Batteries Demystified by Ramesh Natarajan

In this episode of my podcast, I share a real-life case study from a recent visit to the automotive battery industry. A manufacturer was experiencing many warranty claims due to positive grid corrosion. To solve it, they strengthened the grid by adding extra horizontal and vertical wires. The corrosion issue improved—but a new set of problems emerged. Battery capacity reduced OEM customers were un...

In this inspiring episode of The Write Inheritance, industrial marketer Bejoy Peter sits down with Ramesh Natarajan, well-known author and battery industry expert to explore the powerful connection between writing, influence, and legacy. From factory floors to life as a best-selling author, Ramesh shares how his journey through the world of batteries sparked stories that charge minds and move hear...

“Bolt it, or burn it?” That’s the question I explored in my latest podcast episode. Both bolt-on and weld-on cell traction batteries have their pros and cons — but the real difference shows up in: How they’re serviced, How they’re maintained, and How long they last. Most people think bolt-on cells are “better and convenient,” but do they realize the equalization step can make or break the battery’...

🔋 What does it *really* take to succeed in battery manufacturing? It’s not just about chemistry and machinery. In my latest podcast episode, I discuss 11 powerful (and often overlooked) guidelines that separate thriving battery businesses from the ones that quietly disappear. This isn’t your typical technical talk — it’s about the real challenges, the silent killers of profitability, and the stra...

Bubbles on Pasted Plates… but why? Everything looked normal. •Same paste formula. •Same raw materials. •Same paste chemical additives •Same machine settings. But over 50% of the plates were getting rejected. Right after pasting. Before even reaching the drying oven.  The QC team tried everything—tweaking the mix, rechecking materials, and recalibrating equipment. Still, the problem persisted.  👉...

Battery manufacturers specify the end-of-discharge voltage based on battery design and application. Any discharge below the end of the discharge voltage is termed a deep discharge. Deep discharges, especially when more frequent, lead to battery capacity loss and degradation of the active material. Batteries subjected to deep discharges fail prematurely. In the case of lead-acid batteries, deep dis...

Electric vehicles, or EVs as they are more popularly known, are a sunrise sector with a lot of government encouragement so that car buyers shift to EVs from Internal Combustion Engine vehicles. Internal Combustion Engine vehicles are referred to as ICE vehicles. EV buyers are lured by the fuel cost savings that will accrue to them when they buy an EV. However, any fuel cost savings accrued to an E...

Did you know that Lithium-Ion batteries are not similar to lead-acid batteries in terms of safety and handling procedures? The popularity of lithium-ion batteries has resulted in the spawning of many dealers, traders, and assemblers of cells and modules. This is a good development, but many entrepreneurs are unaware of the risks associated with lithium-ion batteries.  Hence, I considered doing thi...

Sulfation is a necessary part of the operation of lead acid batteries and is a phenomenon which is less understood. The various types of sulphation and the problems due to sulphation when a battery is misused have been clarified. The characteristic signs of sulphation have also been explained. You are welcome to write to me with your comments and suggestions. The contact details are on the website...

A battery manufacturer who manufactures automobile batteries faced a problem with their self-discharge. This issue started to arise after he began exporting his batteries.  This is another Case Study. Join me as I walk you through the various steps before I zero in on the problem caused by an unexpected reason. This thrilling episode will make you assess your process. Another unmissable episode fo...

I agree with many people within the battery industry and with battery users worldwide that Lithium Battery technology will usher in a change in the availability of battery technology. A lot of people hold the view that Lithium batteries will replace lead-acid battery Technology.  Is it a far-fetched view or an impossible dream? Is it an unrealistic and non-achievable vision? To hear my views on th...

The manufacture of SMF batteries is not as easy as that of flooded electrolyte vented type batteries. One main reason for this is that an SMF battery has limited electrolyte, and the specific gravity of this electrolyte cannot be measured. Is there a way to ensure the required consistent specific gravity in all the cells while maintaining a constant volume of sulphuric acid? How can a good SMF bat...

A shortage of Antimony metal is causing significant disruptions in the battery world, and the impact goes beyond battery manufacturers.   So, what’s happening? The price of lead itself hasn’t skyrocketed, but the real trouble lies in the shortage of antimony, a key ingredient in the alloy used to make lead-acid batteries. And when something critical goes missing from the supply chain, chaos follow...

Are you manufacturing tubular plate batteries?   Are you adding more active material but still getting lower capacity?   Are you facing issues with tubular bag bursting?   Are your batteries heavier than branded ones but failing during the warranty period?   Click on the link below to access the calculator: https://battech.rameshnatarajan.in/calculator SHARE YOUR FEEDBACK Visit, www. RameshNataraj...

