frequently asked questions

(Causes) 1) Acid wash not done after pasting.
2) Higher moisture content paste used.
3) Low flash drying oven temperature.
4)Plates stacked tightly in racks.
(Causes) 1) Variation in Grid Panel weight.
2) Variation in Paste Density than specification.
3) Improper condition of Pasting Hooper.
4)Improper condition of Pasting Machine.
5) Pasting Machine setting problem.
(Causes) 1) Lead alloy composition not ok.
2) Improper Mould Temperature.
3) Poor cork powder spray on mould.
4)Improper surface of Grid Mould due to age
5) Mould closing mechanism is not proper.
(Causes) 1) Lead alloy composition not ok.
2) Improper Mould Temperature.
3) Mould water Cooling path chocked.
4) Improper Mould spraying.
5) Mould Air venting is not proper.
6)Machine speed higher than standard.
(Causes) 1) Internal Spark.
2) Higher Gas Generation.
3) Vent path chocked.
4) Gassing Space not maintained.
5) Material and Process of Plastic Moulding.
(Solutions) 1) Improper paste Density.
2) Improper curing of plates.
3) Loose Cell fitment.
4) Improper Side packing.
5) Design of Pasting Hopper.
(Solutions) 1) High Antimony percentage in Lead Alloy for grid casting
2) Design the Battery in such a way to accommodate more quantity of acid on top of the plates
3) Over charging of Battery
(Solutions) 1) Poor inter cell welding.
2) Poor group burning.
3) Active material sheading.
4) Iron & Chloride contamination
5) Micro Short
Cause :-
1) Lead Run during Group Burning
2) Lead Run During Pole Burning
3) PE- Separator misalignment
4) PE- Separator Puncher
5) Improper cleaning of Paste on Lug and Plate’s side
6) Separator Height overlapping by 8 to 10 mm
Causes: -
1) Loose wire Connection
2) Improper Pole Burning
3)Highly Oxidised
4)Pole crack
5) Terminal crack
(Causes: -) 1) Lid & container Sealing joint not ok
2) Grade of PPCP Material is not proper
3) Mishandling
4) Acid level is not maintained
5) Vent Plug design is not proper
(Causes: -) 1) PAM/NAM Softening
2) Hard Sulfation formed during plate making process
3) Positive / Negative paste Degradation
4) Improper Charging Inputs
5) Week intercell wielding
(Causes: -) 1) Lead alloy composition not ok.
2) Melting pot dross cleaning not maintained
3) Pencilling in grid mould not done properly
4) Mould Improper cleaning
5) Mould heating is not proper
6) Cork Spray Quality
7) Operator Skill
(Causes: -) 1) Lead alloy composition not ok.
2) Improper Cork spray
3) Improper Mould Temperature
4) Improper Molten Lead alloy temperature
5) Improper cleaning of Mould air vent Bar
6) Mould Surface venting is not proper
7) Mould open/ close system is not proper
8) Improper Lead pouring from Laddle
(Causes: -) 1) Curing reaction not properly done
2) Paste to grid bonding not done
3) Curing program not ok
4) Paste moisture was not maintained
5) Free Lead conversion is not proper
(Causes) 1) Centralising of Spine inside the Bag
2) Flash in spine.
3) Moisture in Oxide
4) Heavy particles like lumps, are formed during mixing.
5) Improper vibration of Oxide Filling Machine
(Causes) 1) Design and dimension of Bottom bar is not correct
2) There is no 2 nd time use of Bottom bar and spine
3) Spine cutting length not proper.
4) Wrong design of Oxide Filling Machine
5) Due to operator skill

WHAT OUR EXPERT SAYS

News

OUR AIM


Battery Engineers Consultancy is a team of highly skilled expert individuals who bring to you the most technologically viable and economically affordable solutions to meet the needs of the Battery Industry. The team will provide complete end to end support of manufacture, design & process (including Lead Smelting and Lead refining Project) of all kind Lead Acid Battery. We assist our Clients to select the most suitable Design and Process for manufacturing Battery of following applications

1. Vented/ Flooded Battery - Automotive, E. Rickshaw, Inverter, Solar, OPzS and Traction Application

2. VRLA/SMF Battery - Car Battery VRLA, Motor Cycle VRLA, UPS VRLA, 2V AGM VRLA, 2V GEL VRLA, 2V AGM GEL VRLA, 12V Inverter AGM GEL VRLA, OPzV Battery.

We strive to deliver consistent quality assurance for Client’s satisfaction.
Our Team is also pro efficient in illustrating to the customer about the technicalities of Productivity and Cost effectiveness throughout the entire Process.

Our Commitment

  • Customer Satisfaction
  • Easy understandability
  • Flexibility of Process and Design
  • Solution and Action in favour of our Client’s Business and interests
  • Battery Engineers Consultancy’s Results and Analysis are Technically and
    scientifically sound and target oriented

Our Expert Team for Batteries

BATTERY ENGINEERS CONSULTANCY IS FORMED IN 2020 AS AN ASSOCIATION OF EXPERIENCED ENGINEERS AND TECHNOLOGISTS FROM BATTERY RESEARCH AND MANUFACTURING. WE OFFER SERVICES FOR SETTING UP NEW PLANT, EXPANSION OF EXISTING PLANT,COST-EFFECTIVE BEST DESIGN OF FOLLOWING ….

p>1. Vented/ Flooded Battery - Automotive, E. Rickshaw, Inverter, Solar, OPzS and Traction Application

2. VRLA/SMF Battery - Car Battery VRLA, Motor Cycle VRLA, UPS VRLA, 2V AGM VRLA, 2V GEL VRLA, 2V AGM GEL VRLA, 12V Inverter AGM GEL VRLA, OPzV Battery.



