storing your golf cart for an extended period, ensure the batteries are fully charged and disconnect them to prevent discharge. Store the batteries in a cool, dry place.

Factors Affecting Battery Life

Several factors can influence the lifespan of your golf cart batteries:

Usage : Overusing the battery without rest and opportunity charging can impact the lifespan of the battery.

Temperature : High temperatures can lead to overheating, while low temperatures can reduce battery capacity.

Maintenance : Proper and regular maintenance can significantly extend the life of your batteries. Neglecting maintenance can lead to premature failure.

Conclusion

Choosing the right golf cart battery and maintaining it properly is essential for optimal performance and longevity. Whether you opt for lead acid, AGM, or lithium-ion batteries, understanding their needs and how to care for them will ensure your golf cart remains reliable and efficient. At UNIK Batteries, we offer a range of high-quality batteries to meet all your golf cart needs, ensuring you get the best performance on the greens.

Solar Batteries for Factories— A Step Towards Reducing Industrial Carbon Footprint

anjali@unikautomation.com (Unik Techno) — Thu, 18 Apr 2024 13:26:48 GMT

Every April, World Earth Day reminds us of our responsibility to protect the planet. This year, addressing climate change is more critical than ever as global average surface air temperatures for March (2024) hit a record high of 14.14 degrees. According to the International Energy Agency, industrial emissions are at an all-time high, at a staggering 37.4 billion tones (in 2023) .

Solar power represents a significant opportunity for manufacturers to reduce their environmental impact with lower carbon emissions and dependence on fossil fuels.

At UNIK we have been exploring how integrating solar batteries into your facility's solar voltaic (PV) system can be a significant step towards a more sustainable future.

Why Choose Solar Energy Systems for Your Industries?

Beyond reducing their carbon footprint and boosting sustainability, solar energy systems for industries offer many advantages, especially in tropical nations like India. These regions bathe in year-round sunshine, making solar power a future-proof, long-term investment.

While the upfront cost of installing photo-voltaic systems may seem high, the price of solar technology has been steadily dropping in recent years encouraging medium- and small-scale industries to embrace this clean energy source.

Some of the other advantages include-

Reduced dependence on the grid power supply safeguards operations from outages and downtime. Solar-powered industries can set up shop in remote regions where the grid supply may need to be better established.
Solar technology reduces cost fluctuations, as grid supply price volatility no longer impacts manufacturing costs. Moreover, solar systems are a one-time investment that provides uninterrupted and free power for approximately 10-20 years .
The Indian government strategically supports investment in solar power. Businesses can leverage attractive tax breaks and accelerated depreciation allowances on solar technology systems, reducing their overall tax burden. Additionally, net metering policies provide an opportunity to generate revenue by selling excess solar energy back to the grid.
Lastly, opting for renewable energy power drives up property valuation, improves attractiveness for investors and creates branding opportunities for companies.

While solar power offers many advantages for industries, integrating photo-voltaic panels with solar batteries unlocks a whole new level of efficiency and versatility for your setup.

The next section of this blog deep dives into solar systems with batteries .

How Do Solar Systems with Batteries Work More Efficiently?

Solar batteries act as the cornerstone of a truly optimised solar energy system. By capturing excess electricity generated during high sunlight, they ensure a consistent and dependable power supply, even during extended periods of cloud cover or night hours. The electrochemical processes within the batteries store this surplus energy as potential energy, allowing for its convenient conversion back into usable electricity when needed.

The Types of Solar Batteries

Lead-acid and lithium-ion batteries are the two most popular batteries for solar cells. Each has distinctive merits and applications.

Lead Acid Batteries

For industries with solar energy systems prioritising affordability and reliability, lead-acid batteries remain a strong contender. These time-tested batteries come in flooded or sealed varieties, each suited for different discharge patterns (shallow or deep cycle). While newer technologies offer higher energy density, lead-acid batteries' advancements in lifespan make them a viable option for several industrial applications.

Lithium-ion Batteries

Lithium-ion batteries are a recent innovation in solar energy storage. While their high energy density allows for smaller and lighter units, coupled with efficiency for deeper discharge, this advanced technology comes with a significantly higher upfront cost.

Factors to Consider While Selecting a Solar Battery for Solar Panels

Selecting suitable solar batteries is a multi-faceted decision. Here are some criteria that should be considered while planning solar energy systems for industries -

Battery Lifespan

Battery lifespan is influenced by maintenance, type, quality, and depth of discharge. Referring to the manufacturer's specifications helps determine a solar battery’s expected life cycle. Additionally, proper maintenance practices can significantly enhance performance and longevity.

Lead-acid batteries typically last 1-10 years, depending on usage patterns. While lithium-ion batteries boast a longer lifespan, the total cost of ownership must be considered when evaluating options.

With their lower upfront cost, lead-acid batteries may be a more cost-effective solution for specific photo-voltaic applications.

Depth of Discharge

Depth of Discharge (DOD) is the amount of stored energy used before your solar batteries’ recharge is needed. Deeper discharges typically lead to a shorter battery life. Most batteries provide a cycle life estimate (number of charge/discharge cycles) based on a specific DOD, along with a recommended maximum depth of discharge. When choosing a solar battery for a solar panel system, consider the battery's intended use. By matching the required DOD to your application, you ensure optimal performance and longevity for your investment.takes up floor space.

Cost & Capacity

While factoring in costs, one must consider the budget, the solar power system's long-term goals, the battery lifespan, and the replacement and maintenance expenses.

Selecting appropriate battery capacity is a critical decision when implementing solar technology. A well-sized battery bank directly influences its ability to store excess energy generated by your solar panel. This stored energy ensures a reliable and uninterrupted power supply, even during periods with minimal sunlight.

Usage & Applications

Consider whether your solar batteries need to provide short bursts of energy or sustain your plant for extended durations, your facility's daily sun exposure, and the depth of discharge best suited for your application.

Since no one-size fits all, answering these questions and consulting experts in solar energy systems for industries can help you make the right choices regarding battery type and capacity.

Energy Efficiency

Energy losses occur during the transfer and storage of collected solar power from panels to solar batteries. The efficiency of this process depends on the amount of energy generated and the system configuration.