क्या आप ट्यूबलर प्लेट बैटरी बना रहे हैं?  क्या आप अधिक सक्रिय सामग्री भर रहे हैं और फिर भी कम क्षमता प्राप्त कर रहे हैं?  क्या आपको ट्यूबलर बैग फटने की समस्या का सामना करना पड़ता है?  क्या आपकी बैटरियां ब्रांडेड बैटरियों से भारी हैं लेकिन वारंटी अवधि के दौरान खराब हो रही हैं?  कैलकुलेटर तक पहुंचने के लिए कृपया निम्नलिखित लिंक पर क्लिक करें: https://battech.rameshnatarajan.in/calculator SHARE YOUR...

Have you ever wondered which of Vanisperse A, Vanisperse HT 1, or Vanisperse DCA is more suitable for the lead-acid batteries that you manufacture? Do you know which of these lignosulphonates is better suited for batteries that gas vigorously and which is better for those that are overcharged and remain at high temperatures? Are you mixing two types of lignosulphonates—Vanisperse A and Vanisperse...

Are you using Lead Calcium Tin Aluminum alloys? Are you facing issues during casting due to grid softening? Are you getting fewer cycles when you use this alloy? Are your batteries failing during the warranty period due to alloy? Mr. Ali Alagheband discusses modifying the alloy to improve its corrosion resistance and cycle life. SHARE YOUR FEEDBACK Visit, www. RameshNatarajan.in to stay connected...

I received a call from a tubular bag manufacturer who shared that he received complaints about the tubular bags shrinking after pickling.  He had even received photographs from the battery manufacturer, which clearly showed the tubular bag had dislocated from some of the spines at one end of the plate.  He was confident his tubular bags were perfect and wanted me to talk to the battery manufacture...

In this episode, we unveil the BaTTech Mobile App, a groundbreaking tool designed to empower battery manufacturers. With its intuitive calculator series, the app simplifies complex calculations, enhances operational efficiency, and drives sustainable innovation. Join us as we explore the app’s features, its impact on the industry, and how it’s set to transform battery manufacturing worldwide. SHAR...

👉 पिकलिंगकेलिएरखीगईपॉजिटिव ट्यूबलर प्लेटों के गौंटलेट/ट्यूबलर बैग सिकुड़ क्यों रहे थे? 👉 ट्यूबलर बैग का सिकुड़न एक समान क्यों नहीं था? 👉 इस समस्या से निकलने के लिए प्रक्रिया में क्या बदलाव आवश्यक था? 👉 ट्यूबलर बैग निर्माता का कौन सा प्रश्न अप्रत्याशित था और मैं उसका उत्तर नहीं दे सका? SHARE YOUR FEEDBACK Visit, www. RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on...

👉  Are Ammonium Sulphate dipped plates similar to Sulphuric Acid pickled plates? 👉  Can the Ammonium Sulphate dipping procedure be accepted as an alternative to the Sulphuric Acid pickling procedure? 👉  Is it acceptable to process the Ammonium Sulphate dipped plates like Sulphuric Acid pickled plates? 👉  Are subsequent processes different for Ammonium Sulphate dipped plates and Sulphuric Acid...

👉 यह एक ट्विस्ट के साथ केस स्टडी है।  ✅ आज का एपिसोड इस बात पर है कि क्या नहीं करना है! ➡️ आम तौर पर, एपिसोड जानकारीपूर्ण, ज्ञान-साक्षात्कार या सलाहकार प्रकार के होते हैं। मेरा मतलब यह है कि वे इस बात पर ध्यान केंद्रित करना चाहते हैं। ➡️ मैं आपको एक कहानी बताता हूँ। मेरा मतलब है कि यह एक सच्ची घटना है जिसने मुझे हैरान कर दिया। मुझे एक समस्या का समाधान करना था और समाधान मुझे नहीं मिल रहा था। अंत...

➡️ बहुत सारे बैटरी वितरक, डीलर और कुछ मामलों में निर्माता भी हैं जो ग्राहक को बताते हैं कि वे बैटरी बनाने के लिए शुद्ध सीसे का उपयोग कर रहे हैं  जबकि प्रतिस्पर्धी  पुनर्चक्रित सीसा का उपयोग कर रहे हैं । ➡️ अब यह वास्तव में सच नहीं है।  ➡️ बड़े स्थापित बैटरी निर्माताओं सहित एसएमई बैटरी निर्माताओं द्वारा उपयोग किया जाने वाला सभी बैटरी पुनर्चक्रित सीसा से होता है।  बैटरी निर्माण के लिए बाजार में जो स...

✳️ Is it practically possible or economically viable? ✳️ ▶️ When a battery stops performing well or even fails within its warranty period, it must be thoroughly checked before being scrapped.  ▶️ As a battery ages, its performance naturally declines—much like the human body.  ▶️ Speaking of which, here's a helpful analogy: think of your body with all its organs. As we age, our organs wear dow...

✳️ A Case Study: Another one on - What Not To Do! ▶️ When a tubular bag or gauntlet fails in a battery – is it always due to the tubular bag? ▶️ As a battery manufacturer, where does the investigation of the battery warranty claim caused due to the tubular bag failure end?  ▶️ As a tubular bag manufacturer what is to be done when repeated claims arise from one or few battery manufacturers blaming...