RANGE OF PRODUCTS – END TO END DESIGN SUPPORT (INCLUDING LEAD SMELTING AND LEAD REFINING)
  • 1. Vented/ Flooded Battery - Automotive, E. Rickshaw, Inverter, Solar, OPzS and Traction Application
  • 2. VRLA / SMF Battery – Car Battery VRLA, Motor Cycle VRLA, UPS VRLA, 2V AGM VRLA, 2V GEL VRLA, 2V AGM GEL VRLA, 12V Inverter AGM GEL VRLA, OPzV Battery.
RANGE OF SERVICES AVAILABLE
  • Turnkey basis Factory setup including Commissioning of Plant and Equipment , end to end design and process support.
  • Turnkey basis setup of Lead Smelting and Lead refining Project, including designing and manufacturing of Equipments.
  • In-depth Process and Product Audit with corrective action plan.
  • Setup and implementation of TPM / Lean Manufacturing / Customised Improvement system.
  • Train the Trainers Programme. Executive Leadership Programme.
  • Selection & Recruitment of Manufacturing team

TEAM PROFILES

COMPANIES WORKED IN AND TOP POSTS HELD

Mr. Chittaranjan Ghosh Chief Technical Advisor

  • Till 2000 worked as Head of Technical Department in Exide Industries Limited
  • 2001-2002 – Abtab Automobile Bangladesh as Technical Advisor
  • 2003. --------- In Luminous as General Manager
  • 2004- 2007 --- Okaya Group as Director
  • 2008 ---------- Eastman Auto as Director
  • 2009 – 2011 – Deepak Power Storage Enterprise as Director
  • Since 2012 Mr. Ghosh started his engagement as an independent consultancy work and research work, resulting by owning US Patent No – 11145855.

Subhashish Sen Managing Director

  • Exide Industries Limited – Haldia, Chinchwad, Shamnagar & Hosur Unit – Section Manager
  • TUDOR INDIA LTD – An Indian arm of Exide USA – Head of Project and Maintenance
  • BASE CORPORATION – Plant Head
  • MINDA INDUSTRIES – DGM
  • PANNA BATTERY (DHAKA)- GM
  • BASE CORPORATION - GM
  • OKAYA POWER – GM
  • JAY ACE BATTERY – CEO

Dr Debashish Mazumdar Nominated R&D Expert from Power Dynamics

Doctorate from IIT, Kharagpur who brings along with him 35 years of working experience in design & development at Exide Industries Limited. Post retirement in 2020, actively engaged in consultancy services.

  • Last Organization worked for: Exide Industries Limited, a leading manufacturer of Lead Acid Battery in India with an annual turnover of approximately INR 12k crores (around 1.5 billion USD). Retired from services effective 31 st May’20.
  • Last Designation held: Executive Vice President (EVP)-R&D
  • Total Years of Experience: 37years (including 2 years post retirement)

Mr. Alwyn Rodrigues

  • KALYANI STEELS / CHLORIDE INDIA / STANDARD FURUKAAWA
  • EXIDE INDUSTRIES (CHINCHWAD)
  • EXIDE INDUSTRIES (TALOJA) – GM OPERATIONS
  • MINDA INDUSTRIES – VICE PRESIDENT AND UBH
  • BASE CORPORATION – SR. VICE PRESIDENT.
  • PILOT INDUSTRIES / TUDOR INDIA – SR. CONSULTANT

Mr. Viswanathan Sankaran

  • CECRI / AES CHEMICALS / TITAN SOLAR ENERGY SYSTEMS / GHANNAMI CHLO- RIDE
  • STANDARD FURUKAWA ~ TECHNICAL MANAGER
  • NIFE POWER SYSTEMS ~ GM TECHNICAL
  • Thin UNION BATTERIES / BASE CORPORATION - GM QA R&D

Mr. Siddhartha Das

  • Last assignment in Deepak International as DGM Technical
  • Working In Exide Industries Limited more than 35 years, lastly as Quality/Technical Head of Exide Shamnagar, unit West Bengal.
  • Experienced in implementation of new technologies to improve production processes effectively with upgraded quality of product.
  • Exposure in achieving best performance across multiple business lines by leading large-sized cross-cultural manpower of 1100 workers and 25+ staff
  • Skilled in enhancing Quality of product, improving operational efficiency, process effectiveness and achieving cost reduction.

Areas of expertise in BEC



AUTOMATIVE

INVERTER

TRACTION

E-RICKSHAW

GEL TUBULAR

OPzS & OPzV Cell

UPS VRLA

E.Scooter Battery

two wheeler vrla battery

2 Volt VRLA

Have an idea? We will make it happen!

BEC is a One Stop Solution. Our Technical team is seasoned in providing Engineering support which entails, to provide end to end Design support ( including set up of Lead Smelting and Lead refining Project ) for manufacturing customised product of ….
(1) All ranges of Vented Lead Acid Battery
(2) All ranges of VRLA / SMF Lead Acid Battery
We are experienced in Green Field Project and Capacity Expansion Project. Being aware of the market dynamics, we ensure our client gets the Best Process and Product design. Our R&D Team also monitors Process/ Design/ Lab Testing. Audit of any operating Plant. We also impart Training and Knowledge sessions to Quality/ R&D team from Client site.