Investing in high-quality, reliable batteries can mitigate these energy losses to a significant degree. .

Today, solar power with battery storage is not just about reducing your carbon footprint but also about securing a sustainable and cost-effective energy future for your factory. With low maintenance and reliable power generation, solar technology offers long-term benefits that pay off for your business and the environment. UNIK Batteries is dedicated to helping you reap the rewards of solar energy with our modular stationary and stationary battery solutions.

The Benefits of Using Lithium-ion batteries in Forklifts

Tue, 20 Feb 2024 06:35:26 GMT

In today's fast-paced industries, material-handling equipment is essential for streamlining operations, increasing workplace safety, reducing rising labour costs and maximising ROIs.

Industrial operations use an array of material-handling equipment, including forklift trucks, pallet trucks, reach trucks, articulated forklifts, battery tuggers, forklift vehicles, and automated guided vehicles.

This equipment runs on battery power, so it is imperative to understand the various options available to power these forklifts based on one's usage, budget and maintenance capabilities.

The two significant batteries for forklifts are lead-acid batteries and lithium-ion batteries.

Lithium-ion Batteries Versus Lead Acid Batteries for Forklifts- The Changing Scenario

Despite being around for about 140 years, lead-acid batteries face stiff competition from lithium-ion battery technology, particularly in the battery-operated forklifts sector, owing to their numerous advantages in material handling efficiency.

This blog highlights the advantages of powering material handling equipment with lithium-ion batteries , such as higher performance, reliability, lower maintenance, cost savings, and fast return on investment (ROI).

Ease of Use & Charging

These batteries are engineered for convenient usage and ease of operation. A major advantage of lithium-ion batteries powering forklift vehicles is opportunity charging, which, if timed correctly, can provide seamless power around the clock during shifts.

The most crucial consideration for charging these types of batteries is ensuring the correct power specifications to match the battery requirements, which can be controlled through load management systems.

Battery Life

Lithium-ion batteries generally have a longer lifespan than traditional lead-acid batteries, which need regular maintenance to sustain optimum energy output and efficiency.

This is primarily because lead-acid batteries are more sensitive to charging conditions. Moreover, maintenance factors such as improper filling up with water, poor cleaning and charging, and not equalising can significantly impact a lead-acid cell's lifespan.

Battery Run-time

On average, lead acid batteries need uninterrupted charging for seven to ten hours daily, making shift operations challenging. The only solution to this constraint is a battery change or using multiple battery-operated forklifts for the same task. This utilises excessive space, funds and workforce, making it an unviable option for large operations.

Regardless of the State of Charge (SOC), lithium-ion batteries offer a reliable high-power supply that doesn't fluctuate during the discharge cycle, guaranteeing reliable vehicle operation. During standard material handling operations, electric forklifts powered by these batteries usually only need a couple of hours charging every shift to operate continuously.

Maintenance

Lead acid batteries are maintenance intensive, requiring heavy-duty upkeep weekly. These include replenishing the fluid levels with demineralised water to prevent damage, cleaning the poles to avoid oxidation, and keeping the battery clean to limit current leakage between cells.

Any negligence drastically impacts the life and performance of these batteries.

Conversely, lithium-ion batteries used in material handling require negligible maintenance. Maintenance for them includes simple routine activities such as checking the cables and connectors and wiping the dust.

Also, the existence of the BMS (Battery Management System) controls the current and usage along with the charging algorithm, hence providing better control of the usage of the battery.

Energy & Space Efficiency

Time, money and space can be saved because of the exceptional energy efficiency of lithium-ion batteries. They are powerful and compact while running for long periods with consistent performance.

On the other hand, even though lead-acid batteries are large and powerful for electric forklift trucks, if they are overcharged it leads to gassing and loss of electrolyte, which results in increased maintenance needs.

With no gassing process, low heat losses, and cutting-edge charging technology, lithium-ion batteries reduce environmental impact while maximising cost-savings. Lithium-ion batteries also take up much less room than their lead-acid equivalents. When lead-acid batteries are charged, they release an explosive H2 gas mixture; hence, a special chamber with safety precautions is required, which further takes up floor space.

Lower Total Cost of Ownership

Lithium-ion batteries offer a lower cost of ownership due to their higher longevity and lower expenditure on charging, labour, and maintenance.

Typically, these batteries provide a higher and quicker return on investment for material handling equipment within 2-4 years of purchase, subject to usage.

The increasing preference for lithium-ion batteries for material handling underscores their pivotal role in optimising performance, reliability, and return on investment in today's dynamic and fast-paced industrial environments. As industries prioritise efficiency, the switch to lithium-ion batteries emerges as a strategic investment for sustained growth and operational excellence.

Contact our team for more information on our lithium-ion batteries for forklifts and other material-handling equipment.

Dry Batteries Versus Wet Batteries: Which One is Best for Your UPS System

anjali@unikautomation.com (Unik Techno) — Mon, 19 Feb 2024 10:24:27 GMT

Why is Choosing the Right UPS System Batteries Important?

During power outages and blackouts, Uninterrupted Power Supply (UPS) backups are crucial in operational efficiency and energy self-reliance. In India especially, one witnesses seasons of frequent power fluctuations, particularly in the monsoon and summer months, making UPS systems an inseparable part of modern industries .

The choice of a correct battery is the most essential component of a UPS, which warrants making an informed decision while choosing UPS system batteries.

Factors such as maintenance, lifespan, power outputs, and depth of discharge, among others, play a significant role in determining the ideal battery life for your UPS system.

Lead acid batteries or wet batteries are predominantly used as UPS system batteries. However, Absorbed Glass Mats (AGM) or dry batteries are becoming increasingly popular along with lithium-ion batteries.

This blog compares the two batteries to help make an informed decision for various UPS system applications.

The Composition of Wet Batteries Versus Dry Batteries

A wet battery or a lead acid battery comprises of lead plates suspended in a tank of diluted sulphuric acid.

However, an Absorbed Glass Mat (AGM) or dry battery contains a glass mat separator that wicks the electrolyte between the lead plates. This material's structure allows the absorptive glass mat to absorb the electrolytes and retain them in a "dry" or suspended state instead of being in a free-flowing liquid form.

What are the Maintenance Procedures and Advantages of Wet Batteries?

While lead acid batteries are considered cost-effective and tried and tested UPS system batteries, they also require maintenance procedures, especially in larger UPS systems.

Considering the nature of the liquid sulphuric acid in these batteries, thorough preventive maintenance is required every quarter.

Ventilation and the position of these batteries are of utmost importance for operator safety. The electrochemical processes that occur within the battery to generate a current produce a gaseous material by-product. These gases must be expelled efficiently through the battery's vents to maintain an optimum internal temperature within the cell. Therefore, the foremost steps in battery maintenance is as follows:

Free the battery of all dust and debris, particularly around the air vents.
Lead acid batteries stored for future use must be kept in a cool environment upright to avoid any acid leakage.
The battery should be checked for any leaks that can compromise the safety of the UPS system.

Once these preliminary steps are complete, the cables can be tightened and cleaned.

The most significant maintenance procedure typical to wet batteries is topping up of the electrolyte solution . This solution comprises of sulphuric acid diluted with demineralized water. The ratio of the two liquids in the solution must be calculated and filled to precision as per the manufacturer's guidelines.

Despite being bulky and requiring maintenance, these batteries offer many benefits, including higher power outputs, resistance to overcharging, and deeper discharge.

What are the Maintenance Procedures and Advantages of Dry Batteries?

Dry batteries require less maintenance and are more versatile as they can be operated in mobile operations. Their lifespan can be extended with simple practices like cleaning and good ventilation, as they are more prone to overheating due to a starved electrolyte construction.

Store these batteries away from windows or direct heat sources to maintain optimum temperature in the cell.

While these batteries are more expensive and need to be discarded once they stop supplying current, they also have numerous benefits that can be applied to specific requirements.

Dry cells produce energy more efficiently. Although expensive, the less rigorous maintenance saves time and operational efficiency. Moreover, these batteries offer higher operator safety and are less likely to result in accidents.

In conclusion, deciding between wet (lead acid) and dry (AGM) batteries for UPS power supply hinges on key considerations. Though bulky and demanding rigorous maintenance, wet batteries offer higher power outputs and resilience to overcharging. Conversely, dry batteries require less upkeep, cater to mobile operations, and boast efficient energy production. The choice should align with specific application needs, balancing maintenance preferences, operational efficiency, and safety considerations for reliable industrial UPS performance amid power fluctuations and outages.

At UNIK, we specialise in manufacturing a vast range of high performing dry charged batteries and wet batteries that cater to an array of industrial applications and standards. Contact our team of experts to find the right battery for your industrial needs.

Maximising the Battery Lifespan of a Traction Battery in Industrial Settings

anjali@unikautomation.com (Unik Techno) — Wed, 24 Jan 2024 13:36:33 GMT

What is a Traction Battery?

A traction battery is a deep cycle rechargeable battery designed to power many industrial applications. These batteries can be in the form of Lead Acid Batteries and Lithium-ion Batteries.

Regular water, in contrast, contains a heavy load of impurities and dissolved minerals such as sodium, magnesium, and calcium which are detrimental to the health of batteries.

In which Industries are Traction Batteries Used?

Traction Batteries find applications in a variety of industrial applications. These include material-handling vehicles like forklifts, stackers, platform trucks, cleaning materials, golf carts and EVs.

The longevity of the battery and its suitability in each industrial application depends on the chemical composition of the cell and the industry requirements.

Moreover, every industry application requires its own maintenance practices to ensure the battery’s longevity and reliable electricity supply.

Maintenance neglect and improper usage can degrade the battery lifespan, which increases costs and hampers operational efficiency.

What is the Degradation of a Traction Battery?

The degradation of batteries is a complex and multi-faceted problem. It is categorised by the progressive loss of battery capacity over time, which impacts the battery’s potential to store and deliver energy efficiently.

This loss of capacity only occurs uniformly across different categories of batteries or even within the same battery variant. Factors such as battery maintenance, battery temperature control, and charging play a crucial role in determining the longevity of a battery. Matching the correct battery and capacity to the desired industrial application is vital for efficiency and a prolonged battery lifespan.

What Causes the Battery Lifespan to Degrade?

Deep discharge, incorrect charging parameters and extreme temperatures are the most significant contributors to shorten battery life.

This section of the blog discusses these factors in detail.

Depth of Discharge

This term refers to the amount of battery capacity utilised during each cycle. When batteries are operated within their recommended DoD range, their energy efficiency peaks. It is best to avoid deep discharges in batteries not engineered to support it, as this can considerably shorten battery life.

Charging Parameters

Batteries are manufactured with specific charging requirements for optimum performance. These include parameters such as voltage and current limits that need to be adhered to lead acid batteries and specifically for lithium-ion battery charging best practices.

Temperature Control

Battery temperature control is integral for prolonged usage and efficiency. Extreme hot and cold temperatures negatively impact the battery’s internal functioning and chemistry, which makes the battery inefficient and unreliable.

Ventilation and other temperature monitoring systems go a long way in increasing the battery’s life.

How Can the Battery Lifespan be Extended?

Tackling common causes of battery degradation with battery maintenance best practices enhances battery performance and reduces replacements and costly maintenance endeavours.

Follow this maintenance checklist to get the most out of your lead acid batteries and lithium-ion batteries.

Maintenance and Inspection

Begin with a battery inspection to check for debris, dirt, physical damage and terminal corrosion. Gently clean any dust particles and debris. Next, tighten all connections, check the demineralised water levels in lead acid batteries, and top up, if necessary, as per manufacturer instructions.

Equalisation Charging

Periodic equalisation charging helps balance the charge levels and the overall energy output and capacity. This addresses the issue of cell imbalance and sulfate buildup.

The battery manufacturer usually lists the correct procedure and frequency of equalisation. When in doubt, contact the experts for more information.

Monitor Charging Times

Overcharging is responsible for battery damage and reduced efficiency, which makes monitoring charging times integral. Implementing efficient battery charging controls is critical for maintaining battery longevity.

Storage Practices

Always store batteries in a cool and dry place away from temperature extremes. Sulfate accumulation occurs in batteries that are not completely charged; therefore, always ensure that batteries are charged to their maximum before storing.

Self-discharge in batteries is very common; hence, when batteries need to be stored for extended periods, it is best to frequently charge batteries to their designated capacities for better performance.

In conclusion, vigilant maintenance, including regular inspections and proper practices, is crucial for maximising the lifespan of industrial traction batteries. Addressing factors like discharge depth and charging parameters ensures efficient and reliable performance, optimising operational costs in the long run.

The Crucial Connection Between Demineralised Water for Battery Efficiency

anjali@unikautomation.com (Unik Techno) — Fri, 24 Nov 2023 11:01:07 GMT

New ParagraphAt UNIK, we are often asked about the role of demineralised water in battery maintenance. This blog aims to serve as a guide for replenishing your battery’s water levels. Regularly replenishing your batteries with demineralised water is a crucial maintenance routine to ensure safety and maximise performance.

What is Demineralized Water, and How is it Different from Regular Water?

Demineralised water is clear of most mineral and salt ions. This is often achieved through ion exchange, reverse osmosis, or electrodialysis.

Regular water, in contrast, contains a heavy load of impurities and dissolved minerals such as sodium, magnesium, and calcium which are detrimental to the health of batteries.

Where is Demineralized Water Used in Batteries?

Every lead acid battery, irrespective of its type, is immersed in an electrolyte solution comprising demineralised water and sulphuric acid. The amount of electrolyte is to be calculated and filled for optimum performance.

While the battery is being operated, the demineralised water undergoes a chemical reaction and is broken down into hydrogen and oxygen.

Why Does Demineralized Water in Batteries need to be Regularly Topped up?

Over time and with consumption, the water level in the battery drops and no longer covers the electrode plates, reducing the battery’s conduction capacity. Therefore, regular top-ups with demineralised water are essential to ensure the longevity and effectiveness of the battery. While tap water or RO-purified water may seem like a viable alternative, they are not recommended for optimum battery performance and maintenance due to its impurities and minerals.

With time, the dissolved minerals in non-demineralized water could clog the battery's electrodes by forming a layer of sediment. This eventually inhibits the battery from generating current.

When Should You Top up the Demineralized Water in your Batteries?

Overwatering and underwatering your battery can be equally harmful to your battery’s performance.

Ideally, a battery should be topped up with demineralised water after charging. However, ensuring that the electrode plates are covered with adequate fluid before charging is also important.

The frequency of demineralised water top-ups depends on the amount of usage. For instance, a sparingly used golf cart may need water top-ups monthly, while a forklift may need a weekly top-up. An inverter battery used as a back-up power source in urban areas could be topped up quarterly.

Old batteries and hot weather warrant more frequent demineralised water level top-ups.

Precautions to Follow while Topping up Demineralized Water in Your Batteries

Before undertaking any maintenance work yourself, always check the warning labels to confirm if your battery can be opened for servicing.
Although topping up demineralised water for batteries is a relatively safe maintenance procedure, always wear protective gear to prevent any accidents and injuries.
Never add sulphuric acid to your batteries during top-ups. Batteries only consume water during normal usage; hence, sulphuric acid can compromise the safety of batteries and imbalances different cell specific gravities.
Avoid overwatering your batteries as the electrolyte levels expand during the operations and cause the battery level to overflow, which damages the cell

Incorporating demineralised water for battery maintenance, along with regular servicing and checkups, can significantly enhance the performance and longevity of your battery.

Need more information on topping up demineralised water in batteries?

UNIK’s Commitment to Quality: The Art and Science of Battery Manufacturing

anjali@unikautomation.com (Unik Techno) — Tue, 17 Oct 2023 11:06:43 GMT

"Energy is the currency of the universe."

- Albert Einstein

The Art and Science of Battery Manufacturing

Welcome to the fascinating world of battery manufacturing, where the fusion of art and the precision of science give rise to the powerhouses driving our modern world. At UNIK Battery Manufacturing Company, we are devoted to crafting these energy storage marvels with the utmost attention to detail and innovation. New Paragraph

The Science of Battery Chemistry

Battery manufacturing hinges on a profound understanding of chemistry, particularly electrochemistry. Batteries are essentially chemical devices that convert stored chemical energy into electrical energy. Here's a simplified look at how they work:

Electrochemical Reactions: Inside a battery, two different materials called electrodes (usually one is positive and the other negative) interact with an electrolyte, which is a substance that allows ions to move between them. When you connect the battery to a device, chemical reactions occur at the electrodes. Electrons are released, creating an electric current.
Cycling: Batteries can discharge and recharge because these chemical reactions are reversible. When you charge a battery, you're essentially reversing the chemical processes that occurred during discharge.

Sustainability in Battery Science

Sustainability plays a vital role in battery science. UNIK is committed to reducing the environmental impact of battery manufacturing. One way we do this is by designing batteries that can be charged using renewable energy sources, such as solar or wind power. This reduces greenhouse gas emissions and contributes to a cleaner planet.

The Art of Customization

Customization is where the artistry of battery manufacturing shines. It involves tailoring power solutions to meet specific needs. For example, our stationary batteries are designed to seamlessly integrate into various industries, providing uninterrupted power to critical systems.

Modular Design for Flexibility

Our modular stationary cells exemplify the art and science of adaptability.
Assembled cells make a battery and modular construction ensures better heat dissipation during an exothermic reaction, hence reliably operating under all conditions.

They allow businesses to assemble power solutions like a puzzle, ensuring efficiency, reliability, and flexibility.

As you explore the intricate world of batteries, we invite you to discover our range of battery products at UNIK. Our passion for innovation, commitment to sustainable solutions, and deep understanding of battery chemistry drive us forward. Whether you need batteries for heavy machinery, electric vehicles, or critical systems, we offer solutions that combine the art and science of battery manufacturing.

Let's embark on a journey towards a greener, electrifying world together!

Your Partner in Power,

UNIK Battery Manufacturing Company

The Role of Storage Batteries in the Future of Energy

anjali@unikautomation.com (Unik Techno) — Thu, 17 Aug 2023 08:16:02 GMT

Welcome, fellow energy enthusiasts, to a captivating journey into the future of power! Let's explore the incredible role of storage batteries in revolutionizing how we consume and conserve energy. 

Unleashing the Potential of Renewable Energy :

Picture this: a world where renewable energy sources like solar and wind can shine their brightest, even when the sun hides behind clouds or the wind takes a brief nap. That's where our superhero, the stationary solar battery, swoops in! These power-packed energy storage systems save surplus energy generated during peak times, ensuring a constant supply during low production periods. Renewable energy can unleash its full potential with stationary solar batteries, bringing us closer to a greener and cleaner world.

Empowering Electric Mobility :

Rev your engines, folks, because we're heading towards the electrifying realm of transportation! Semi traction batteries are the driving force behind the electric vehicle revolution. Say goodbye to tailpipe emissions and hello to smooth, eco-friendly rides. With advancements in battery tech, electric vehicles now boast longer ranges and faster charging times. So, buckle up and get ready to join the electric mobility movement!

Shaping Energy Grid Resilience :

Let's momentarily look at the big picture—the energy grid. Stationary batteries are vital in maintaining stability and resilience in our power networks. They act as backups, storing excess energy during low-demand periods and releasing it when needed most. This ensures a balanced and reliable grid, minimizing the risk of blackouts and optimizing energy resources. It's like having a trusty sidekick, always there to keep the lights on!

Repurposing and Recycling :

The magic of traction batteries doesn't end when they retire from their electric vehicle duties. These clever batteries can find new purposes in stationary storage applications. It's a second lease on life! By repurposing retired batteries, we extend their lifespan and maximize resource usage. And when their time finally comes, we give them a superhero send-off through recycling, recovering valuable materials and reducing the need for new mining. It's a win-win for the environment.

These remarkable energy storage systems are changing the game, unlocking the true potential of renewable energy, propelling us towards a greener future, and fortifying our energy grids. So, let's embrace the power of UNIK traction and stationary batteries, work towards a brighter future, and create a sustainable world for generations to come. Together, we can be the green change our planet needs!

The Evolution of Battery Technology: A Chronicle of Power Innovation

anjali@unikautomation.com (Unik Techno) — Mon, 29 May 2023 08:58:10 GMT

Tracing the Progression of Batteries Through the Ages And The Best Batteries Of UNIK.

The Humble Beginnings of Battery Technology

The tale of battery technology is a narrative of constant evolution and innovation, underpinned by humanity's continued quest to meet it's escalating energy demands. In its nascent stages, rudimentary energy storage devices were invented, laying the groundwork for what we now recognise as batteries. However, these initial models needed more efficiency, reliability, and longevity required by contemporary applications.

The Advent of Traction Batteries

The birth of traction batteries signalled a significant advancement in energy storage solutions. In contrast to their antecedents, these batteries offered higher energy density, extended lifespan, and superior reliability. The innovation of traction batteries also ushered in an era of electric vehicles and stationary machines, which relied heavily on these efficient energy providers.

The battery market was dominated by diesel engine operated vehicles in the material handling (MHE) segment. Advent of pharmaceutical and food industries primarily had a requirement of pollution free, decontaminated and a dust free environment. Also, reduction in noise pollution requirements and lesser maintenance compared to diesel IC engines furthered the growth in population of traction batteries powered material handling equipment’s.

A Quantum Leap with Semi-Traction Batteries

The emergence of semi-traction batteries represented a quantum leap in technology. Leveraging deep cycle technology, these powerhouses offered improved discharge rates and an even greater lifespan, providing unprecedented efficiency to mobile and stationary applications. The semi-traction battery thus became an indispensable component in electric vehicles and various industrial machines, further fuelling the progress of battery technology.

Innovation Continues The Pursuit of Excellence

As technology advanced, so did the push for more efficient, reliable, and sustainable batteries. The industry began focusing on improving battery longevity, performance, and ecological sustainability, leading to the advent of greener, more efficient energy solutions. 

Future Directions in Battery Technology

The current trajectory of battery technology points towards a future of continued innovation. With the growing global consciousness around sustainable energy, the demand for eco-friendly and efficient batteries is higher than ever. Battery technology of the future is expected to deliver more power, last longer, charge faster, and have a minimal environmental impact.

Looking back at the journey of battery technology, we see a story of relentless progress and unwavering commitment to innovation. It is a testament to human ingenuity and the pursuit of better, more efficient energy solutions. As we turn the pages of this ongoing saga, UNIK aims to leave an indelible mark in the history of this exciting new technology. We promise to bring exciting innovations as batteries continue to shape the future. 

What are the charging methods of batteries?

anjali@unikautomation.com (Unik Techno) — Thu, 12 Nov 2020 11:15:32 GMT

The charging method usually used for first charge of a battery prior to commissioning is constant current charging.

Constant current charging is a charge given to the battery at a pre determined or manufacturer recommended constant current for a certain duration as prescribed by the manufacturer with no regard to the voltage which rises.

Usually the temperature is monitored to ensure that it does not rise high - sufficiently high enough to damage the battery internal components. Such a charge ensures that a defined Ah in relation to battery capacity is fed in to the battery.

Once the battery has been fully charged the sp gr are equalized - wrt temperature as measured.

A battery once used is recharged generally using a constant voltage charger. Constant voltage chargers have a current profile such that the current reduces as battery or cell voltage increases.

Chargers used in large electricity sub stations or as UPS systems in telecom sector or as battery back up for inverters have a float mode. In float mode a trickle current is given to flooded electrolyte lead acid batteries - such that the voltage per cell is maintained between 2.16 volts to 2.20 volts. Such chargers are known as float boost chargers flooded electrolyte.

AGM batteries cannot be charged with higher DC output voltage since charging at high currents can damage the battery - if float voltage is not set to supply a trickle current in the range between 2.25 volts 2.30 volts.

Cycling batteries have a tougher duty to perform when in use. Chargers meant for cycling batteries have an equalising mode - in addition to boost charge facility.

What is the difference between a solar battery and a general battery?

anjali@unikautomation.com (Unik Techno) — Thu, 12 Nov 2020 10:58:39 GMT

A solar battery is a tubular positive plate battery unlike an automotive engine starting battery which has pasted positive plates. Both these batteries do however have negative pasted plates. But the negative pasted plates of tubular plate solar batteries are very thick compared to the negative pasted plates of automotive batteries.

When you say general battery you must be referring to the car, bus or truck batteries which are classified as automotive batteries.

Batteries with tubular positives and thick pasted negative plates are used in stationary and traction applications.

Stationary batteries are used for
1. Large UPS systems in industries.
2. Telecom back up systems.
3. Emergency backup in power supply stations.
4. Reliable power supply in Nuclear Power Installations.
5. UPS systems in home inverters, clinics and shops.
6. Railway signaling and air conditioning systems.
7. Storage of solar energy to use in remote locations as the only source of power or to augment power as a renewable energy source.

Stationary batteries used for solar power are different from stationary batteries used in UPS or other applications though both are made using tubular positive plates and thick pasted negative plates.

A battery made for solar application is rated at 120 hr rate for a discharge at very low current over a long duration. This is necessary since these batteries must have a 5 day autonomy at the very least. That means they must be able to deliver power for 5 days which is 120 hours even without getting charged. Such situations arise when there is heavy rainfall and sun is not available to provide charge to the battery through the collecting solar panels.

In case a 2 volt stationary battery cell made for solar application is rated at 500 Ah at the 10 hr rate and can deliver 50 amperes for 10 hrs it means that battery can deliver 6.25 amperes for 120 hours. This battery is therefore rated as 750 Ah at the 120 hr rate.

Solar batteries are designed and manufactured specially at the factory - with characteristics different from UPS batteries. They are manufactured so as to

1. have a low topping up frequency.
2. accept charge efficiently so that battery gets charged in the short duration when Sun is available.
3. be capable of discharge over a long duration.
4. be able to withstand operation in high temperature outdoor storage areas.
5. have low maintenance characteristics.
6. have a low internal resistance.

A solar tubular positive plate lead acid battery is a battery connected to a solar photovoltaic system with an inverter and charging system as an interface between the solar photovoltaic cells and battery.

The solar photovoltaic cells charge the storage battery using power from the sun to do so. The photovoltaic cells are connected to the charger. Once the battery is fully charged the energy from the battery is used as per load demand. An inverter converts the DC power of battery to AC power suitable for the load.

What are the physical differences between a lead-acid car battery and a lead-acid deep-cycle battery?

anjali@unikautomation.com (Unik Techno) — Tue, 08 Sep 2020 11:27:54 GMT

The physical differences in the external construction is generally wrt the take off terminals.

A car battery classified as automotive battery invariably has taper terminals with positive terminals being of a bigger diameter compared to negative terminals which are of a relatively smaller diameter. These are of a defined standard size conforming to international standards and SAE specifications.

Deep cycle batteries have taper terminals or L shaped terminals or embedded type terminals such that the customer can connect lugs of cable using different types of terminations.

The physical differences in the internal construction is as follows:

Automotive batteries have very thin positive and negative plates with number of plates being more so that the surface area is very high to enable delivery of high currents required for engine cranking applications.

On a like to like same Voltage & Ah basis deep cycle batteries have thick negative plates and much thicker positive plates if the batteries are of pasted plate type. In case they are of tubular type the positive plates are of heavy tubular design construction types and negatives are made of thick pasted plates. The number of plates per cell is also lesser in relation to automotive batteries.

The separators used in automotive batteries are very thin with low electrical resistance and the separators have a lower back web thickness.

The separators used in deep cycle batteries are much thicker with thicker backwebs to resist the effects of oxidation during cycling.

The lead busbars used for connecting the plates together in parallel and lead components for interconnection of cells as well as pillars on the end terminal sides are much thicker in deep cycle batteries compared to automotive. This is required since voltage drops are not acceptable when connected to a continuous load during long duration operation of the deep cycle batteries.

The vent plugs of a deep cycle battery are of the Flip Top type to enable water topping up which is required more frequently in the case of deep cycle batteries. Deep cycle batteries are subjected to 80% depth of discharge on a daily basis followed by a recharge daily thereby requiring water top up more frequently.

In certain cases the vent plugs of deep cycle battery are designed to be compatible to the auto filling system unlike in automotive batteries. Automotive batteries are nowadays fitted mostly with coin flush vent plugs which need not be opened for upto six months at a stretch.

The weight of automotive batteries are much lower compared to a deep cycle battery of same voltage and Ah capacity.

I have restricted my answer to the physical differences externally visible and to the physical differences of components which are obvious during manufacturing process.

What is the industrial installation procedure, maintenance, and calibration for a float-type level sensor?

anjali@unikautomation.com (Unik Techno) — Tue, 08 Sep 2020 11:21:53 GMT

In a lead acid battery the float sensors are generally used only for flooded type industrial batteries. These type of sensors are used in stationary batteries having opaque or translucent containers & for motive power traction batteries.

As regards installation the following points are usually considered:

The manufacturer of sensor usually needs to know whether the vent hole has a threaded type vent plug or bayonet type plug or Push Fit type vent plug.

The manufacturer of sensor needs the diameter of the vent hole which is usually 25 mm or 27 mm or 35 mm.

To provide a float which determines the minimum level of electrolyte and maximum allowable level of electrolyte the manufacturer needs to know the space available between the bottom of vent hole and top of separator or separator guard. This detail also needs to be given to the sensor manufacturer by the battery manufacturer.

The battery manufacturer also has to provide the sensor manufacturer the difference in min and max level which is the range in which the sensor shall function.

As regards maintenance of this sensor system it shall need to be done at the battery user end and the only maintenance such float level sensors need is a periodic cleaning of float plugs to prevent clogging with consequent malfunctioning. This cleaning is a physical activity involving washing with water.

There is no calibration to be done for float plug sensors since the level of minimum and maximum has been determined and set by the manufacturer at the design stage with no need of a periodic calibration. This level does not change throughout the life of that particular battery. However please note that such sensor float plugs tailored for one battery are not necessarily interchangeable unless the design of the new battery is matching to the original battery.

What are the points to be considered before setting up a lead acid battery manufacturing plant?

anjali@unikautomation.com (Unik Techno) — Tue, 08 Sep 2020 11:09:01 GMT

To put it simply, following are the key checkpoints -

1) Adequate finance for the project preferably along with a tentative project report though the report is not a necessity if finance fully arranged.

2) Plot and building of a size based on desired battery manufacturing capacity.

3) All permissions and approvals from various government authorities including from pollution control board.

4) Technical knowledge and process knowhow of battery manufacture.

5) Machines of good quality with proven product output giving a consistent quality saleable battery.

6) A consultant with sufficient knowledge of batteries to liase between you & the machinery vendor.

7) Machine vendor who can preferably guide you as regards materials sourcing, materials specifications and the material test procedures in addition to guidance on process - sufficient to produce a battery.

In case you are in a position to cater to Sr. No. 1 to 3 stated above on your own you may contact the undersigned who can satisfy your requirements as regards Sr. No. 4 to 7 in a comprehensive manner.

What are the reasons for blasting of Tubular/Lead-Acid Batteries?

anjali@unikautomation.com (Unik Techno) — Thu, 03 Sep 2020 12:36:37 GMT

The possible reasons for explosion of a lead acid battery can be either or a combination of the following :

1) The battery can explode if it is subject to a overcharge i.e. charged continuously though it is fully charged.When a battery is fully charged it means the active material has converted to sponge lead on the negative plates & lead dioxide on the positive plates.

In such a condition there is no lead sulphate active material to be converted chemically on both positive & negative plates.The electrical energy fed by the charger which is supposed to be converted to chemical energy is converted to heat energy.

The electrolyte is heated & the evolving explosive hydrogen gas generated builds up pressure under the vent plugs causing the vent plugs to pop up or builds up pressure sufficient enough to explode the battery.

2) The battery can explode if an improper charger is used to charge the battery. When a battery is connected to a charger which is meant for a larger capacity battery the charger starts charging the battery at a higher than recommended current.

In such cases the battery life is affected and the active material from the plates start shedding creating an internal short. The internal short causes heat and explosion. In this case the internal short is not because of a manufacturing defect but due to incorrect charger selection.

3) The battery can explode if sources of static electricity cause spark in the vicinity of batteries. Also naked flames or sparks of welding or any other sparks near batteries whilst batteries are on charge can cause a fire or explosion. As and when batteries are on charge hydrogen gases are evolved.

Hydrogen gas is very flammable and yields explosive mixtures with air and oxygen. Since hydrogen gas is flammable the source of spark with oxygen from the atmosphere can lead to a fire and explosion of battery. Hence even smoking cigarettes is not recommended in rooms where batteries are on charge.

4) The battery can explode if the batteries are on charge in a room with improper ventilation. When batteries are on charge hydrogen & oxygen are both evolved as gases.They do recombine to form water but not fully.

If the hydrogen gas is evolved to such an extent that the concentration of hydrogen gas is greater than 4% it can cause an explosion of the battery.Hence batteries must be charged in an atmosphere where the gases can escape.The battery manufacturers usually recommend battery charging areas or rooms to have adequate ventilation with at least six air changes per hour.

5) The battery can explode if batteries of smaller than recommended size or lower Ah capacity are used. At times – due to non-availability of correct capacity batteries or cost consideratons – batteries of lower capacity are fitted to equipments or vehicles.

In such cases the charger being of a much larger capacity than required by battery – it tends to overcharge the battery, heating up the battery, causes bubbling & gassing with a possible explosion of battery due to pressure build up within the battery container.

6) The battery can explode if battery terminals are shorted externally with any metal object or conducting substance.

7) The battery can explode if battery has an internal shorting due to manufacturing defect.

8) The battery can explode if the vent holes of vent plugs are clogged due to battery being kept or used in a dusty/dirty environment.The batteries having such clogged vent holes of vent plugs shall not allow gases to escape due to which there shall be pressure build up leading to an explosion.

What is the difference in manufacturing a 150Ah and a 200Ah lead acid battery?

anjali@unikautomation.com (Unik Techno) — Thu, 03 Sep 2020 06:56:39 GMT

The manufacturing process is similar and so is the chemistry I.e. chemicals and raw materials used.

What shall change however is the qty of materials used and overall battery size maybe.

Obviously the 200Ah battery in comparison to 150 Ah battery has to have either or a combination of -

More number of plates per cell.
Bigger plates of higher capacity.
Larger volume of electrolyte.
Bigger size container with suitable cover possibly.
Separators and any other material of qty matching plate qty. and size.

What are lead acid batteries used for?

anjali@unikautomation.com (Unik Techno) — Thu, 20 Aug 2020 12:19:12 GMT

Lead acid batteries are used for automotive and industrial applications. They are still very popular and widely used because lead acid batteries are:

1. Proven as regards performance.

2. Economical to use.

3. Recyclable.

4. Safer compared to alternatives.

5. Easier to service.

6. Does not need a battery management service necessarily.

7. Is capable of operation over a wide range of temperature.

As regards applications automotive batteries are used for engine starting and lighting and to power the various equipments like power windows and air blowers and stereo systems etc etc. in cars, buses, vans, trucks, tractors and IC engine fuel operated forklifts and cranes. The motorcycle batteries are also used for lighting and engine starting in certain cases.

As regards industrial batteries they are generally classified as:

1. Stationary batteries.

2. Motive power traction batteries.

3. Monobloc semi traction batteries.

4. Submarine batteries.

Stationary batteries are used in the following applications:

1. As uninterruptible power system batteries for continuous process industries, power stations,

telecom systems, hospitals, software industries and atomic energy instrumentation systems.

2. In railway signaling systems to ensure continuous power.

3. To power burglar alarms, fire alarms and security systems.

4. Solar photovoltaic systems used in remote locations not having grid power and needing

batteries to store energy for use at night to power lights, fans and small televisions.

5. As inverter batteries for ensuring continuous power in homes, offices and clinics.

Motive power traction batteries are used in the following applications:

1. For powering battery operated pallet trucks and platform trucks used in industries.

2. For powering battery operated forklift trucks and reach trucks used in logistics and cargo

godowns.

3. For powering industrial scrubbers and sweepers used in large industries, railway stations and

airports.

4. For running electric vehicles in certain applications like mining locomotives and in die loaders of

large industries.

5. To power wheel chairs.

6. For running Automated Guided Vehicles popularly known as AGVs in industries and for special

purpose defence applications.

Monobloc semi traction batteries are used in the following applications:

1. As a source of power in scissor lifts, aerial work platforms and for battery operated cranes.

2. As a source of power for small battery operated scrubbers and sweepers.

3. To power electric toy trains and buses used in malls, amusement parks and exhibitions.

4. To power golf carts used in golf courses, hotels, amusement parks, resorts, large industries and

airports.

5. To power electric vehicles, recreation vehicles and boats.

Submarine batteries are a series of two volt cells of very high capacity and usually of high voltage. These batteries are the only source of power when a battery operated submarine is under water. Lives depend on these batteries and these are made to exacting standards. A major chunk of the submarine weight is the weight of its battery.

My 12v 150Ah lead acid battery got leaked through vents due to improper unloading. Should I refill acid to it?

anjali@unikautomation.com (Unik Techno) — Thu, 20 Aug 2020 11:43:18 GMT

What happens if lead acid battery runs out of water?

Based on your clear indication that the acid has leaked through the vents during unloading and presuming that there has been no breakage of containers by any physical damage the steps to be taken is as follows:

Check the specific gravity of the electrolyte in the battery. Procure sulphuric acid of the same specific gravity for filling.

If sp. gr. not clear or if you are unable to measure please contact manufacturer and arrange to get sulphuric acid of same specific gravity.

Ensure that the battery is not kept dry since internal components can get damaged due to a exothermic reaction which starts on the surface of the negative plates and this in turn can damage the separators and other battery components.

In case the entire qty of electrolyte has spilled you may fill demineralised or distilled water till such time as the electrolyte is available. As soon as electrolyte is available this water shall need to be thrown out and acid shall need to be poured in. In this case you may have to fill acid of slightly higher sp. gr. or adjust sp. gr. at the end of charge with remote or onsite help from manufacturer.

Ensure that refilling is done to the recommended level and also ensure that level is same in all cells.

It is not possible to recommend the sp. gr. of acid since different batteries need different concentration of electrolyte.

A traction battery needs 1.280 whereas a single cell stationary battery needs 1.210 or 1.240 depending on whether it is NDP or TBS type. A home inverter battery needs 1.240 sp. gr. acid. These are the details pertaining to a fully charged battery as per IS specification.

Further if the battery was in a discharged condition the gravity shall be lower and refilling has to be done accordingly of lower sp. gr. acid.

What happens if lead acid battery runs out of water?

anjali@unikautomation.com (Unik Techno) — Thu, 20 Aug 2020 11:33:12 GMT

What happens if lead acid battery runs out of water?

A lead acid battery has positive & negative plates fully immersed in electrolyte which is dilute sulphuric acid.

The concentration of electrolyte is defined & specified for batteries of different applications based on the application & in line with national & international standards.

This concentration is expressed as specific gravity.

This specific gravity is usually determined at design stage by battery manufacturers with relation to the volume of electrolyte which can be accommodated in a cell. The specific gravity is always in a defined range with the maximum specific gravity specified in such a manner so that it does not accelerate corrosion of battery components & allows for release of sulphate from the plates when a battery is on charge. The minimum specific gravity is also such that it retains the conductivity of electrolyte so that there are no problems to charge a fully discharged battery. Thus the volume & concentration of electrolyte form part of the design of battery.

As regards battery plates the active materials of the plates are decided in such a manner that the quantity of active materials as well as surface area of the plates decide battery capacity.

When the level of battery electrolyte reduces to an extent that the top portion of the plates are exposed - a situation is created wherein a certain portion of the plates do not take part in the reaction.

This leads to reduction in battery capacity. This is undesirable & hence it is not recommended to allow the battery to run out of water.

Regular topping up with distilled or demineralized water ensures that level of electrolyte is maintained. Evaporation of water component of battery electrolyte has to be compensated by topping up with water on a regular basis at defined intervals.

Another effect of reduction of electrolyte due to evaporation of water is increase in concentration of electrolyte i.e. increase in specific gravity. An increase in specific gravity of electrolyte with plates not fully immersed in electrolyte results in heating up of cell on charge. The battery can get damaged since corrosion of internal components used in battery manufacturing is accelerated in the acidic electrolyte at elevated temperatures.

A physical effect of reduction of water is heating up especially during the last stages of charging or in case of an undesired overcharging. Electrolyte also acts as a coolant though this may not be its main purpose for its presence in a battery. Hence the problems of thermal runaway faced by sealed maintenance free (SMF) or valve regulated lead acid (VRLA) batteries is not a phenomenon faced by designers of flooded electrolyte lead acid battery designers.

Finally coming to the main question as to what happens when a lead acid battery runs out of water – totally i.e. electrolyte has fully dried up or battery has been tilted or stored upside down due to which the electrolyte has spilled. Please note that we must not remove acid completely from flooded electrolyte lead acid batteries once it has been filled with acid & charged.

A lead acid battery consists of a few major components viz. the positive electrode, negative electrode, sulphuric acid, separators & tubular bags.

In charged condition the positive electrodes are lead dioxide and negative electrodes are sponge lead.

Sponge lead is highly reactive in the presence of moisture & oxygen and gets converted to lead oxide. In the process of conversion to lead oxide it gets discharged & heated up.

Hence it is necessary to ensure that the acid is not spilled or drained from a wet battery once it is filled and charged.

As and when a battery filled with acid is drained of acid the wet moist negative electrodes come in contact with atmospheric oxygen. An exothermic reaction takes place releasing an enormous amount of heat thereby discharging the negative plates (electrodes) and oxidizing the sponge lead to lead oxide.

During this exothermic process of heating up of the negative electrodes, the other components within the cell i.e. separators, tubular bags, plastic components like bottom bars, vent plugs, cell covers and rubber bushes fitted to cell covers get deformed, degraded or damaged.

Whilst it is possible to revive such batteries if they are not fully damaged, the life & performance of such batteries do get adversely affected and hence it is very important to ensure that there is no spillage of acid from fully charged batteries. Loss of electrolyte from the top of the plates in the normal course without exposing the electrodes is however different and cannot be equated to spilling.